Builds DUKE - 1993 HDJ80 / 1HD-T / 5-Speed / 3x Locked / LHD *A slow DIY build / resto*

[bryce0225]

The trip back to CA was a smooth one. When I found the time, I pulled apart the stock intake and crossover pipe if there was as much oil as there was with the intercooler... nope! Everything looks nice and dry. The oil must only be present when the seal on the intercooler piping blows and there is a lack of back pressure, so it pulls oil through the catch can or turbo, and into the intercooler piping.

 

[bryce0225]

Salvaged a used CT25 core from my friend's HDJ81 (he swapped in a Garrett turbo and had this laying around). I took it to Drift Motion to get rebuilt, resealed, cleaned, upgraded, and balanced. Went from a stock 40mm spool to 46mm, upgraded 360 thrust bearings, and VSR balancing.

 

[bryce0225]

New OEM hood insulation and clips from Partsouq:

 

[FJRanger]

Wow, what a nightmare; was following the intercooler shenanigans on IG. I had no idea they were that bad. Glad you made it home.

I still can't remember what hose came off on mine. Once I got it back on and retightened it's remained in place. Or course checking the clamps have become a part of routine maintenance.

 

[bryce0225]

Wow, what a nightmare; was following the intercooler shenanigans on IG. I had no idea they were that bad. Glad you made it home.

I still can't remember what hose came off on mine. Once I got it back on and retightened it's remained in place. Or course checking the clamps have become a part of routine maintenance.

Yeah it was gnarly! Comes with the custom DIY territory I guess. Hoping everything gets dialed in soon!

 

[bryce0225]

A big chapter of maintenance and upgrades begins:

1HDT Compression Check and Glow Plug swap:
Since owning the 80, I have never checked the compression. Everything runs well, but knowing where things stand is important to me. Luckily all of the old glow plugs came out easily and on one piece! Compression numbers all looked great. I used a Harbor Freight diesel compression kit, so Im not sure how accurate it was...

Feels good to have this checked off of the list!

 

[bryce0225]

While I had the front of the truck torn apart, I figured id replace the front body mounts with new OEM units... what a massive PITA to get the old ones removes. Sawzall ended up doing the trick! Fresh ones are in and it feels good to get this annoying job checked off the list!

 

[SNLC]

A big chapter of maintenance and upgrades begins:

1HDT Compression Check and Glow Plug swap:
Since owning the 80, I have never checked the compression. Everything runs well, but knowing where things stand is important to me. Luckily all of the old glow plugs came out easily and on one piece! Compression numbers all looked great. I used a Harbor Freight diesel compression kit, so Im not sure how accurate it was...

Feels good to have this checked off of the list!

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You actually have 100psi spread there which is out of specs. Max spread is 70psi. When an engine has a small spread between cylinders it tells you they are worn evenly.

Cheers

 

[bryce0225]

You actually have 100psi spread there which is out of specs. Max spread is 70psi. When an engine has a small spread between cylinders it tells you they are worn evenly.

Cheers

I’d be interested to have it tested by a pro with a tester they trust… cylinders 4 and 5, I had to use a different compression testing kit to get access, so I don't fully trust the numbers, seeing as those are the two that are lower.

All I do know is that it runs smooth and great with zero blowby and I can’t afford an engine tear down

 

[SNLC]

If I did your compression test and got those numbers I would not recommend a tear down and rebuild.

Cheers

 

[bryce0225]

If I did your compression test and got those numbers I would not recommend a tear down and rebuild.

Cheers

Well that’s good to hear! I appreciate it!

 

[bryce0225]

New turbo going in: I had an OEM CT26 core rebuilt and upgraded my Drift Motion here in SoCal. Look beautiful and is upgraded in all of the right places. bored from 40mm to 46mm with upgraded spool and bearings. VSR balanced. I cleaned up and resealed the exhaust manifold. New hardware and gaskets. Everything torqued up:

 

[bryce0225]

Fit the new M2k 270A Alternator: Looks beautiful and bolted right up. plug and play if you fit the high clearance alternator bracket. I also upgraded all of the Alternator wiring to 1AUG

 

[bryce0225]

Heat shield in. Vacuum lines in. Intercooler piping in. lots of other odds and ends tackled. Very proud of how all of this is shaping up!

 

[bryce0225]

All wired up!

First test run and I have sprung a fuel leak. Seems to be coming from underneath the spring on the throttle arm. I found there is an o ring and washer underneath so I put in an order and Im hoping I can replace it without removing the pump. seems like I will be able to if I just remove the intake manifold for access. I seemed to stop the leak by tightening the bold on top of the throttle arm by a tiny bit... less than 1/4 turn, but I don't feel good about that lasting a long time.

 

[ofer bruhis]

All wired up!

First test run and I have sprung a fuel leak. Seems to be coming from underneath the spring on the throttle arm. I found there is an o ring and washer underneath so I put in an order and Im hoping I can replace it without removing the pump. seems like I will be able to if I just remove the intake manifold for access. I seemed to stop the leak by tightening the bold on top of the throttle arm by a tiny bit... less than 1/4 turn, but I don't feel good about that lasting a long time.

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Waiting for a video of it running mate! Intercooler piping looks fantastic.

 

[bryce0225]

I believe i have fixed and sorted the fuel leak. It was leaking from underneath the throttle arm. There is an O-ring and washer under the governor cover that I replaced. The old washer looks pretty worn out.

I had two of the 4 hex head bolts round out on me, so i had to grind off the tops to pull the cover off. Once the head was off, they spun freely and came right out. They were luckily seized at the head. To gain access, i had to pull the intake manifold and everything around the IP. much bigger job than i was expecting, so I'm hoping all is well for miles to come.

 

[bryce0225]

New Tires! Now that Im committing to pulling the flares on the 80 to go for a more simple, lightweight look; Toyo M55 255/85r16 and i mounted them on the OEM steelies for now! LOVE THIS LOOK.

They are noisier than the ATs but not too bad. The 80 is already a noisy car so it doesn't matter to me. You can see the size compared to the 295/75r16 I had before.

 

[AnalogMS]

Great thread and build, i just picked up a very similar HDJ80 in France except in green. europe definitely got the best options for those of us who prefer LHD.

i may have missed it if you mentioned it, but after the turbo and intercooler changes, did you have to mess with fueling at all?

 

[bryce0225]

Great thread and build, i just picked up a very similar HDJ80 in France except in green. europe definitely got the best options for those of us who prefer LHD.

i may have missed it if you mentioned it, but after the turbo and intercooler changes, did you have to mess with fueling at all?

Congrats on the HDJ80! I'm biased and convinced there is no better 4x4 out there.

I have nit messed with any of the fueling... yet. The performance gains with the new turbo (even at stock 10PSI limit) and the IC were pretty great. Im not looking to hot rod this thing... just keep it cool and reliable.