Project Canyonero - GMC i5 swap into FZJ80 (1 Viewer)

[Jsin]

Project Canyonero - GMC i5 swap into '92 FJ80

Greetings all!

I joined IH8 because Land Cruisers are rad and to share this project. I’m calling it the Canyonero project. Dropping in a 2006 GMC i5 3.5 motor and transmission from a 2WD Colorado Canyon. (I got Canyonero from a Simpson’s episode) I hope some of you stay tuned as I update progress start to finish. I also hope to get some ideas, suggestions and source needed parts from other members with the combined knowledge and experience in this forum.
I know there are a lot of different options on how things should be done, but if you don’t have anything good to say on my thread, please kindly move along.

I have owned my LC for almost 9 years. It had 200k on it when I bought it and have only put 24K since then as it was our third vehicle and really only used it for camping, exploring, mountain bike/ snowboard shuttle or when our family of six needed to go somewhere together. I love our LC. I love how it rides and its toughness. What I don’t like is this thing is a slug and has horrible mpgs. The GMC motor not only has a lot more power and torque, it is also 600 pounds lighter. When done, I should be able to get 18 city / 23 hwy mpgs. Stock I was getting 9 and 11.

Before we pulled the motor, we recorded some data. Recorded weight and few passes recording time and speed/rpm. Also some runs pulling a 4460 lb. boat up a 6% grade. Motorweek reported a new 1992 LC had a 14.5 time 0-60 mph. Mine with 224k miles put down a painful 21.7 avg.

Stock curb weight is 5,060. w/boat: 9,800 (½ tank fuel)
Avg. time:
60 ft. – 21.7
330 ft. – 10.2
1000 ft. – 19.2
¼ mile – 22.7 @ 2100 rpm (4th gear)
0 to 60 mph – 21.7 3000 rpm in (3rd gear)
(average of 4 passes ea.)


Towing boat: uphill, 6% grade – avg. 45 mph, 2nd gear, 3600 rpm
40-50 mph level road time: 11.2


Anyone looking for a stock ’92 FJ80 motor and/or trans? I no longer need it. The motor/trans run well.

Parts I need (so far) from a FJ80:

Stock trans cooler and bracket
Stock A/C condenser

Any help with needed parts would be GREATLY appreciated!

I have uploaded a few albums of the progress so far.

I only get shop time once a week, so progress will be a bit slow.

New motor

Jan.15th - Pulled the motor and started making a list of parts to reuse/not use.

Jan.22nd – Test fit the transfer case to GMC trans. w/ new adaptor shaft.

Remounted the stock transfer case, cut the motor mounts and mocked in the motor/trans.

Looking at what’s going to clear and what’s not. The oil pan clearing the front drive shaft is the biggest issue right now. Hopefully, the new Hummer pan will work. Will not need to reroute the brake lines.

Jan.29th - Started looking at the wiring. Pulled temp sensor and oil pressure sensor from stock motor. Some other stuff I am forgetting.

Feb. 7th – More wire play. Pulled the stock gas pedal. Made a new bracket for the GMC pedal.

flying by wire now

Pulled the stock fuel pump. Modified the pump bracket to fit the GMC pump and to make sure it sat down in the tank far enough like the stock pump did.

Mounted the stock oil pressure sensor by tapping into an aux port/plug on the motor.

More to come. Starting back up Feb.28th and looking to make better progress in the next coming couple weeks.

Jason\m/

 

[Douglas S]

Very cool! Nice to see someone doing things a little differently.

Subscribed.

 

[Jsin]

Very cool! Nice to see someone doing things a little differently.

Subscribed.

Thanks!

 

[Trapper50cal]

Just one quick correction for you...

91-92 = FJ80 not FZJ80 so the engine is different

A 92 FJ80 is going to have a 3FE and an A440F transmission

93-97 FZJ80 is going to have a 1fzfe - (hence the "Z" in the nomenclature.) and (for 93-94) an A442F tranny or (for 95-97) an A343F tranny.

So you may want to clarify what you have...

I'm pretty sure you COULD have an FZJ80 that is titled as a 93 and has the 1fzfe but has a late 92 build date
or you could have a titled 92 that has the 3FE.

 

[cc93cruiser]

I'm confused.. You stated it's a 92 cruiser, but you keep referring to it as a fzj? You sure it's not a 3fe?

 

[KoalaCruiser]

Interesting choice for an engine swap. Im digging the the name, are you planning on adding "High intensity halogen headlights"?

Sent from my iPad using IH8MUD

 

[jatrekker]

Very interesting engine swap. Can't wait to see the finished product.

 

[half k cruiser]

I believe someone on here has done this already. I think they took there motor out of an H2 or something. Pretty sure its the same guy that swapped the Saab seats up front.

 

[thatcabledude]

Sub'd.......... Post lots of PICS!!!

Yes, this swap has been done before. The guys user name on here was "TwoTonic". I really like this swap, but if it were me I'd spring for the I6 motor. I am going to go that route when/if my 1fz dies. I like the idea of keeping the swap an inline motor.

OP, does your truck have a lift? I ask because as you already know, the front end is about go way up. You stated 600lbs lighter, have you weighed the two engine and trans combos yet? I was thinking more like 400-450. Eitherway, that is a performance gain in it's own.

You mentioned having clearance issues with the oil pan? "Twotonic" cut the pan in half and flipped the sump around to get around that.

Here are some links to info on these swaps.

https://forum.ih8mud.com/80-series-te...o-91-fj80.html

https://forum.ih8mud.com/80-series-te...onversion.html

https://forum.ih8mud.com/80-series-te...-i-5-fj80.html

https://forum.ih8mud.com/80-series-te...o-cruiser.html

https://forum.ih8mud.com/80-series-te...sion-fj80.html

 

[Jsin]

Thanks Trapper. Pardon my ignorance everyone. My LC is a FJ80 with a 3FE and an A440F transmission. Build date of 3/92 VIN starts w/ JT3J80W9N so I stand corrected and edited post.

Cabledude, Thank you and I will keep posting progress pics. Pics added to OG post I have more pics in my albums.
I am quite familiar with the i6 swap Twotonic did. Most of the help and direction is from the guy who did that one and I think this go around will go much smoother. One of the reasons for the i5 motor is so (hopefully) we don't have to go through the task of custom making a pan. But that might be plan B if the H3 pan does not work. But the main reason is the i5 will get better mpg with just about the same amount of power. I haven't weighed each motor/trans as we don't have a way to. I will go to the scales and re-weigh once done though.
I don't have a lift on it now, but I will probably just get new rear springs made to get her level. Not wanting to lift it too much after that. But a new suspension is also part of the plan. It's more than likely going to be the wife's daily driver once finished. I think she is going to s*** once she drives it. She didn't like driving it before cause it never got out of its own way. I am going to film her reaction without her knowing it. Should be good for a laugh. (then I'll never get to drive it) I am hoping to have this project finished late spring/ early summer.

And thanks to every one who replied and subscribed so far!

 

[Jsin]

OK. Back on track......

Feb.28

Before nailing down the motor we needed to address the front drive shaft clearance of the trans pan. The new pan fits but there is a component that sits a little to low for the pan to seat so we had to create space in the pan for that. Turned out well. We lowered the body all the way down onto the bump stops to see if it clears and it does, just barely. We even checked clearance lowering it down on the right side only.

Down on the bump stops:

Pan modification:

Getting more into the wiring harness and discovered that the ECU is 2006 and harness is 2008. Also discovered the motor is a 2006 3.5 and not a 3.7. Bit of a bummer discovery. So on the hunt for a new ECU plug/harness for a 2006 ECU.

Started making the templates for the motor mounts.

More pics in my albums and stay tuned for next weeks updates.

 

[rockrod]

nice work! glad to see another swapper on the board.

I had similar front shaft clearance issues and ended up replacing the toyota shaft with a spicer style CV shaft that has a 2in dia tube. That plus the 3 inch lift in the front made enough room to clear the 4L60e trans pan without any mods to the pan.

can't wait to see it finished!

 

[nukegoat]

Sweet! Very ambitious.

 

[murf]

I see your hoping for effectively doubling your gas mileage. It still is a heavy truck - I hope you do!

Any increase is a good thing ~

What are the stock Hp/Torque readings for the I-5? I remmeber reading about it when it came out and seemed like an impressive design.

 

[thatcabledude]

No sure on the I5 motor, but the later 4.2 I6 put out pretty close to what the 5.3 does.

Pretty bad ass motor IMO.

 

[desertdweller]

I see your hoping for effectively doubling your gas mileage. It still is a heavy truck - I hope you do!

Any increase is a good thing ~

What are the stock Hp/Torque readings for the I-5? I remmeber reading about it when it came out and seemed like an impressive design.

220 hp at 5600 rpm and 225 lb·ft at 2800 rpm, huge upgrade from the 3f-e. Also, like a 400lb weight loss. I think 18-20 mpg might be possible.

 

[thatcabledude]

Oh jeez, forgot this was going into a 3fe truck. Yup, big upgrade power wise.

 

[speyrod]

WIKI power ratings, I think the i4 (last listing) will be US bound in 2015 or 16. That would be cool when one is made to fit an 80. With a slight tune 200hp/ 400lb-ft would not be difficult.


Years Engine Power Torque
2004–2006 3.5 L (214 cu in) L52 I5 220 hp (164 kW) @ 5600 RPM 225 lb·ft (305 N·m) @ 2800 RPM[5][6][7]
2007–2008 3.7 L (223 cu in) LLR I5 242 hp (180 kW) @ 5600 RPM 242 lb·ft (328 N·m) @ 2800 RPM[8][14]
2009–2012 3.7 L (223 cu in) LLR I5 242 hp (180 kW) @ 5600 RPM 242 lb·ft (328 N·m) @ 4600 RPM[10][15][16][17]

2012–Present 2.8 L (170.9 cu in) Duramax Diesel I4 180 hp (134 kW) 347 lb·ft (470 N·m)

http://www.dieselpowermag.com/news/1307_july_2013_torque_the_other_duramax/

 

[Doc]

I like different.

 

[alia176]

220 hp at 5600 rpm and 225 lb·ft at 2800 rpm, huge upgrade from the 3f-e. Also, like a 400lb weight loss. I think 18-20 mpg might be possible.

18-20mpg may be doable with a completely stock 80. As you weigh her down with armor, tires and lift, you'll be seeing more like 15mpg. Still less engine weight and a flat torque curve is always a good thing.

Curious if the OP will be able to tune the torque converter lockup on this PCM.