Howdy Y'all!
I am finally swapping out the original stock 2H from my 1985 HJ75 RHD Australian troopy (#1393 so at the beginning). I bought a very low miles 2016 1HZ with turbo from @joekatana and I'm ready to tackle a challenging project! My goal with this thread is to provide a resource to those thinking about making the swap, so as I get questions answered and discover tricks they can be shared here. I've looked all over mud and have found bits and pieces, but nothing comprehensive and hoping this can fill in some gaps.
Background on me: I've never swapped an engine, but everyone tells me it's easy. I have tools, experience with the 2h, 1FZ-FE and 1HDT, and resources, like y'all. The troopy was at a local shop since Feb and they finally said they couldn't do it. I tried reputable shops nearby (@Trollhole or @Gun Runner 5) and would have preferred to pay them, but they are super busy and after many months of waiting already, I'm anxious to get er done. I'm not working right now, so why not?
Yes, I will be selling the 2H, preferably as a whole and in pieces of not. Cyl#6 has no compression and there is a leak up front (water pump seal?). It still runs, but needs a rebuild. The price for the whole will be cheaper than the sum of the individual parts. I'd rather be rebuilding than disassembling and selling.
The plan:
1. Remove the old engine with transmission in tact and try to retain as many original parts as possible. No wire cutting. Remove/retain old engine mounts.
2. Remove the fenders to get at air plenum rust holes.
3. Clean up the engine bay and remove now unnecessary bits. Rust remediation and paint.
4. Rebuild the trans and t-case (since it's out) then attach to the new engine.
5. Prep electrical connections in the engine bay. Trying to source the connectors.
6. Slide the engine/trans in place and bolt up the gear box to locate the engine mounts. Remove engine/trans.
7. Hire welder to attach new engine mounts.
8. Put it all together.
9. New 3" exhaust all the way back.
10. Air/water intercooler. I'll install standard xover pipe initially.
11. 2 week road trip to CO/UT because I really miss the desert!
As I get questions answered, I'll edit the post and insert them in red. I'll add to the resources below as they're found.
Manuals: 2H engine, 1HZ engine, HJ75 chassis, HZJ7x chassis, Toyota electrical connectors
Toyota FSMs
Helpful links:
glow plug wiring, electrical connectors
Gear box videos (can't have too much info):
Terrain Tamer gear box tear down (2 parts) , H55 rebuild (2 parts), getting old input spline out, another gear box tear down (starts at 1:15), Georg's tcase video
Here's the rig (the CO plate is defunct). Lot's of interior and electrical accessory mods.
and the engine: 2016 1HZ from Europe with about 37kmiles
I am finally swapping out the original stock 2H from my 1985 HJ75 RHD Australian troopy (#1393 so at the beginning). I bought a very low miles 2016 1HZ with turbo from @joekatana and I'm ready to tackle a challenging project! My goal with this thread is to provide a resource to those thinking about making the swap, so as I get questions answered and discover tricks they can be shared here. I've looked all over mud and have found bits and pieces, but nothing comprehensive and hoping this can fill in some gaps.
Background on me: I've never swapped an engine, but everyone tells me it's easy. I have tools, experience with the 2h, 1FZ-FE and 1HDT, and resources, like y'all. The troopy was at a local shop since Feb and they finally said they couldn't do it. I tried reputable shops nearby (@Trollhole or @Gun Runner 5) and would have preferred to pay them, but they are super busy and after many months of waiting already, I'm anxious to get er done. I'm not working right now, so why not?
Yes, I will be selling the 2H, preferably as a whole and in pieces of not. Cyl#6 has no compression and there is a leak up front (water pump seal?). It still runs, but needs a rebuild. The price for the whole will be cheaper than the sum of the individual parts. I'd rather be rebuilding than disassembling and selling.
The plan:
1. Remove the old engine with transmission in tact and try to retain as many original parts as possible. No wire cutting. Remove/retain old engine mounts.
2. Remove the fenders to get at air plenum rust holes.
3. Clean up the engine bay and remove now unnecessary bits. Rust remediation and paint.
4. Rebuild the trans and t-case (since it's out) then attach to the new engine.
5. Prep electrical connections in the engine bay. Trying to source the connectors.
6. Slide the engine/trans in place and bolt up the gear box to locate the engine mounts. Remove engine/trans.
7. Hire welder to attach new engine mounts.
8. Put it all together.
9. New 3" exhaust all the way back.
10. Air/water intercooler. I'll install standard xover pipe initially.
11. 2 week road trip to CO/UT because I really miss the desert!
As I get questions answered, I'll edit the post and insert them in red. I'll add to the resources below as they're found.
Manuals: 2H engine, 1HZ engine, HJ75 chassis, HZJ7x chassis, Toyota electrical connectors
Toyota FSMs
Helpful links:
glow plug wiring, electrical connectors
Gear box videos (can't have too much info):
Terrain Tamer gear box tear down (2 parts) , H55 rebuild (2 parts), getting old input spline out, another gear box tear down (starts at 1:15), Georg's tcase video
Here's the rig (the CO plate is defunct). Lot's of interior and electrical accessory mods.
and the engine: 2016 1HZ from Europe with about 37kmiles
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