FJ80 with 1HD turbo diesel conversion

[Hog Head]

That is nice of Oregon state

Yea, they told me CA is getting pretty anal about diesel powered cars and trucks.

 

[curious1]

Not getting a half cut would be a night mare. There is a ton of electrical to go through. There is info for reference in the service manual for the gasser, but there is no manual available for diesel at this time. I am sure there is one out there, but I have not found it yet. Meanwhile the Ellery manual is working just o.k.

There are issues to be figured out with the A.C., Tranny controller, Dash functions like tach, glow timer, cruise control, 24 volt starter, just to name a few.

This engine could be installed very easily if you had no care for electronics. So you would have a bunch of stuff that would no longer work in your cruiser.

I am in the business of performing conversions. I just want to share what could be done and is involved. There is going to be so much electrical to be done that there is no way that I will be able to document it or share it wholely. I have been up all night studying the electrical while doing mechanical during the day.

 

[aamiggia]

If you're looking for an English repair manual try these guys.

This is from Australia $49.95 CDN

 

[curious1]

I have the Ellery one already. It is good if you use it for maintenance. For a conversion it has limited info. Good news though. I just got back from purchasing an original FSM. It cost $169.00!!!! But it has all the info I will need.

 

[Radd Cruisers]

I think you may have this wrong, in one install the wiring harness was not available so the entire unit had to be wired into the gassers wiring harness.

So yes the level of dificulty did rise.

This is one of the first half cuts that I am aware of.

Rob

Up to now all that I've heard about 1HD swaps was that there's a lot of wiring needed and it is not easy. I have a feeling that these people are just trying to protect their own intrests. I guess I can understand, but in this community MOST people are open with their knowledge.

Robbie and RavenTai give tons of mechanic information all the time. I'm sure they could just say "bring it by the shop so I can get paid". But they don't, I neither would I if I ever gain that type of knowledge.

I really commend you for being very open and detailed about this swap. People are watching with wide eyes.

 

[AMMO]

George,

Any idea what the weight comparison is between the old and the new power-plant?

-Matt

 

[Radd Cruisers]

George,

Any idea what the weight comparison is between the old and the new power-plant?

-Matt

Darn close.

 

[curious1]

Unfortunately I have not seen any weight information. As Radd Cruisers said it should be close. The transmissions are the same weight. The 1FZ has an aluminum head as compared to the cast iron one of the 1HD. So the 1HD probably weighs a little more.

Today I spent the day working on the wiring harness. I will post more pictures up Sunday by noon.

I was considering using the gas guage console, but it looks like now I will be installing the console from the diesel. This will allow the use of the diesel version tach and turbo lights, oil pressure and water temp. The diesel speedometer is cable driven instead electric and it will now read in K.M.

As a side note......... If one were interested in installing this motor for the sake of just having a diesel, it would be fairly easy to do. In it's simplist form and with a 5 speed there is not much when it comes to the electrical. The basics would include starter(as 24 volt), fuel cut solenoid, glow plug switch, and alternator.

If you wanted to complete everything electrical as an option than you would also need to figure out and connect: Tach, turbo switches and lights, oil pressure sender, H20 temp sender, fuel heater, filter warning indicator, ECT sensor, cruise control (still figuring out compatibility), dash guages, A.C. idle up, A.C. amplifier (still figuring out compatibility), glow plug timer, ECT sensor. With automatic the wires for the gear selector, fluid temp, CDL, and other transfercase switches come out of different pins and connectors compared to a gasser. There are a couple more things I am not thinking about at this time. When I remember I will add them.

 

[Kalawang]

I believe you can run your 1HD with a 12 volt starter. Drexx has that on his 1HD and it starts very well, but you'll have to ask Drexx the part number of that starter.

We did try to install one of my 24 volt starters in Drexx's 1HD but regardless that the starters are interchageable bolt ons, it needed 24 volts to start the starter and that required some considerable changes. 12 volts on the 24 volt starter can crank, but not fast enough to start the engine as I myself also experienced with my own LC.



Kalawang

 

[curious1]

You can definately install a 12 volt starter. The system this comes with is kind of cool. The car is 12 volts, but the car cranks with 24 volts. I guess Toyota did this for quick and efficient starts, especially in cold weather. On the 12HT conversions I have just had the 24 volt starters rebuilt to 12 volts. They ended up working fine.

 

[curious1]

This is a picture of the diesel wiring harness. I will post a picture of it later when I have gutted it out of what is not needed.

 

[curious1]

The wires and connectors on back of diesel motor that will be spliced into gas system. These wires contain:
Gear selector, reverse light, oil pressure, fuel cut off solenoid, tach, h20 temp, glow plug hot, a/t temp, 4x4 switches, starter, and speedo signal.

 

[curious1]

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.

 

[curious1]

This is the diesel guage console out of the diesel. It has the tach in it that will read correctly from the signal sent from the injector pump. If you look closely you will also see the turbo lights. The dash will now read in Kilometers.

 

[curious1]

These are some of the electrical pieces that will be added in. They include glow plug timer, glow plug relay, cruise control, turbo light switches, starter relay, CDL switch, 4 wheel drive control

 

[curious1]

This is the cruise control motor on the left and the 24/12 volt battery solenoid.

 

[curious1]

This is the Vacuum reserve can on the top and the fuel filter with priming pump on the bottom.

 

[curious1]

These two pictures show how the gas frame has holes for both motors. The diesel frame does not have these.

 

[curious1]

The motor in its final resting place. A U.S. FJ80

 

[AMMO]

Great thread George!!!

Keep up the great work, as I know it's even harder to document.

-Matt