Dual battery in a 1991 FJ80

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Joined
Nov 2, 2021
Threads
3
Messages
20
Location
Connecticut
Anyone out there installed a dual battery system in a 1991 80? Seems like all the guides cater to the 93-97s. If anyone has suggestions for placement and battery trays that would be much appreciated.
 
The 93-97 battery tray/box is a direct bolt in on the 91-92 driver's side. The batteries are on opposite sides.
 
The 93-97 battery tray/box is a direct bolt in on the 91-92 driver's side. The batteries are on opposite sides.
Thanks for the reply - I saw that it was the case but because the configuration of the engine bay is different seems like that won’t work. The washer fluid bottle is in a totally different location. Looks almost like either up back near the horn or on the other side of the air intake would be the best place for a second tray

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The 93-97 battery tray/box is a direct bolt in on the 91-92 driver's side. The batteries are on opposite sides.
Thanks for the reply - I saw that it was the case but because the configuration of the engine bay is different seems like that won’t work. The washer fluid bottle is in a totally different location. Looks almost like either up back near the horn or on the other aowould be the best place for a second tray
 
Thanks for the reply - I saw that it was the case but because the configuration of the engine bay is different seems like that won’t work. The washer fluid bottle is in a totally different location. Looks almost like either up back near the horn or on the other aowould be the best place for a second tray
Should work no problem, you only have to remove the fan setup on the right side. The "injector cooler" apparatus or whatever the heck it is (believe "engine cooler" is correct term) is basically a hair dryer pointed in the intake manifold's general direction. Might have to "relocate" the EGR as well, can't remember though.

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Should work no problem, you only have to remove the fan setup on the right side. The "injector cooler" apparatus or whatever the heck it is (believe "engine cooler" is correct term) is basically a hair dryer pointed in the intake manifold's general direction. Might have to "relocate" the EGR as well, can't remember though.

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This is great intel. Thanks so much. I had not previously seen a pic of a 91 done this way. Time to get to work!
 
Managed to get this all sorted out this weekend. Using a battery tray from the FZJ80 was a great suggestion - we did the “hair dryer” delete and there was plenty of room to fit it in. Happy to field more questions in the future if people have questions about the kit we used etc. View attachment 2972708

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Was the hair dryer delete all that you needed to do? How does this effect the vehicle?
 
It’s fully broken - I just got this home and it has a lot of issues that need addressing. I have new terminal on order.

Second battery is for the fridge and the winch!
Just seeing this now, but I did some research when recently re-wiring my terminals on my dual battery '94. At least with the IBS dual battery controller on mine, they specifically note to wire the winch to the primary battery with all other "extras" pulling from the secondary...fridge, secondary lighting, extra outlets, etc. Hope this helps and that your project is coming along ok!
 
Managed to get this all sorted out this weekend. Using a battery tray from the FZJ80 was a great suggestion - we did the “hair dryer” delete and there was plenty of room to fit it in. Happy to field more questions in the future if people have questions about the kit we used etc.
How’s the setup working are you stilling running it aside from the fzj tray what kit did you use?
 
You will have to perform a de-smog to run dual battery for the 3-FE. I have a 62L dual zone and been running just a AGM battery for 5 yrs now without problem....
 
If you are ultimately aiming for what the OP did (rear drawers etc.) I would highly recommend locating the second battery in the rear next to the drawers and using a DC-DC power management system from Redarc or similar. Much easier to install, no desmogging and the battery is located where the heat of the engine won't kill it.
 
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