Installing new Engine 2015-FJ09

[redfjniner]

7 hours ago, skipperT said:

I was wrong in my post above (corrected). The outputs are the same. I mixed up some of the info in my head from way back, anyway…

yes both charging systems are identical. Nice that the costs of the stator assy have come down. 

did the new to you engine not come with LH and RH case covers? 

-Skip

Engine came with LH and RH side covers, but they are scratched up, so I will replace them with the ones off my 106K engine.  Just requires a few gaskets, and an opportunity to look inside at the clutch and stator.  (not that I could notice anything bad)

[skipperT]

13 hours ago, redfjniner said:

Engine came with LH and RH side covers, but they are scratched up, so I will replace them with the ones off my 106K engine.  Just requires a few gaskets, and an opportunity to look inside at the clutch and stator.  (not that I could notice anything bad)

Oh so if they left the stator in, i would swap it to your original LH cover as well. If it were me anyway. 
-S

[redfjniner]

All wires are disconnected and labeled.  Removed the exhaust today, fiddly deal, but followed advice on this site.  Ready to drop the old engine and install the replacement.  I will probably exchange the side covers after installing the replacement engine.

Skip?  Why would you replace the stator that came with the replacement engine that only has 4Km on it?

[skipperT]

I wouldn’t. Pretty sure we’re on the same page-

What I was trying to say was: use the newest stator with the least time on it.

if they included one on the new-to-you engine, Pick the nicest crankcase cover and install the newest stator to it, and put it on the engine. You were right, they are identical parts and the charging output is the same on both models.

(sometimes hard to convey my thoughts clearly…)

-S

Edited January 16, 2022 by skipperT

[redfjniner]

Question?????  Here are two pictures of my two Oil Cooler water hose connections.  The one on the left is from the New Used Engine and the one on the right is the one on the 106K Engine being replaced.  There is a kink in the Alum. piping coming off the Cooler.  It kind of reroutes the rubber hose a little but as is doesn't present any problems with other parts of the engine.  My questions is:  Should I be concerned regarding the reduction in volume of coolant to the oil cooler?  The water coming out of the OC goes to the engine block.

[roadrash83]

I don't have my shop manual handy but look at where the coolant goes into the block, if it goes to the radiator with out passing through the head I wouldn't worry about it. If it goes to the head clean up the old one and use it. I would not want to restrict flow to the head.

[2and3cylinders]

I'd use the new one, the little kink shouldn't affect anything significantly.

 You may be able to stick a little wood dowel in the pipe and straightened it out a bit while squeezing the sides of the kink with some rubber clad pliers.

 But again IMO I wouldn't worry about it.

 

[redfjniner]

The outlet hose from the oil cooler goes to a "water jacket joint" attached to the head,  this joint has two inlets and one outlet.   #1 inlet from the head and #2 from the oil cooler, and the third is the outlet that runs directly to the radiator.  

[skipperT]

Based on the diagram starting on page 2-37 of the service manual, it appears to me that the fitting in the left (in your picture) feeds the bypass inlet of the T stat housing (basically allowing coolant flow from cooler when Thermostat is closed I think) and the upper fitting of the cooler is a secondary return flow from the fitting of the cylinder/head area.  The primary line from that cyl fitting feeds the radiator. 

see if that interpretation makes sense. But basically once the engine heats up, coolant flow wouldn’t matter if it was minutely restricted. IMHO of course.

hth (?)

-skip

[roadrash83]

 If you have access to good old fashion radiator repair shop, let them look at. It's amazing what those guys can do.

[redfjniner]

Was able to get a friend to come over to help drop the engine out of the frame.  Disconnected the wire to the kick stand, pulled the bolts out of the back (2) motor mounts and finished removing the engine guard on the left side of the bike.  Set the center stand at full open and removed it from the frame.  Went to loosen the lower engine bolt's "adjustment bolt" and found it to be smaller in diameter than the special tool I had made.  Stopped for the night.  Will have to make another similar tool using a 11mm 1/4" drive socket, cause it fits in the smaller.  The bottom bolt was hard to remove, had to use tapered punch and then an extra long screwdiver for the final 1/2'.  There was corrosion on the bolt and in the hole, causing the friction.  The upper long bolt could be turned with you fingers after the nut was removed.  I got new bolts with the engine guards and those were showing corrosion as well, but were easy to remove.  

When I install the replacement engine, I'm going to tie strings to the electrical connector that are placed in the correct path, so when I raise the engine up into the frame I can put the wires from above.  Just a thought.  Pictures to show that I am really doing this.  See Center stand on floor.  Engine with 4 wheels.  Tires arrived today.  Note:  The PR2s are close outs, and have 2019 mfr dates, but I have done this before and I'm sure they will do just fine.  The Road 5 is new new.

[redfjniner]

You all know that I am a 75 years old and I'm retired, but still manage some apartments.  I only did 11,700 miles last year and 11,050 in 2020.  Because of the Pandemic and that I am getting older.  I want this FJ09 to last me until ?.  I have already started to plan two trips this year, both  5K ea.  Colorado (4,600m) and Alaska (6,000m).  I don't know if I will make 20K+ like I used to, but I will be riding year round.  I know I'm progressing awfully slow on this engine replacement, but issues have come up that take president.  Jan 5, 22 I was advised that I had colon cancer, which invigorated me with wonderful thoughts and expectations for the future.  You may find this funny or unconceivable, but it is true.  5 years ago, I was informed I had esophageal cancer (Dec 6, 2016) and in 60 days my wonderful wife and I got rid of the cancer.  It was a miraculous healing.  I was hoping to do the same, but this time the cancer is forming a stricture in the colon and the possibility of a blockage is there.  They couldn't even get the colonoscopy scope to pass by the stricture and had to use a endoscopy scope to continue on.  I have decided to go ahead and have surgery asap.  Besides being gone to Phoenix next week, I will return to getting surgery Feb 4, followed by rehab.  My plan is to be able to do my motorcycle rides in late March and April on.  I do plan on having the engine back in the FJ before April, and if that means I can't do the side covers now, it won't be a problem.  So bear with me, it will get done.

[dazzler24]

Great attitude in the face of adversary!   Good luck with your health and of course the rebuild.  Following closely.

[betoney]

I hate to hear of anyone getting a diagnosis like you have but you seem to be handling it well.  Best wishes for successful treatments and a speedy return to two wheels.

[2and3cylinders]

Yesterday I saw 2 pain management doctors and am having a exploratory procedure Feb 2 ( soonest available) on the nerve from my right shoulder.  Then on Feb 4 am having exploratory procedure in my colon by a new gastroenterologist specialist, as prior doctor doesn't know what's wrong as prior scope jobs, biopsies and blood tests were inconclusive other than colitis and diverticulitis which antibiotics presumably took care of but other issues persisted.

I hope that you beat your colon threat soundly and quickly, with minimal trauma, drama and stress!

I've been trying to live with my colon issues for a long time, decades, but they have not been able to figure it out. Very frustrating, painful and debilitating. I've been scoped without a sedative so I could watch and remember what they saw.  Not fun.

You are very ambitious by looking beyond your new threat.  More power to you!  Beating your prior threat so quickly was amazing.

I have had so many issues on different fronts simultaneously for so long it's worn me down.  Pain will do that.

Hopefully you won't suffer...

Good luck on the engine swap too!