FJ80 with 1HD turbo diesel conversion

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The 1HD radiator was used because the fittings are slightly different for the intake and outlet. The fan shroud from the 1HD was also used, so that it would line up with the fan. You could use the original gas radiator, but would have to figure out the hoses and may have issues fitting the fan shroud.

Heater hoses... The ones from the motor to the inlet valve and the return hose from the fire wall to the motor are from the diesel. The rest of the hoses are the original gasser ones.

Power steering lines... Used transmission fluid hose for the L.P. side. On the H.P. side the gasser line was used. It had to be modified a little bit.
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Rob,

Thanks for the comments. I am hammering out the last of the electrical and it is a real time consuming ordeal. The FSM from the 93 actually has a few errors in it that are typos. The errors were in the combo meter section.
 
curious1 said:
The green light means your are making boost and running right. The red light means you are gonna blow your Sh!T up.
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reccomend a boost gauge and a pyrometer (autometer gauges) if you tow... gives a better indication of exhaust gas temps....mount the gauges on the drivers side pillar like cdan
nice writeup


Andy
 
Removing fuel pump

Back seats were removed and the carpet pulled up to access the cover over the fuel pump. The fuel pump was removed and a section of hose was added in its place.
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Removing gas nozzle restrictor

The fuel filler was removed so that the restrictor could be taken out. To do this a right angle die grinder was used with a cone tip. The two spot welds that held the restrictor inside were ground down. You have to be careful not to grind all the way through. Once the spot welds were ground I had to work the restrictor out by using cutters and plyers. It was a P.I.T.A.
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You might as well do the Coolant temp gauge mod while you have the cluster out. And replace the bulb in D location with a new one cause it'll probably go out the day after you install the cluster!!!

Ali
 
C1,


I have a ford f 250 powerstroke most guys will try not to exceed 1300 deg for an extended period of time when hauling.... things start to melt after that....being that yours is a six cylinder temps will probably be a little different...the tap for the sensor on my truck was done pre turbo.. i use the autometer gauges and highly reccomend them...the boost gauge is more of a luxury but nice to know how the turbo is doing...also a intercooler will help reduce your gas exhaust temps and may see a a bump in HP...also recommend a larger diameter on your exaust system.... diesels seem to run better with mimnimal amount of exhaust restriction...


Cheers Andy:)
 
Riad- A gasser tranny could be used. In this conversion the diesel tranny was used along with the transfer case from the gasser. If you used the gasser tranny you would have to figure out how to give the tranny ECU a TPS signal that the diesel motor does not have.
 
curious1 said:
Before putting the engine in I decided to install a block heater. It is installed into the most rearward freeze plug hole on the passenger side.
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Good idea. Can I ask what the diameter of the frost plug is?

And thanks for taking the trouble to document and post all this. Reminds me how fortunate we are to be able to import JDM trucks into Canada.
 
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The HF2AV transfer case on the right which is the gasser one was installed on the back end of the diesel tranny. The left transfer case is the HF2A which doesn't have the viscous coupler. I used the gasser one because it is the one that Toyota designed to go with the ABS system in the USA. I had to extend the VSS wires 4" to accomodate the extra length of the HF2A transfer case. The rest of the wires plugged in the same.
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You're right, a turbo diesel 80 is pretty much the perfect 4wd.:flipoff2:See my sig line.
x2 on the recommendation of a boost gauge and pyrometer. My pyro normally sits on about 350*C on the highway but if the motor gets a load on it ie; overtaking uphill, towing a trailer, etc. the EGTs will start to climb to about 450-500*C. I usually back off the loud pedal at 500*C but have had it up to 650*C without problems.
My 80 has the standard 1HZ with a DTS turbo running 12psi of boost, it's had the fuel wound up, snorkel, K&N, 3" mandrel bent exhaust and a turbo timer. It puts out simillar hp more torque but uses about half the fuel why would any one want a gasser?:flipoff2:
 
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