78 fj40 , 1kz-te , h55f , orion

[beerfart]

Thanks for the photos . You got me thinking now .

 

[beerfart]

I was having overheating problems , so I bought a 4 core radiator and a liquid to air intercooler . The one on my rig was a 3 core . It was still overheating , so I modified the 3 core and put it in front of the new radiator .

 

[beerfart]

This is what I did to move the fan up , and raise the radiator up high for clearance .
Added a bearing mounted pulley and another belt . The other pulleys are already there for an air cond .

 

[beerfart]

This gives me much more clearance over the front axle for the radiator hose . It also gets the radiator up out of harms way .

 

[beerfart]

I flipped the fan shroud , and it worked out perfect . Lucky !

 

[beerfart]

I got the intercooler and intercooler radiator from just intercoolers on ebay . I'm very pleased with them .

 

[beerfart]

I have had it out on a 96 deg. day and it runs cool now . It will go up steep hills at 65 mph in 5th gear without getting hot . EGt's rarely get over 1000 F going up a steep hill . I have been wheeling on a hot day and it stayed cool . I have been getting between 22 and 26 miles per gallon mixed driving . It really runs great , and sounds great . It has been my daily driver . Has not used any oil at all . It does vibrate at idle , but not too harsh . I know I don't have the right motor mount set up for this engine . I also wonder if the stock dual mass flywheel would make a difference in idle ? Just above idle and higher , it is real smooth and quiet .

 

[Ambrew]

Fantastic work! Just read the whole thread. It's nice to see quality happen!

 

[Chamba]

I love it when a Rube Goldberg design works! Something in those radiators speaks to me. Nice work.

 

[beerfart]

3 Radiators , I win , right ?

 

[Chamba]

Hands down, the winner. Love it!

 

[beerfart]

I finally figured out for sure what the extra solenoid does . It increases the pressure inside the fuel pump , which causes the timing to go to full advanced . This is for cold starting . I wired the solenoid to the glow plugs , so it is energised with the glow plugs . If you have one of these do not wire it to the fuel cut solenoid , or you will be running with fully advanced timing . I could hear pinging when I wired it to a switch and turned it on while driving .

 

[racerpat]

Thoroughly impressed with this build! I'm sending you a PM regarding some of the pump internals.

 

[crushers]

amazing.
i have driven a couple 1KZTE in the past, loved the torque. fuel mileage is supposed to be very good.
sadly, that head is what turns me off that engine ... and the "E" version sucks, period.

your workmanship, amazing. outstanding.

seriously, i wish you hundreds of thousands of trouble free km.

<shaking head in astonishment>

 

[beerfart]

I'm getting 25 to 27 mpg on the highway at 60 mph. I can also run 70 mph all day if I want but mileage goes way down . I get 17 to 19 mpg in town . I have about 7000 miles on it now and still running great . It is my daily driver .

 

[beerfart]

 

[beerfart]

I added a custom radiator and eliminated the radiator mess I had before . The engine is running great and I really like the little diesel in it .

 

[beerfart]

can you post a video of how it runs?

 

[dbbowen]

This is still my favorite build on all of mud. Hows it running? Make any changes? I would kill to be able to mount my orion to a h55. Id also kill for that 1KZ haha If you ever made these adapters for the orion to sell i bet you would make some bank. Lots of guys with Orions who want the h55

 

[beerfart]

Thanks for the compliment ! I have almost 30,000 miles on it now , and it is still my daily driver , except when it rains . My 40 is rust free and the last one I had rusted out . I want to keep this one rust free .I have a Chevy Blazer that I have been doing a frame off restoration on all winter , so the fj40 is the only vehicle I have running now . The 1kzt doesn't have enough power to tow anything , but it has more power than the 2f engine had and nearly double the gas mileage , but I didn't have 5 speed on the 2f . I never got around to posting photos of the custom radiator I made , but it really cleaned everything up and always runs cool ever since I installed it . There is more to the orion to H55 than an adapter plate . You have to find a hub that fits the output shaft splines of the h55 , bore out the center of the orion input gear and weld splines into it as in the photo I posted . I don't understand why orion doesnt offer an h55 kit . They could sell so many more kits if they did . The orion really is an incredibly strong transfer case . I love it , it has worked perfectly .