Builds 2002 HZJ76 Build

[Rigster]

So both my ARB bumper is in and of course the PDI intercooler kit, so after work today I started pulling off the bumper, winch and grill to get started on this upgrade. This is as far as I got this evening...

(Only) broke 2 or 3 bolts dismantling, so all in all it came apart and off relatively well...

The winch I will need to replace the positive post as it was rusted up pretty bad, despite the rubber boot covering it, and I will also take the time while it is out to replace the oil and clean it up...

Looking forward to getting this all installed and back on the road because with everything taken off the poor cruiser looks fugly! LOL

 

[coldtaco]

If your PDI intercooler went like mine you will need a plastic grill that you can trim to fit on the back side of the grill.

 

[Rigster]

If your PDI intercooler went like mine you will need a plastic grill that you can trim to fit on the back side of the grill.

Yep, already have anticipated that, and fortunately I DO have a plastic grill, so it looks like the dremel tool will see a fair bit of action towards the end of the install.

I was starting to read up on the instructions, and it looks like they want me to move the air dryer to where I currently have a washer bottle for the headlights. Plus, I will need to see if I can reroute the washer lines for the headlights because they come through the bib where the right side of the intercooler is supposed to go. I am sure this won't be the only snag I come across, but I will need to think about this a bit, because it is really humid where I live (lots of lakes) and I want to limit the amount of time that my AC is open.

 

[Rigster]

Did not have a lot of time to work on this yesterday after work as I was running kids around to various things, but I decided to look after a couple of maintenance items more for when it is time to button everything back up. Anyone that has worked on Land Cruisers, especially the older models will have had to drill out broken nuts and retap for new ones. This kit is a must have...

The nuts I was drilling out were M6x1.0 so I tapped them the same to accept new nuts when it comes time to reassemble....

after:

Also picked up a generic air dryer for the PDI install

 

[mt72]

Making some progress! Nice to see

 

[Rigster]

I had a huge scare that PDI had not included the bag of goodies with all the nuts, bolts, clamps and the fitting for the air conditioning compressor to mate up with the new hose they provide. Fortunately I managed to find it dropped down between some items in the shop, it must have fallen out when pulling stuff out of the box!

Painted the frame and holes I made for the intercooler to make sure there is no exposed metal

I was delayed by having to retap some holes, replace nuts, but was able to finally get the intercooler installed!!

I had a heck of a time with relocating the air dryer with the headlight washing system... I was concerned that I may have to pull it all out. They tell you to put the air dryer in the location where the washer bottle for the headlights is. Additionally, the headlight washer lines run along the lower bib support right where the intercooler rests. Fortunately I was able to mount the new dryer on the forward battery tray support, and I was able to reconnect the headlight washers by running the lines below the support instead of above. Whew...

For those looking to do this install, the grill trimming is a test of patience and a steady hand. I initially used a hand grinder to cut lengths of the grill away and a dremel tool to do the more detailed adjustments. Still, as it was I was finding myself getting frustrated and impatient.

Overall, I am impressed with the quality of the product and fitment, but that is not to say all was perfect. I ended up having to make the center top hole of the PDI intake attachment larger as it was just off enough that I could not start the nut without it wanting to cross-thread.

 

[Rigster]

Additionally, I had to grind away the flange of the top middle bolt as it was such a tight fit that it was rubbing on the housing and making it difficult to tighten it up

The flange they provide has 2 holes that are tapped... wasn't sure what they were for as there is only one vacuum line to attach. I noticed they provided two vacuum line fittings, so in order to not have a hole open, I connected them both, and fortunately I had a "T" I could use to connect the one vacuum line:

Installing the intercooler pipes was... fun? It is a tight fit... but some dish soap helped make installing, adjusting hoses, etc. a little easier.

I had to trim a couple of the silicone hoses to make things a little lower to fit under the hood, but eventually I got everything installed.

Once I had that all installed, I needed to install the ARB bumper. Compared to the intercooler install, it was a piece of cake. Though it would have been easier if I had another set of hands. Definitely easier with 2 people, still, I think I had the bumper installed in under an hour

I have to service the winch and clean it up before putting it in, but that is a project for another day... I need a break... lol.

 

[Rigster]

Test drive went well... definitely has made a difference. I can leave my foot in it a little longer before it gets to around 1200F. Still need to watch the right foot, but not as much. I noticed the intercooler robs around 2 psi from the boost, so I will need to adjust boost and possibly fuel to get the most out of the system. All in all, I am really pleased with the product. I would definitely recommend, and in fact, I would just pick this kit up with a turbo at the same time.

 

[mt72]

If I understand correctly: you need the trim around the headlight to pass the piping through and eliminate the support, and air cond tank

 

[Rigster]

If I understand correctly: you need the trim around the headlight to pass the piping through and eliminate the support, and air cond tank

View attachment 3026624

Hey Tom,

Yes, that is correct... among other things. They provide instructions, though very few pictures. And they must not have headlight washers in AU because there was no mention of those. Other than that, it is pretty intuitive for the mechanically inclined. I had to make some changes as mentioned above, but otherwise it installs fairly clean. If you decide to turbo the HZ, this is a must have IMHO. It will increase performance and longevity with right-foot management...

 

[mt72]

Hey Tom,

Yes, that is correct... among other things. They provide instructions, though very few pictures. And they must not have headlight washers in AU because there was no mention of those. Other than that, it is pretty intuitive for the mechanically inclined. I had to make some changes as mentioned above, but otherwise it installs fairly clean. If you decide to turbo the HZ, this is a must have IMHO. It will increase performance and longevity with right-foot management...

I definitely want to make this later on during my build 100% Thank you for all the great input and appreciated it! Do you have to re-tune ou re-do the timing with this new PDI

 

[Rigster]

I definitely want to make this later on during my build 100% Thank you for all the great input and appreciated it! Do you have to re-tune ou re-do the timing with this new PDI

Definitely need to re-tune if you install and tune for the turbo without the PDI like I did. I lost about 2 psi boost because of the intercooler. It is not a huge issue, I was planning on increasing the boost once the intercooler was in anyways. I may play with upping the fuel a bit too.

I already advanced my timing quite a bit with the turbo, so I will probably back it off a little now that I have an intercooler. But I would advance the timing if it is stock with adding a turbo. Mine had more power when I did so, and it ran a fair bit cooler too.

 

[Rigster]

Had a little more time to tinker today and decided to shorten my actuator on the turbo. First go-round had my boost up to 12 PSI from 9... then I shortened it some more (OUCH! Careful, it's HOT after the test run!) and I ended up with 15 PSI. That is the most I was able to tighten it and still manage to get the rod reattached to the wastegate with the turbo still in the truck.

I am pretty happy with 15 PSI though, as it pulls way more than I think I will ever need. Normal driving the EGT's don't even get above 800F and cruising down the highway it keeps steady at 100km/hr & 600F. Not bad pushing the 35" tires. If I keep my foot into it for long pulls, I will still need to keep an eye on the pyrometer, but it is a far cry from where it was!

Next up, methinks, I will need to get on installing the HD clutch I ordered some time ago. If I put my foot right into it, the clutch is slipping in 3rd gear and up at higher boost/RPM's...

 

[Rigster]

Sorry... forgot some eye candy... this was from Tuesday... took the kids to the outdoor pool in town...

 

[Rigster]

I was looking after 'other' jobs and priorities over the weekend, but still took a few minutes to open up the control box to check the condition and see what all I might need for parts. Fortunately inside it looked pretty clean, so it looks like the positive post is the only thing I need to replace.

I decided to just cut the post our as any attempts at getting something to grip the nearly gone nut on the outside failed miserably. I was confident that even it Toyota did not carry these parts anymore I could put in a generic post in there.

Fortunately Dave (Japan4x4) will be able to obtain these from Toyota, but they have to run a special order to make them up. There are 2 insulating plastic 'washers' and the original stud. I could only find the stud on Megazip, everywhere else was showing no stock for any of it. Not sure on exact turnaround, but he put the order in for me.

Part numbers required are as follows:
38625-60010　　460yen

38626-60010　　535yen

38627-60011　　140yen

 

[AirheadNut]

I was looking after 'other' jobs and priorities over the weekend, but still took a few minutes to open up the control box to check the condition and see what all I might need for parts. Fortunately inside it looked pretty clean, so it looks like the positive post is the only thing I need to replace.

View attachment 3034042

I decided to just cut the post our as any attempts at getting something to grip the nearly gone nut on the outside failed miserably. I was confident that even it Toyota did not carry these parts anymore I could put in a generic post in there.
View attachment 3034044

Fortunately Dave (Japan4x4) will be able to obtain these from Toyota, but they have to run a special order to make them up. There are 2 insulating plastic 'washers' and the original stud. I could only find the stud on Megazip, everywhere else was showing no stock for any of it. Not sure on exact turnaround, but he put the order in for me.
View attachment 3034045

Part numbers required are as follows:
38625-60010　　460yen

38626-60010　　535yen

38627-60011　　140yen

I need to do this exact thing to my winch. Is yours 12v or 24v? Great to know that it is still possible to get the OE parts; looks like I’ll have to get in touch with Dave and see if I can get a set of those also.

 

[Rigster]

I need to do this exact thing to my winch. Is yours 12v or 24v? Great to know that it is still possible to get the OE parts; looks like I’ll have to get in touch with Dave and see if I can get a set of those also.

My winch is a 12V... my whole Land Cruiser is 12V.

I am not 100% sure, but I think when they went from the HZJ77 in 99 to the HZJ76 they changed to the 12V system.

However, I don't imagine that would change this part in any way?

I also noticed that the ARB bumper will need some modification to accept the OEM factory winch. Most of the anchoring for the factory winch occurs from the 8 bolts on the BOTTOM of the winch. So I will need to weld in a plate on the bottom of the winch area on the new bumper. But at over $4000CDN for a new 8274, I might as well utilize this unused OEM factory winch. It just needs some minor refurbishing/refresh. This winch has literally never been unspooled or used... except when I was testing it. unreal.

 

[janyyc]

I'm sorry if I missed this earlier, but why did you have to cut the positive post? What led to that issue?
BTW I am going through the same re: modifying bumper/bar to fit OEM winch. It is possible from what I've read, and some people say it's "easy" but basically YMMV.

 

[Rigster]

I'm sorry if I missed this earlier, but why did you have to cut the positive post? What led to that issue?
BTW I am going through the same re: modifying bumper/bar to fit OEM winch. It is possible from what I've read, and some people say it's "easy" but basically YMMV.

Yep, you missed it! No worries, it's all good. When I took the front end off/apart for the intercooler install I could not get the outside nut off the post it was so rusted. So I ended up cutting the end off the positive wire to remove the winch and now that the intercooler and ARB bumper install is done, I am getting after the OEM winch restore to put it back in.

 

[JDMBC]

Sorry... forgot some eye candy... this was from Tuesday... took the kids to the outdoor pool in town...
View attachment 3029962

ooph she looks good!!!!!