FJ62 destruction --> turbo HZJ62

[esh]

Thanks. I need to do a prequel set of posts of what I had done to the truck before the engine swap.

Off the top of my head-

used HD OME, 2 extra leafs on each corner
33x10.5 BFG ATs
~'92 larger calipers
a few knuckle rebuilds- new version Marlin seals
Hella Horns
Wayne Tangen headlight harness
2x 85/100W Hella H4s
2x 100W Hella H1s
my own 1/0 battery cables, military top posts from WranglerNWPowerProducts
vinyl floor, RAAMMat deadening (need to get to most the doors/side panels still)
Littlite 12V red/white LED map/reading light
Tuffy 6" stereo console (glad I didn't do 8")
TuffDuck seat covers
JVC-AVX33 head (bluetooth phone/streaming, Sirius XM, remote, video input for remote spotting camera, USB, DVD player...), Infinity Kappa 5-1/4" coax fronts, 6.5" coax rears (replace w/Focal K2P components), 10" Infinity Kappa sub in a cheap box, Zapco 350.2, 500.1 amps, Zapco SPL-4 eq/volume/sub control, power stuff to run it
Yaesu FTM-350R dual band/dual monitor/APRS HAM radio
Garmin 60csx GPS
Itronix Duo-Touch Tablet PC, Windows XP Tablet Ed, Natl Geo TOPO! with all Western States from Colorado to the coast
bent up sch 40 pipe, with u-bolt RAM mounts for the PC, hh 2m radio (yaesu VX-7R), phone, GPS, SLR camera mount
4+ Ubolt flip kit
Marlin 5spd shift knob (!)
WagonGear tailgate and fender storage panels
Hannibal aluminum roof rack
Hannibal 1.2 roof top tent
Hannibal awning
4x4Labs rear bumper w/tire carrier, ladder swingouts
4x4Labs sliders
Australian Toyota sliding cargo windows
darkest tint the law allows
George Sclero LED front/rear dome replacements
custom SA-inspired front bullbar (up for a redesign into face-mask/pre-runner style, similar to Metal Tech)
Warn 9.5 XP winch

Probably more.. I will try to get pics of the individual components.

It is starting to need a repaint with a million layers of gloss overcoat. Have replacements for all the dinged up body.

 

[esh]

Ran B99 this week. I wasn't planning to, but it was on sale for $2.99/gallon at a truck stop. I need to change fuel lines and do something about the IP seals if I wanted to run it regularly.

Pretty cool to smell french fries when I fire it up in the morning. No noticable difference in power, but slight difference in mileage (I have been pushing it though).

Also going to try Amsoil 15W-40 for the long trip. I have thoroughly enjoyed the Mobil 1 5w-40 Turbo Diesel Truck oil.

 

[TLC Norway]

nice thread... that green 60 also looks adventure ready.
When camping, i regret not making my storage higher, but DD'ing i guess half that height is ok.
You do have a lot of gizmos, so what do you store in the back?

I would probably have a thin steel frame made to support the front of the sleeping platform, if mine were permanent like yours. Just a tip. That 2by4 is right there for anything you want to put in there.
Hinged headrests are genious, i'll make mine adjustable!!

Oh, i love your toyota beer cooler... favorite part of this thread, amongst all the amazing upgrades!!

 

[esh]

Dual Battery setup

Took some time to get pics of the dual battery setup.

I am using a BEP Marine VSR (voltage-sensing relay). Let me show you the comparison with another brand

BEP Marine 300A VSR
- 300A continuous, 1250A instantaneous rating
- marine-grade, sealed
- $135 on Ebay, + 2nd voltage gauge (~$30) or aus dual digital volt gauge (~$65) = up to $200
- on (combine batteries), auto (voltage sense mode), off (isolate batteries)
- auto mode- isolates Aux battery until Main reaches 13.7V
- control switch on unit housing with wiring/plug for remote switching (both on/auto/off)

Brand "NL"
- 85A continuous
- rubber covers, automotive sealing
- $375
- not quite so similar or simple operation, but has low-voltage protection system (see below)
- auto mode- (bear with...) if the Main goes above 13.1V, a 5m timer starts.. after 5m, Aux batter can be charged.. 12.7V cutout automatically disconnects both batteries but can be overridden.. on engine shut-down, both batteries stay connected until 12.7V level is reached
- remote monitor/controller has cutout override/jump-start (combine) mode


I used Marco's (Rover67) writeup on Rising Sun Toyota 4x4 Club * Denver, CO as a guide. It is nearly identical to my connections. I think the only minor differences are my starter is connected directly to the Main and the alternator is on the VSR +battery post.

My cable runs, battery locations, and VSR location were decided upon by how difficult it would be to modify existing wiring and make new runs. The 1HZ starter is on the driver's side so my Main went there (shortest distance). Likewise the factory wiring came out on the passenger, so instead of extending the "bundle" I just turn it all aft and connected to the +battery post of the VSR. The only added cables were a 1/0 cable from Main to +battery, and another 1/0 from Aux (+) to the VSR's "load" post.


VSR locating. Used a simple piece of steel channel with one side cut off for an L bracket(scrap on hand), also made two small spacers to push the air filter housing out about 3/4" All used existing captured nuts and Toyota fasteners.

mount bracket painted with Duplicolor Wheel Paint (Graphite). i am obsessed with that paint, it is great stuff. also rounded all the edges and corners near cabling

wiring.. 3 connections. had to hog out the oem connector a little. you can see the marine sealing of the VSR's housing

Main battery- G34 (32? forget now) Sears DieHard Platinum on stainlesstrays.com tray, my cables and military top posts from WranglerNW Power Products in Portland. oh and my fugly battery clamp made from scrap

Aux- was my main, a Blue Top Optima (same as yellow with extra top posts.. handy). Connections are VSR, wayne tangen's headlight harness, stereo amps, winch, accessory fuse block in passenger kick panel. Need to reroute the Main VSR cable more stealthily. VSR in background.

VSR installed. looped cable is the remote switch cable/connectors

dual gauge showing Auto (voltage-sensing) mode readouts. top is Main, bottom is Aux

readout with VSR set to Off (isolate) mode

did run into a minor design flaw. the coil spring arm hits my spaced air housing mount now. have been meaning to swap to struts and design around it. note: fender panel has my last 3FE compression numbers behind the engine swap.. Cyl 6 was 165 before the engine was ejected. (cylinder #6 now has much, much greater compression )

another interference shot

 

[TLC Norway]

nice and tidy.

 

[missipboy]

Have you driven over 55-60mph for any length of time? I'm curious about the cooling characteristics of your setup vs mine. I had a 1hz and now have a 1hd-t in my 88 fj62 and both start to run warm when I go any faster than that.

 

[esh]

Most of the summer. I did two weeks to California, three to Colorado and am now on two weeks in Utah. I generally drive 55 as the cabin noise is much less than at 60-70, but around home and sometimes for stretches I will do 65.

Coolant temps generally range from the 1st to 2nd tick on the OEM gauge. At 55 it is "cold" on the 1st mark. 60 is just above the mark, 65 is halfway to the 2nd mark. Pushing up hills will get it to the 2nd mark or just over, but it never seems to get much past. I will reach 1050-1150 EGT by that point and have to back out anyways. This winter I'm going to try some different turbo combos and see what I can do with dropping EGTs a little. I know they aren't optimum yet and it is likely a CT26 made for a truck diesel will work better. Kevin Rowland's EGT for comparison (he has an HZ with the HD-T turbo parts) are 1/2-2/3 my temps after doing a couple long trips together. I think Bob's HZJ60 is closer to mine, not sure what turbo he's got.

I'm pretty happy with the coolant temps. They seem similar to what the 3FE produced at similar loads.

 

[Tapage]

This winter I'm going to try some different turbo combos and see what I can do with dropping EGTs a little. .

so you are gonna make more boost .. ?

Are you going to try garret . ?

 

[esh]

Mainly just to get EGTs a little lower. There's a Garrett on it now.

 

[esh]

Just did a two-week trip out to San Rafael Swell in Utah. The alternator didn't appear to be charging for a day on the way out, but after getting in touch with Kurt @ Cruiser Outfitters to check for spare 1FZ alts (possibly the same/similar to 1HZ) and picking up spare brushes and a regulator, it started working fine and didn't have a hitch the rest of the trip. Need to take it out and do a comparison to the spare 1FZ alternator I have in the shop (but not in the truck, doh).

Got my 2nd tire carrier built for the 4x4Labs rear bumper. My welds aren't as pretty as Luke's.

Also got APRS up and going sporadically throughout the trip. I have the GPS module in my Yaesu FTM-350R. Also mounted the display above the rear-view mirror with some RAM mount bits. APRS is a good tool for friends and family- Location of KF7EOX - Google Maps APRS It works by sending the GPS coordinates (and other bits of info) into a global network. The Finland site picks it up and makes it available for mapping.


So, after 3 long trips this summer in a variety of challenging environments (technical wheeling Rubicon, altitude in Colorado, and dry/hot/dusty environments in Utah), I think the only problems I had was a busted shock mount and a fuse that had fallen out my fuse block preventing Sirius radio from working. The shock mount was a bugger weld fix previously that a Rubicon boulder unfixed.

The sleeping setup is outstanding. I can stop anywhere, crawl into the back and sleep within seconds. It takes a little more effort with a passenger.

Some fuel info given from the aCar Android app-

(over trip, 2 weeks)
Total Running Costs: $417.68
Running Cost/day: $27.85
Running Cost/mile: $0.171
Cost/gallon: $3.125
Miles/$ : 5.86

Avg MPG: 20
Min MPG: 16
Max MPG: 23

Total Miles: 2700 (est)
Total FillUps: 10
Total Gallons: 133.64

Miles/FillUp: 244.6
Miles/day: 163.07

Leaving the roof rack off helped a lot with fuel efficiency on the highways. Maybe 2mpg better without it. I only run the awning since moving to sleep inside.

 

[esh]

Oh, I swapped out the 10" Infinity sub for a 12" MB Quart in a cheap box. Wired it for 2ohm operation and it worked very nice. Now to get the new Focal components in and build a decent sub box.

 

[OyajiJon]

Nice! Can you please post some pics of your 350 head unit mount? I put mine over the ashtray hole.

And, it looks like you have sliding rear windows...do you have any leaks? I picked up a set recently, and a guy I know at TLC says they've had leaking problems with them.

Thanks for any and all info!

 

[kevinmrowland]

Hey Ken,
I run the FZ alt in mine, fits prefect, compared on the bench to the 24v HZ alt and it was the same thing.
The brushes are a breeze to replace, but unfortunately the voltage regulator is not.

Oddly enough I think mine is crapping out right now, I get a no charge situation from time to time.

 

[esh]

Nice! Can you please post some pics of your 350 head unit mount? I put mine over the ashtray hole.

And, it looks like you have sliding rear windows...do you have any leaks? I picked up a set recently, and a guy I know at TLC says they've had leaking problems with them.

Thanks for any and all info!

Sliding rear windows. Mine are OEM, bought from SteveO (here on mud) at Man-A-Fre. No leaks, weatherstrip is getting ready to deteriorate more but is about an 8/10. Attached with strips of butyl and have been solid for 3-4 years now. I need to get some cladding to cover the interior part (using clips right now).

Pics of the mount. I slapped it all together. I use RAM mount stuff for pretty much everything in the truck. They are excellent build quality and solid. The radio uses 2 photo/tripod ball mounts I had (stole from camera use that could have been handy this trip) and a regular arm. This allows both the passenger and/or driver the ability to view the display.

My final build will be more of an overhead console. I am going to bend some thin-ish sheet metal with a brake to attach to the rear view mirror and dome light bolts, then build stuff off that like overhead consoles do. I have become interested in carbon fiber lately so maybe I will make a bitchin carbon fiber skin after it is done (note, it is never done with this truck).

I haven't figured out how to route wires yet and might do a conduit/pull-string approach like we do with our large fiber runs at work. The overhead console will get (at least)- sunglasses holder, pocket o stuff, yaesu radio display, radio speaker.

the "center section" of my electronic stuff, tablet in Portrait

radio mount detail

another perspective, changed the tablet's orientation to Landscape. it is pretty adjustable and you can swing the mount around the bar I have the ball-mount u-bolted to for just about any angle you can imagine.

the kind of detail I see on the tablet (showing 1:100k detail on natl geographic TOPO! State Series, 1:24k level view gives even more detail). the "GC" waypoints are geocaches loaded from GPX files run from Pocket Queries from geocaching.com ($20/yr membership to run batch pocket queries)

the only niggle is TOPO! won't display the Notes/Hints/Log info, so I use GeoBeagle on my Android phone for that.. or my friend used his Garmin 550t that shows everything

Oh, the yellow flowers are toilets and the green tent is our campsite (campsite #1 @ The Wedge, San Rafael Swell, Utah)

 

[esh]

Guess I should post why I mentioned that campsite on The Wedge specifically. Behind the chairs is where our campfire and sleeping stuff was setup. I am sitting in the middle.

 

[esh]

Hey Ken,
I run the FZ alt in mine, fits prefect, compared on the bench to the 24v HZ alt and it was the same thing.
The brushes are a breeze to replace, but unfortunately the voltage regulator is not.

Oddly enough I think mine is crapping out right now, I get a no charge situation from time to time.

Woot! Thanks for the info. I sent it along to Chris as he had eyeballed thinking they were similar but hadn't done a direct comparison. The connector socket shape can be different is all I knew.

The only other weirdness mine had (and the reason for getting a regulator as a spare) was I would see short spikes to about 15.3V from time to time, usually after a long hot day of driving while running the fan. The fan noise increase would tip me that something was going on. Didn't happen at all this trip.

Since that single day where the charging appeared to be sub-normal, everything has been working perfect. The VSR does exactly what it should do (isolate the batteries while engine is off, and when the main is at 13.7V for 5 seconds, it opens the connection for the aux to charge).

I didn't realize that the 1HZ's operation was slightly different than the 3Bs that I have in the BJ42s in that a solenoid in the IP runs off 12V to keep fuel open. When it loses 12V it allows a valve to close in the fuel path to shut the motor down. You can optionally remove the valve in the solenoid in a pinch, and kill the motor with the clutch. The 3B can run without any power at all and the shutdown process swings the EDIC motor arm to close the fuel from the engine.

 

[boots4]

...in that a solenoid in the IP runs off 12V to keep fuel open. When it loses 12V it allows a valve to close in the fuel path to shut the motor down. You can optionally remove the valve in the solenoid in a pinch, and kill the motor with the clutch.

The bosch VE pump on my 4bt is similar. There is a solenoid that gets 12v to keep the fuel path open. I ran into this just recently at work when the truck wouldn't start. After troubleshooting other avenues I finally removed the plunger inside the solenoid and reinstalled it (needed to seal the hole) and it started right up. We get a manual shut-off lever on the side of the IP so I've hooked up my choke cable to activate it from inside the cab.

 

[OyajiJon]

Thanks for the pics, Ken! It looks like you've got it all figured out, although I don't think my simple mind could take in the info you've got at your fingertips. Nice set up, and great campsite you posted.

 

[FJTOYMAN]

Wow! you've done a lot of work since I've seen you last. Is your shop still in the same place? I might have to stop by and drool.

 

[Captain Caveman]

Was cool to see you on the cover of 4wd toyota owner out in silver city. I wished the weather would have held so I could have drooled over your rig a little more. Build is looking good! Looking through this thread it was fun to see mine in the background of a few of the photos.