Locked Up's 4Runner

I picked this up back in December and have already put a chunk into it ....

2003
4wd
V8
Limited
LB42 Leather
215,000 miles
Bilsteins/Spacer lift
265/70 R16 Cooper Discover S/T
XD "Hoss" 16" Wheels

Motor has plenty of power and it drives nice and straight.
Dealer said "The PO said they did timing belt and water pump" ... but no sticker so I had it redone.

Known issues are the 4wd actuator, passenger side air mix servo and rear main seal.


Plans:
Fix EVERYTHING noted above.

The front seems a little stiff so may investigate swapping something else in.

There are dents and dings that I am going to try to correct or at least minimize.

Might repaint/recolor it as well.... the black is sexy and all but it's hawt here in TX.
If I don't do a color change I might just do a white roof to reflect that sun!

If I keep the black I may look for some of the newer Limited wheels.
I generally like black wheels on white/silver vehicles and shiny metal on black/dark blue.

I will need to refurbish headlights so I may crack them open and convert to something brighter.

Grill needs some love. Emblems were plasti-dipped. Not sure if I like it.

On the inside I also want to replace the dash so will probably do a coverlay unless I find a nice one at the 'yard.

I am also going to look at replacement carpet, refurbishing the leather and some new floor mats.

Audio is the JBL system but I want something more modern.
I will investigate swapping that out for something touch screen assuming I can keep the steering wheel controls.

May remove the running boards and relocate the lights in them to under the body. We will see if they are necessary for the wife. lol

 

Going to use this post as my maintenance log.

1/8/24
215,473 Miles
OEM AC Condenser - 1/13/24
215,473
OEM B2 S1 O2 Sensor - (8946560150) Tom Wood Toyota
OEM Coil Pack - (90919-02230) Tom Wood Toyota

1/30/24
215,473
Detroit Pass front Wheel Bearing -

$84 Detroit Axle - 4WD Front Wheel Bearing Hub for Toyota 4Runner FJ Cruiser Tacoma Lexus GX460 GX470, Replacement Wheel Bearing and Hub Assembly

Amazon
Denso Coil Packs - (6731303) Rock Auto x7

2/7/24
215,495
OEM Radiator Shroud - OEM Fan Clutch - (1621050090) Tom Wood Toyota
OEM Fuel Tube Clamp - OEM Fuel Tube Clamp - 2/12/24
215,501
New Spare tire changing tools
Amazon

3/2/24
215,511
Cleaned Sun Roof Drains
OEM Relay Block Cover - (82663-35090) Toyota Parts Deal
OEM B1 S1 O2 Sensor - (8946560150) Tom Wood Toyota
OEM PCV Valve - (12204-50030) Toyota Parts Deal
OEM Gas Cap - (77300-47010) Toyota Parts Deal
OEM PCV Hose - (12261-50060) Toyota Parts Deal
OEM PCV Hose - (12261-50050) Toyota Parts Deal

3/11/24
215,520
OEM Feul Resistor - (23080-50130) Toyota Parts Deal
OEM MAF Sensor - (22204-75020) Toyota Parts Deal
OEM Vapor Hose - (23829-50070) Toyota Parts Deal
OEM Vapor Hose - (23820-50140) Toyota Parts Deal
OEM Thermistor - (88790-22131) Toyota Parts Deal
Battery Duralast Gold 27F-DLG - AutoZone

3/21/24
215,532
Bearden Automotive. They use OE parts and for this they used the ASIN kit.
B2 S1 O2 Sensor Ground fix
Timing Belt Idler
Cam Seal x2
Crank Seal
Timing belt
Water Pump
Idler lower Timing
Coolant
FIPG Sealer
Thermostat Gasket
O-Ring Bypass
Inlet O-ring
Thermostat
Tension Adjuster Timing
P/S Hose 3/8
P/S Feed Hose
Power Steering Fluid
Oil Pickup Gasket
Oil Pumo/RM Housing O-Ring
Oil Pump
Tensioner Accessory Belt
Harmonic balancer
Alternator
Cooling Bracket Assembly

4/8/24
215,674
Lubed front & rear driveshafts (slips & u-joints)

5/13/24
215,690
Krawltex Motorsports
Installed SafeTcap Frame Repairs 200,201 & 202 on both sides

5/22/24
215706
Bearden Automotive.
New Radiator & Cap

 

I am working a little backwards on this thread because I had started my log elsewhere. So some of these pictures will predate this thread but here goes....

1/13/24
Today's plans were a new coil pack, new fan clutch, new wheel bearing and new 02 sensor...


I started with the 02 sensor and with the right tool, that was pretty easy.
Access was easy for me since it's lifted and there isn't wheel well liner there.




I highly recommend this tool if you are doing an O2 sensor:

$14 OEMTOOLS 25249 Oxygen Sensor Crowfoot Wrench, Reliable Oxygen Sensor Socket for Efficient Vehicle Sensor Maintenance, 22MM Wrench for Sensor Socket Kit, Durable Automotive Repair Tool

O2 Sensor Socket on Amazon


Then I started with the coil pack and since I was in there, I checked them all.
Access is very easy on the driver side:



Passenger side requires removal of the air filter housing:


I knew one was cracked but didn't know ALL of them were cracked.
Ugh.

I had help when it was time for the fan clutch and we were able to get it apart and out by pulling the fan shroud at the same time.
Didn't have to take any hoses off!

Unfortunately, it looks like the PO cross threaded one of the studs so it had to come out:


New one on order.
Ugh!


Thankfully since it was out and getting late-ish, we decided to not do the bearing today. That led us to discover some questionable wire routing, which we temp solved with bright ass zip ties. Bright so that I will notice them and they will irritate me so I will order the proper clips! lol






I also noticed a few missing nuts & bolts.
Hoping to get to the parts yard soon to find a few of these:




Also, while sitting under the frame checking things out ... I noticed there is something missing.
What is supposed to go in these clips (driverside):

 

Keep the pics coming, we love pics!

Keep up the good work…

 

Thanks.
I will have to find a way to resize those pics. I thought I hit "thumbnail" but they seem to be pretty big.

 

1-21-24
Scored a few smaller items at the 'yard because the two 4Runners there were picked pretty clean!

Found hood release & cover, lumbar assembly, 1 fuel/evap clip, fan clutch stud and a bunch of misc clamps nuts & bolts. The hardware is to replace a few things I have but that aren't in great shape.

Couldn't find the radiator cover, radiator shroud nuts & bolts, spare tire tools and one fuel/evap clip. Hope I can find those elsewhere.

 

1/30/24
Well the hood latch assembly has some sort of sensor built into it. Must be a limited thing. No way to remove the sensor from mine and add it to the new one without breaking them apart. I was only swapping it out to clean things up a little, so I ended up wire wheeling it and hitting it with some paint.

The larger project I got done was the wheel bearing which went really smoothly. I did see that the PO had replaced this before because they poked a hole in the disc shaped cover trying to get it off. So I massaged it back to close the hole as much as I could and slopped some RTV on the hole. Meh.



We also swapped in all new coil packs to match the one I had done a few weeks ago. So it should purr like a kitten now.


I also removed the plastidip from the V8 Emblem.
I'm not a chrome fan but the total black murdered out look isn't me either.


Waiting on some replacement hardware to put the new radiator shroud, new belt and new fan clutch in.

 

2/7/24
Got a new engine cover in place.
I know it does nothing but I like the look!


Also replaced a few small brackets that hold evap lines on the driver side.
Got a few more to find part numbers on and swap out.
Including replacing those bright yellow zip ties with the proper clips!



Also got the new fan clutch & shroud in.


PO had said it ran a little hot on long trips. I have not experienced that but also it's winter and I have not driven far.
I'm wondering if it has/had to do with the aftermarket radiator or cap? Maybe it had to do with the AC Condensor leaking (as in maybe it was running constantly?). That was changed out so I guess time will tell. Considering going back to OEM for the Radiator & cap and doing the thermostat with it. Just to be sure.

Currently looking for a mild water leak. It had rained a TON here and I suspect it was a sunroof drain. Should get that sorted out in the next week.
Also doing a power steering flush and checking the hoses out.

Then it's on to taking care of the 2 spots of bad frame on the passenger side and sorting out the leaky actuator.

After that I will do timing belt, water pump and thermostat. Need to do something with the dash, the CV boots and I want some aftermarket UCAs. Thinking I like the look of the Dirt King with the Ball Joints. Also need to scope out a rear Track bar bracket.

It's coming together!

 

Glad to see you getting her back in shape. She looks good. Memorial Day may be a good time to look at suspension options since you mentioned it.

I have a 2004 v8 Limited 4x4 with 248k and have sort of gone through a lot of what you have, replacing bits here and there getting mine back to tip top shape. I've spent more than what I paid for it so far - so there's that, lol.

 

3/2/24
I got both front sunroof drains cleared.
It has rained since then and I didn't find any wet spots so I think I'm good there.

Somehow the PO had cracked the fuse box cover/base.
So that got replaced as well.

I'm now trying to track down a Bank 2 Lean condition (P0174).
I also replaced the driver side O2 sensor ... so both fronts are new.
(Side note, thread chaser is < thread tap. Just FYI)

I have the rear sensors too but have not put them in.

Cleaned the MAF.

Also replaced the PCV valve, PCV hoses and a few misc bits of hardware and clips.

I'm thinking it might be a vac leak since I did replace a few brackets under the hood.
Maybe I popped off a hose or bumped a brittle one?

That or a fuel injector.
Ugh.

Time to bust out the smoke tester I guess.

 

3/3/24
Did a smoke test today and couldn't find any major leaks.... but I did find a few Evap hoses that need some love, so those are getting replaced.

During the smoke test I did see the slightest amount , and I mean super slight, coming out from near the TB/Intake connection. I tightened that up and noticed the intake housing is looking a little ragged. Might order a new one to be safe.

I also noticed that the fuel line to the passenger side must have had a leak at some point and the PO patched it.
You can see it in the back of this pic (please ignore the missing evap lines). That would technically be going to "Bank 2" so I might replace it when I do the injectors if I can figure out the part

 

3/21/24
Had to go out of town and I need an inspection before the end of the month. So I had to drop it off at a shop.

Of course the battery was dead so dropped in a new 27F-DLG because it has more CCA.

Anyway, glad I brought it to the shop because I was about to try to change the injectors to solve my P0174.
Turns out it was a broken ground wire to the O2 sensor. They repaired the break and no CEL now.

While it was there I had them do a bunch of stuff so that I can get some miles on it before inspection.

Needed a Timing belt service so I told them to change out pretty much everything "while they were in there"...
Belts, Cam & Crank Seals, Idler, Adjusters, tensioners, Thermostat, water & oil pumps, Harmonic balancer, Alternator
& Cooling Assembly Bracket.

Also needed 2 power steering hoses.

Don't ask how much it all was.... but it runs like a champ now.

After it passes inspection.... next up will be to address the spots in the frame which I am planning on going overkill with, as in SafeTCaps.

Then I need to do something about the actuator leak. Thinking about an FJ case.... is that crazy?

After that I am thinking about leveling it out. I don't like the rake but not sure it's wise to go up on the Bilsteins in the front for added lift. So either I need to go big money up front or lower the rear an inch... which I don't really want to do. Hmmmmm.

 

4/2/24
I got all the SafeTCap parts ordered.

Went with 200, 201 & 202 on both sides as well as some fish plates and gussets.

I don't think it will need them all, but the shop I am using is far away and I didn't want to have to make a second trip/order.


Some before shots:
This is everything I can find (and I am looking hard) on the driver side.
3rd picture is down the gas tank side and it looks clean.
The outside (outboard side) looks immaculate everywhere. It's just the inner (inboard) side.

 

Pass side is worse and the photos make it look horrible...but still not like the catastrophic stuff I see on the web... and again the outside (outboard side) looks immaculate. very strange.

I think even on this side the 202 parts are overkill but that is my goal.

I never want to do this again (and if I have to I will re-frame it).

 

4/8/24
Got the front & rear driveshafts lubed up today @ 215,674
(Had the typical clunking)

Opted for Valvoline with Moly for u-joints and Mobil 1 synthetic for the slips.

Seems to have solved it.



Dropping off tomorrow at my local 4x4 shop for the Saftcap install.
I'll share pics when I get them!

 

5/3/24
The shop was backed up but getting to me now.

Driver side was very clean inside except for the very bottom.
Passenger side will look worse inside but hopefully not too far up.
I guess as thick as these caps are it doesn't matter.... not gonna go anywhere now!

Will share pics from pass side when I get them.

 

I will be following this thread. I just bought an identical 03 except no sunroof.

 

5/13/24
Got her back from Krawltex and the frame is STOUT.










Unfortunately, on the way to Krawltex I noticed that it was running hot.
I was running a Bluetooth code scanner with live data.

So I brought it from one shop to another... back to Bearden Automotive.
Since they just did a bunch of engine work I just want to make sure it's not something they did.

 

Bearden traced it to the Radiator.
Said it looked like the PO had used some stop leak and it probably clogged it up. This explains the overheating that PO mentioned.
It had hot & cold spots so that got replaced along with the cap. Pretty happy to have this sorted out.


While it was there I asked them about the no heat on the Passenger side that I had noticed last winter and forgot about.
They poked around and said the Air Mix servo isn't working so I will order one of those after I verify. Hopefully that is it and nothing to do with a clogged heater core from the dang stop leak used by PO.

Additional shot of Engine bay because I forgot to post after I added the new intake assembly and new MAF so here they are...


And the passenger front turn signal went out and was causing the fast blink.
So swapped this out too.

 

I believe those clips were used for a removed XREAS system that's on all Limiteds.

 

Damn you're going balls deep in this, i like it!

 

Thanks.
I didn't intend on having to go this far with it as far as the frame goes, but I don't like to do things half ass. Probably could have had a few spots plated here and there and redone it every few years but I just wanted to do it all at once, while I have a second vehicle I can use. Eventually this will be my DD/Work truck so I want it to be as dependable as I can get it, even if it is a little beat up on the outside.

 

Xreas, the 2003+ Limited and Urban Runner came with Xreas suspension which had a series of metal lines connected to an expansion chamber. This connected the shocks in a big X and acted as a huge crossover and remote reservoir. Whoever did the lift took the Xreas shocks and lines and all out.