FJ62 destruction --> turbo HZJ62

[esh]

Made a little progress today.. turned into a long day to get things done before some storms arrive (the 40 just has a bikini on it, so getting the wagon done was necessary).

I had a small exhaust leak at my manifold adapter. One nut I couldn't get on so I figured this was a good time to try out the .64 A/R exh housing for the Garrett 2860RS. Gifu had good results and I was looking for a way to build boost earlier for high altitudes, and this seemed the ticket. When I ordered the .86 A/R setup I had no idea which of the two would work better. At least I know the difference now.

The .64 A/R makes the turbo much more active. It builds boost earlier and you can (probably not a good thing) reach max pressure quicker. I noticed my max went up from 10 to 11psi (maybe more, didn't feel like fully testing on a burn in run), but that is adjustment stuff.

What a better way to test it than getting a call at midnight from a drunk friend who needs a drive home just as you are installing the last hose? Luckily it all worked fine and I only have a couple things to return to in the next month to get everything solid.

I've been using the last turbo/engine setup for the past 3.5 years and still love it. Going to a tiny bit taller tires (33x10.5s to 255/85r16) dropped RPMs by 100, but otherwise no major changes to the drivetrain since the motor went in. Mileage still around 20... 19 to 23 is about the range over winter/summer fuel and all kinds of driving conditions. I went 850 miles on one tank, and need to do a better large tank setup as mine is pretty unusable for the 1/4 bottom of the tank.

Anyways, pics I got on the crappy cell phone camera from the 12 hour marathon tear down and build up.

a lonely, gaping exhaust maw

new exh housing on, everything cleaned up

I figure people don't see angles of the exh manifold and turbo much, so here are a few angles

 

[GLTHFJ60]

Sweet! I don't see a pyrometer in there though.

 

[esh]

Third pic up from the bottom, you see a hole in the neck of the manifold above the flange. A bung goes in there with the pyrometer attaching to it. It is all hidden under the heat shield and I get that question a lot when people see it in person. It is about as close to pre-turbo as you can get.

 

[esh]

I need to start documenting changes. Different turbine housing @ 277300mi on the odometer (which is about 292,000mi after the tire change stages are factored in).

Good to know 16" tires have been on since "265,500"-ish, so with 16% off on odo, I have about 14k miles on the Cooper STs. Not as much as I'd thought but they are holding up well.

 

[GLTHFJ60]

Third pic up from the bottom, you see a hole in the neck of the manifold above the flange. A bung goes in there with the pyrometer attaching to it. It is all hidden under the heat shield and I get that question a lot when people see it in person. It is about as close to pre-turbo as you can get.

I see that now. Shadow made it difficult to see first time around.

Did you observe an increase in EGTs after you installed the smaller turbine housing?

 

[esh]

Because the turbo kicks in much sooner, you see an immediate bump in EGTs that normalize quickly after reaching your speed target. Haven't been on the interstate so up to 60mph EGTs are nearly the same as what they've always been (~550-600F). I'd like to say they are 50-100F cooler, but ambient temps around here have dropped suddenly so I think that has more to do with the difference. 65mph usually sees 650F on level ground, up to 80F ambient.

It will take some runs up mountain passes over the next year in different ambient temps to get a better feel for any difference.

Although I was anxious at my temps after the initial motor swap was done, mostly because I compared a lot against Kevin/Wagongear's truck when we were on trips together, I have been very pleased with the non-intercooled temps I have with the HZ. Gifu, on the other hand, in his LHD converted BJ74 (now HZT74-L), tells me he's impatient and is in the middle of designing a mega intercooler setup. Mark @ MetalTech is also doing some major intercooler design for his Grunter GTurbo 12H-T HJ61. I rather like backing off the throttle and keeping pressures lower.

 

[esh]

Now having it all apart and to myself, it would be fun to design and fab a 1HZ to Garrett T25 exhaust manifold. Just to make the system better more than anything. I'm sure that would be easy and cheap to do...

 

[esh]

Another interesting note(or not! heh), it appears cheaper to buy the Garrett 2860RS turbo body and turbine housing (exh side) separately than as a unit. By about $300 from what I can tell on ebay.

 

[esh]

Not a lot new to report. I do feel the difference between the early boosting .64 housing and the .86 power housing. It feels like there is a decrease in top end power but nothing dramatic. I need to drop the pressure some and play with fuel to get it dialed in, but currently it is working fine. EGTs do not seem to be affected.. if anything they don't appear to climb as high but it is still inconclusive.

I did have fun last night.. got 11 gallons of petrol in the tank before I caught it. Oregon doesn't generally allow you to pump your own fuel (there is a grey area station to station for diesel). I have big stickers on either side of the rear quarter "4.2 Litre TURBO DIESEL" so the station attendant was ultimately to blame. Since I caught it, and I generally check every time, we just had to drain it out, then I had it towed home, finished draining what the Super Siphon couldn't get (their crank siphon was totally non-functional), flushed with a gallon or two of diesel, then filled it up.

What it did let me do is re-verify the fuel tank capacity, which is near exactly 50 gallons.

I'm going to have an area tank builder remake it with at least a sump and more internal baffling at some point. I'll also dial the fuel level sender in better. Just another todo. Looked briefly at the tank Mark has at MetalTech for his HJ61 and the Load Ranger is really nice compared to my home made jobber from AUS.

 

[esh]

And maybe a pic to entertain my one reader. Oregon is on Autumn's doorstep and I thought this came out well.

Looking forward to some Fall color runs.

 

[Dirtgypsy]

you need lockers and your bumper rattles...



see you friday

clint

 

[Pacer]

That makes at least two of us who are watching.

I've read that some folks mix a little regular gasoline in with their diesel as an additive of sorts...
11gal may be too much, but I would not stress the leftovers...

you need lockers and your bumper rattles...



see you friday

clint

 

[GLTHFJ60]

Damn man, it would drive me nuts if I couldn't pump my own fuel, for situations exactly like that. Glad it's sorted though.

Beautiful picture

Now it's three watchers.

 

[esh]

I was on a low sleep run out to Moab years ago in the BJ42 and put 2 gallons into the 22 or 24 gallon stock tank. Ran fine from about Cedar City to Moab, but when we hit Kane Creek for the event it was a miserable day, cutting out and not wanting to run. I won't do that again. But I did get to ride briefly with Jeff Zepp, so it all worked out. At about half a tank I filled again and it ran pretty well.

If anything, I would mix a gallon of biodiesel for lubrication. A friend that has my '81 BJ42 now does that. Gasoline seems like it would be miserable to mix in.

Only the new can carrier (stolen from the 40's bumper) wobbles now!

 

[esh]

Did a 3500 mile trip out to Colorado and back for a friend's wedding. On the way back I came through Utah and spent a couple days in the boonies, and then took Hwy 50 through Nevada and California. Filled up the tank near Carson City, NV, and came through Tahoe, Camino, Stockton, and Sonoma before heading home along the coast Hwy 101 to Grants Pass. During that 700 miles or so I didn't fill up.

Best tank was 24mpg and I averaged 22mpg doing mostly 60mph. The turbo at altitude worked fantastic. I think I was up around 10,000ft maxiumum and because the turbo spooled quicker the truck ran smooth without doing any fuel adjustment. So problem solved there. I had a small water leak before I left and was worried that it was in the head gasket because I couldn't find the culprit. Turned out it was in the stupid radiator flush host adapter I never have used and was dripping onto the head and evaporating. Replaced with a plastic coupler for now and had no coolant loss during the entire run.

There were also no other issues during the trip other than realizing I had R and L swapped on my amp. The truck worked perfectly and had great power for all kinds of different situations at 6400lbs loaded weight (2800 front 3600 rear thanks to the tank and the heavy stuff I keep in the big rear drawer). Oil never moved, oil pressure never moved, EGT and water temps were very controlled.


Also...

(Utah is really really cool)

So the next thing to do really is get the Walbro lift pump in and remake my fuel tank. It needs a sump and a deeper fuel pickup. I can't get to my last 10 or 15 gallons from what I can figure. If I could, I would easily get 1000 miles from a fill.

 

[OGBeno]

 

[wardharris]

X2 What Beno said!

 

[GLTHFJ60]

Good work man

 

[gregnash]

Very nice dude... Would have loved to have seen your truck come through Carson City!

 

[MicahMan]

That is a sweet pic! I love the write up and wow the places you can go!