78 fj40 , 1kz-te , h55f , orion

[beerfart]

My rig , at S. M. O. R. R. , Seymore , Mo.

 

[beerfart]

Could not get the electronic pump to run good , so I got a 2lt pump and used some of the 1kz pump parts to make a hybrid . It runs good now . Still need to get the pump adjusted .

 

[85Diesel]

Details on the pump conversion?

 

[85Diesel]

And what did you end up doing with the number two solenoid?

 

[coleman2347]

Magnificent work, looking at stuff like this almost makes me want to move back to the states, almost but not quite...subcribed

 

[roscoFJ73]

Thats a great swap.Ive always wanted someone to put a 1KZ into an older model like a 40.
Might be easier to send the pump to someone in oz to work on.
$2450 exchange at cooma diesel

 

[beerfart]

And what did you end up doing with the number two solenoid?

The #2 fuel cut has a green wire the same color as the #1 fuel cut , and they go to the same connector , so I wired them together to the ignition
. It runs great , but I still have no idea what it does ?

 

[beerfart]

Details on the pump conversion?

I pressed the bushings out of both distributive heads , and pressed the 1kz-te bushing into the 2lt head . It is the same as 2lt , except 12mm bore .You have to have a method of precisely locating the bushing before pressing it into place . The fuel delivery slot must be perfectly centered in the port from the fuel cut solenoid for the distributive ports to be aligned correctly . I used a 2.5mm carbide drill to bore the plunger deeper to connect to a spill port . The plunger is rockwell 60 . I can't remember what size drill I used , but Ihad to cross drill a spill port through the center bore . Then I had to square the leading edge of the spill port . I made a spill ring to fit the kz plunger out of 440 and hardened it to 58 rockwell . The 2lt spill ring is 60 rockwell , but I think mine will be fine . I used the 1kz-te cam plate and spring , and plunger springs . I used the 2lt delivery valves , because they were new . Not sure if they are the same as 1kzt ? I used the 1kz-t manual to set up the pump .

 

[Christian]

I'm with Rosco on this one, I have been wanting to see that conversion for years too.
IMOP an ideal swap engine-wise, allthough I would have used a R151f and splitcase, but that's because I can't even begin to make an adapterplate myself

Please post a driving test!

 

[subzali]

can you post a video of how it runs?

 

[beerfart]

I'm with Rosco on this one, I have been wanting to see that conversion for years too.
IMOP an ideal swap engine-wise, allthough I would have used a R151f and splitcase, but that's because I can't even begin to make an adapterplate myself

Please post a driving test!

I drove it about 200 miles this weekend . It will go up a steep hill on the highway at 65 mph in 5th gear without downshifting at about half throttle . I have the soft top on it , so 65 mph is as fast as I can stand . The 2F engine that was in it would slow down to about 50 mph with the pedal to the floor , and it was in good shape . Pyro says 1100 degrees f going up a hill . I don't know if this is good or not . This is pre turbo at 10 psi boost . No intercooler . I have no idea about mileage , because my odometer is so far off [ big tires ] . I still have more pump adjusting to do .

 

[Christian]

I drove it about 200 miles this weekend . It will go up a steep hill on the highway at 65 mph in 5th gear without downshifting at about half throttle . I have the soft top on it , so 65 mph is as fast as I can stand . The 2F engine that was in it would slow down to about 50 mph with the pedal to the floor , and it was in good shape . Pyro says 1100 degrees f going up a hill . I don't know if this is good or not . This is pre turbo at 10 psi boost . No intercooler . I have no idea about mileage , because my odometer is so far off [ big tires ] . I still have more pump adjusting to do .

Sounds like an excellent match
We didn't get but a few FJ40's, but we got the BJ42.
A lot of them has been converted to 2H and 12H-t's but I always felt those engines were too heavy for the short wheelbase and front axle.
The 1KZ-t (mechanical pump version) seems like the ideal upgrade for the BJ42.
It's a sweet engine with the balancing axles and all, I like it so much I fitted one in our Volvo TGB1314 6X6
Wish I had your fabricating skills!

 

[beerfart]

can you post a video of how it runs?

I'll post a video soon . May take a few days .

 

[beerfart]

Sounds like an excellent match
We didn't get but a few FJ40's, but we got the BJ42.
A lot of them has been converted to 2H and 12H-t's but I always felt those engines were too heavy for the short wheelbase and front axle.
The 1KZ-t (mechanical pump version) seems like the ideal upgrade for the BJ42.
It's a sweet engine with the balancing axles and all, I like it so much I fitted one in our Volvo TGB1314 6X6
Wish I had your fabricating skills!

Thank you so much for the compliment , I was pretty much adamant on getting a compact , light engine . I really wish there was more available . 2F was not an option [ hate it ] . I think gasoline engines suck ! I'm happy I at least have a toyota engine in it .

 

[beerfart]

This is the 1kz-te bushing pressed into the 2lt head . Next photo shows home made spill ring and spill port machined into 1kzte plunger . The 2lt spill ring could be bored out to fit the 12mm plunger with a carbide boring bar and then lapped to fit , but I didn't want to ruin it , since it is brand new and lapped to fit the 2lt plunger .

 

[85Diesel]

You must have some experience rebuilding i.p.'s? Did you work in an injection shop or something? So is the 2L-T plunger 11mm? I've heard that's what the plunger in my mitsubishi 4m40 pump is, but it's made for a 2.8L turbodiesel and seems to have plenty of power in my 1KZ-T. Very interesting posts, please keep it up!

 

[beerfart]

You must have some experience rebuilding i.p.'s? Did you work in an injection shop or something? So is the 2L-T plunger 11mm? I've heard that's what the plunger in my mitsubishi 4m40 pump is, but it's made for a 2.8L turbodiesel and seems to have plenty of power in my 1KZ-T. Very interesting posts, please keep it up!

The 2lt plunger is 10mm . There seems to be a lot of people using the 4m40 pumps . I have read they supply more than enough fuel to raise the boost higher than stock on a 1kzt . They may have more plunger stroke from the cam plate . No , no experience on i.p.'s , I'm learning as I go . There are several threads about converting 2lt pumps to 1kzt . Same pump , different bore and cam plate . The internet is a wonderful tool . I've been a machinest since the 80's . All that experience building and repairing equipment makes it much easier for me to figure things out .

 

[DanS HJ-45]

Dear lord that is some amazing work.

Those bendable metal hoses suck, however. I've never had one that didn't decide to loosen itself up after a few years, and leaking all of the coolant out pretty quick.

Much better once I switched to rubber hoses connected to plain metal tubes.

I'm absolutely blown away by the 2L-T pump onto the 1KZ-TE.

Dan

 

[beerfart]

Dear lord that is some amazing work.

Those bendable metal hoses suck, however. I've never had one that didn't decide to loosen itself up after a few years, and leaking all of the coolant out pretty quick.

Much better once I switched to rubber hoses connected to plain metal tubes.

I'm absolutely blown away by the 2L-T pump onto the 1KZ-TE.

Dan

Thanks for the tip , Dan . I've never used them before . I'll have to keep an eye on them . Losing coolant in a head crack prone engine like the 1kzt would be a very bad day!

 

[Chamba]

I'm with Dan and Roman. Amazing work! I wish I could make an adapter like yours to put my wife's Jeep liberty crd engine in my LX.

When I lived in Australia, I always wanted to see a D4D put into a 40. This is right up there with the D4D for cool factor.