94 FZJ80 6.2 conversion begins!

[JimCrow]

Sepentine belt setup

"Lorax" I saw your post about pieces needed, you will also need the plate between the water pump and the timing cover, the sep/belt w/p has a different bolt pattern where it bolts to this plate.
Jimmy

 

[rtarh2o]

Lorax, tell me a bit more about your 80, does the cruise control work? What about the A/C, is it working ok with a GM compressor? I need to get down that way and see it, how about some pics?
As for mine, I am thinking I might be going the serpentine belt route pretty quickly. I got all new belts and a good pulley installed Saturday (as mentioned above) Today I took it around and registered and liscensed it so now I am legally driving it. From there I drove it to work. I have probably gone about 30 miles today and on the way home tonight the belts started squeaking again! Not as bad as the last time but still annoying. I opened the hood when I got home and checked the belts, they seemed tight enough, not sure how tight they need to be, they are pretty long so maybe they need to be a bit tighter? I squirted some Belt Ease on them and let it idle for a minute or two. About that time I stopped for dinner, I didn't rev it any to see if they are still squeaking, I really don't want to know if they are, so I am putting it off until morning to find out. I also am developing a clatter/rattle in the engine, I am hoping there is a bolt I missed tightening the other day, it sounds like a loose bracket or something (or a rod knocking) I will look into that a bit more in the morning too.
All in all a pretty good day, the gas (fuel, sorry) gauge hasn't budged with a little over 30 miles since fill up, either I am getting pretty good mileage or it is stuck!
I am going to check with the A/C shop tomorrow and try to make a little road trip this weekend to see how it does.
I will work on more pictures of the finished product, and maybe even a video so those of you wondering about the noise level can get an idea of what it is like.
Rusty

 

[lorax]

I started a thread on my truck. Here is the link:

https://forum.ih8mud.com/diesel-tech-24-volts-systems/216143-fj80-w-6-2l-diesel-getting-turbo.html

The cruise was working (once for me), so I hope it can be fixed. The AC was not working, but is all hooked up. I think it leaked out and since it was winter, the previous owner did not do anything about it. I am switching compressors due to the serpentine, so I we will see...

Glad to see you are running. Let me know if you are in Austin (or if you want to get to Dallas sometime in the next week, before I take it back to Austin).

Cheers.

 

[rtarh2o]

I am planning on being in Dallas the first week in May, it will probably be back in Austin by then but if not I would love to see it. Otherwise I do get to Austin every once in awhile, I will let you know when I do. Good luck with it all, let me know how it turns out.
Rusty

 

[knorrena]

Damn, I was supposed to be in Dallas this week, and the first week in May. I coulda taken you out for lunch and had a look at your cruiser. Plans changed though, and now I have no idea when I would be down again.

Karl

 

[rtarh2o]

Been driving alot of short trips this week and doing great, the shifting is still hard and revs too much but I ordered a governor kit to adjust it, sounds simple enough to do myself. I went to the A/C shop yesterday to show them what I have, they called back this morning and said to bring it today after lunch and they would get on it and hope to get it finished by tomorrow! Wow, wouldn't that be nice, I am not holding my breath but I on my way there now.
Rusty

 

[rtarh2o]

Believe it or not the A/C is finished! They called around lunch today and said it was done and working great! Unbelievable, I really didn't expect to get it back so fast but I guess I am due a bit of good luck. It is not that hot here yet, only about mid 70's now but they said it was blowing out at 40º, I used it for a few minutes going home and it got too cold so I turned it off. It is suppossed to get to the 80's this weekend so I may get to test it out. I plan to take it on a little road trip this weekend to see how it does. All I have left is to figure out the cruise control, get a tach hooked up and some tires. It is now my daily driver. My driving impressions are very good, the power as I said is more than the 1FZE by quite a bit just waiting to find out about the mileage. Right now I am at 90 miles and it right on 3/4 tank but as I recall with my old 94 the first half of the tank go by a lot slower than the 2nd half. I will be able to tell this weekend after about 300 miles, I am hoping for around 20 mpg, hope I am not too dissapointed.
Rusty

 

[made4surf]

Rusty,
Can you please post a pic of the finished AC in the engine conpartment? I've been to lazy to do mine but summers coming pretty soon and maybe yours will inspire me to do mine.

 

[CruisinFJ60]

The FJ80 w/6.2L diesel is mine. i got it about 1 month ago from someone in South Texas. The 80 is in great shape, but the belt system sucks. So I talked to "The Diesel Depot" and Randy and got all the parts for a Serpentine conversion and the turbo install.

Randy is working on getting it put together.

My intension is to be able to tow with the 80 (Tow an FJ40 on a trailer), so I need the turbo.

Without the turbo, I was getting 14-15mpg. Not as good as I hoped.

You are welcome to test drive, either in Dallas or Austin. How far are you from Austin?

Cheers.

thats pretty sheisty on fuel i would think it would be much more than that. i dunno how much a turbo is gonna help your fuel miledge but it will be way mo better on power.

 

[rtarh2o]

I will get some pictures of the A/C set-up tomorrow when I get back home. The compressor is the old style (can't remember what model) great big. They say it takes quite a bit of horsepower to run it but it really wasn't noticeable when I turned it on. As far as performance it blows so cold I had to turn it off but it isn't hot around here yet, 80's today I will know for sure in another month. I put about 170 highway miles on it today and it just hit 1/4 tank. I know the first half seems to go alot slower than the second half of the tank as I remember but 170 is alot for the first quarter considering I rarely went 300 miles to a tank before, so needless to say I am optimistic about the mileage. More about the trip, I am debating about tire sizes, I like the way it accelerates with the stock tires and it was really nice on the highway at about 65 mph. I don't have a working tach yet so I am not sure of the rpm's but it seemed a little high. From the research I have done it should have been turning about 2180 rpm with the 265's at 70 mph. I was driving at 65 today thinking it would be about the same as 70 with the 285's. I have an old set of 285's in my shop I am going to mount this week to see how it drives with them, I think it will be better on the highway and doubt I will loose much acceleration either. It should turn about 2050 rpm with the 285's at 70 mph which might help the mileage a bit.
On the highway it felt alot like the 1FZE, noise level wasn't bad but not the 1FZE either. Acceleration was a bit slow at highway speed, 2 lane passing would require some room but divided highway it is fine. Around town it accelerates well, it feels faster than stock and now that I have the trans shifting a bit better it is nice.
That's it for now, I will post more tomorrow after I get home and fill up and have an accurate mileage report.
Rusty

 

[rtarh2o]

The results are in! 340 miles, 17 gallons of diesel, right on 20 mpg. I am somewhat excited. Probably not enough savings to ever pay for itself, maybe $500 per year or so, but it is nice to be able to go 400-500 miles on a tank. I still have the stock tires so I was driving around 65 to keep the rpm in the range where the 285's should be so I don't expect any better mileage with the larger tires. I was driving most of the time with the A/C on and probably put about 50-60 in town miles on it while I was there so true highway mileage might be a bit better. The more I drive it the more I like it, I am sure I am a bit biased but so far I would highly recommend this engine swap to anyone. If you are happy with the 1FZE performance you will be fine with a non-turbo 6.2. The good news is you can easily add the turbo and make it even better but so far I can't see myself doing that. I would like to drive a Cummins, Isuzu or Toyota diesel to see how they compare but I can't see any of them perform enough better to make them cost 3-4 times as much and I really can't see anything getting much better than 20 mpg in an 80. My plan now is to get my WVO processor going and start blending to really save some money!
Rusty

 

[Dazza]

Sounds like I'll never get to see my project to finished. I am leaving the country and selling all of my possessions, including my project fj60

here's a link:

https://forum.ih8mud.com/vehicles-trailers-sale-wanted/215361-83-fj60-sale-seattle-wa.html

sorry for the hijack... good luck with your project!

 

[Chas Stricker]

Rusty I think you've got to be happy with the mileage and power. Great job on the installation. Just keep on driving.
Chas

 

[rtarh2o]

Has been running great but tonight on the way home from work the transmission shifted so hard and stuttered I thought everything was going to fall out on the ground! Much to my surprise it kept going after I gave it a little fuel then going up a steep hill towards my house it slipped on the downshift, almost came to a stop but again after a little fuel it chugged up the hill in probably 3rd or 4th gear. I babied it home and parked it. It is only about 4 miles from work to my house so hopefully I didn't drive it too far to cause any more damage. I am going to check the fluid level tomorrow and then probably tow it back to the trans shop. Well it was fun while it lasted! Hopefully it is just low on fluid, but I think that usually just makes it slip so probably back in the shop for who knows how long!
Wish me luck, I guess this will give me a chance to get my WVO processor going. I might also start thinking about a 5 speed so I don't have to worry about breaking and shift points!
Rusty

 

[addicted56]

Geez,

You can not get a break.

I have the same set up as you in my garage. Was going to use the transmission just becuase I had it but after hearing your horror stories and becuase I wanted a manual anyway I went a different route. NV4500 on a 4bt swap. So if it makes you feel better all of your pain has hopefully saved me some .

Good luck and I'm going to continue watching.

 

[Chas Stricker]

Rusty I used mine pretty hard and once built the right way it never gave me any problems. I still don't think they have the right gov pack nor the right shift kit. Mine was turbo'd and I used it (eating Fords and Dodges) with 35" with no issues. That gov pack is a big deal as is the TV cable. I'd say try to stick with it.
Chas

 

[rtarh2o]

I hope it is something as simple as an adjustment, there wasn't any grinding or anything and when it didn't have to shift it ran fine so maybe so? Anyway, I am going to check the fluid in the morning then probably have it towed back to the shop to see what they say. I ordered a governor kit for it but was waiting to play with it all. At this point I am planning on sticking with the 700R4, I think it might be difficult finding all the parts for a 5 speed conversion in the States since they never imported any that I am aware of.
Will keep you posted.
Rusty

 

[JimCrow]

trans tv adj.

I have been following your build, very interesting and am sorry for your trans issues. I also saw your inf. on diesel place so I thought I would try to help. I will show a picture of the brk.,the connector rod that hooks to the inj. pump, & cable hookup that GM has. The cable outer casing is premade to length as well as the enter cable, no changing cutting of the inner cable. when hooked up push the tab in pull the outer casing to the rear of veh. then use your hand and rotate the inj. throttle to full throttle the cable will adj. itself you will hear it clicking when you do this. It is set ready to drive after driving you may need to adj. the outer casing to the front of veh. a couple notches at a time for desired shift. moving the casing fwd. softens the shift.
Jim.

 

[rtarh2o]

Jim, thanks for the information. I am thinking about getting an OEM cable but here is the situation. I have a military take out 6.2, from what I have been told they used the TH400 transmission. The 6.2 uses a bracket and a metal rod going from the throttle lever back towards the rear of the block where it attaches to the TV cable. My concern is that the rod and brackets I have are not the same as a 700R4 set-up would be. Your picture for some reason is not loadinig all the way (it might next time so I will take a look at it again) so I can't tell if your set-up is the same as mine. If it is not the same I guess my options are to find the correct brackets and get the OEM cable or make the aftermarket cable work. So my question is, when you first install the inner cable (which is a preset length on the OEM cables) is there any slack in the cable, and if so about how much. I would think there shouldn't be any slack in the cable but it shouldn't be tight either. The resistance should be the throttle valve moving as you move the cable. Also it looks like the throttle valve is spring loaded to keep it closed so I don't have to worry about making sure it is closed before I set the initial cable length. I really don't see why and aftermarket cable wouldn't work if the length is set correctly. I think what must have happened is that they got the initial length of the inner cable a little too tight since it won't go beyond about half throttle before the cable is too tight.
They are supposed to be working on it now, they drove it around the block and are pretty sure something is broken so it looks like it will be coming out again. Would the cable missadjustment cause it to break something?
Rusty

 

[JimCrow]

You are correct the TV is spring loaded in the trans., if you got your brk. and rod off a 6.2 it is for a 700r4 that's the only trans. that had it behind a 6.2. TH400 only used vac. for shift, an electric kick down or passing gear. Do you have the electrical sw. for the lockup t/c ? The aftermarket cable will work fine if adj. properly, there is usually a small amount of slack in the cable at idle when adj. is correct, but every trans. has it's own setting that works best. I have rebuilt and installed plenty of them and not all like the same setting