FZJ105 -> HDJ105 (1 Viewer)

[wedgetail]

So I got a bit done this evening... A heap of parts turned up from toyota so I got the new rocker cover gasket on. Which meant I could put the intake back together and attach the associated wiring. Left the heater out, will have to alter it's brace.

Got all new coolant hoses, including the little turbo ones. A ruptured one of these would be as fatal as a main hose, and doing one in the bush/byt the side of the road would not be fun!

As I'm trying to do everything I can with the motor out and it all very accessible I thought I'd check the alternator brushes.

They weren't too bad but they're cheap and I'd rather not pull it out for a long time and the FTE obviously really needs a healthy alternator.

Looks like my gamble of getting the HZJ105 pick up worked as its a perfect fit with the mystery sump. As I mentioned it seemed I lucked out with the level sensor too - it swapped straight over.

HDJ100 pickup

HZJ105 pickup

Was going to use loctite 587 on the sump then realised I had some of this - specifically for doing the sump and timing case.

Water pump, timing belt, idler/bolt, tensioner, cam seal. All genuine.

A mate gave me a flywheel bolt so I torqued it up and fitted the clutch. Did a mock up with the fork and throw out bearing - still not 100% sure how the HZJ80 fork, VDJ bearing and FZJ slave will go but measuring up I think it might work...

Seeing as I'd done the waterpump and hoses I might as well service the fan hub. It's approaching 0* outside so I've left it to drain - the oil was barely moving!

Also have decided to piss the vac pump off, it's now redundant. Blocked the oil passage and will make a plate tomorrow. That's enough for tonight I'm buggered.

After the cruiser's stunt last weekend it's been in disgrace for the week. Bolts fell out of the receiver for the gearstick allowing it to slide on the shaft = no gears as I went to change up a hill. Had to get towed to a mates. Then towed it 30km back yesterday. Pushed it in with the tractor. Drained the oil just now and thankfully it was like new - hopefully the bolts didn't go through the box. So hopefully I'll at least have it ready for the FTE to go in by the end of tomorrow...

 

[mudgudgeon]

While you have your fan clutch apart, have a read here if you haven't already

Blue fan clutch mod

I tuned the clutch on my HZJ105 and it made a big difference to how it operated.
I damaged the o-ring on mine and the CST oil leaked out in just a few weeks.

 

[mudgudgeon]

Also have decided to piss the vac pump off, it's now redundant.

Is the vac pump not needed for brakes? All my diesel cruisers have had a vac pump and vacuum accumulator to provide vacuum for the brake booster

 

[wedgetail]

While you have your fan clutch apart, have a read here if you haven't already

Blue fan clutch mod

I tuned the clutch on my HZJ105 and it made a big difference to how it operated.
I damaged the o-ring on mine and the CST oil leaked out in just a few weeks.

Was yours operating too much? Or overheating? Looks like a good service, I'll see how I go for time I'm kind of on a mission to move onto the car now... I've have a few apart and haven't rooted an O ring yet but I'll head your warning - certainly don't want to do it now!

Is the vac pump not needed for brakes? All my diesel cruisers have had a vac pump and vacuum accumulator to provide vacuum for the brake booster

ABS 100/105s don't use vac for brakes - it's all in the electric pump/nitrogen accumulator. I think pre 02 FTEs used vacuum for the shutdown butterfly but mine is electric. Obviously electric idle up too.

 

[mudgudgeon]

Ahh, I haven't had an ABS cruiser. Makes sense.

My HZJ105 had an overheating problem, the fan was lazy, never really heard it fully engaged, even when it probably should have been. I tuned the fan looking for a solution to my overheating.
My problem turned out to be a cracked head.

I think tuning the fan hub is worth while. I'll do it with my current cruiser at some point.

 

[wedgetail]

Yeah might put it on the to-do list

So minor update, pretty mixed day. Spent the night worrying the upper timing case didn't go on properly and the bolts were too short. So after doing the washing, washing up, feeding the horse, two calves and 10 dogs I finally managed to pull the cover back off. It probably did sit right but felt wrong as it hit the rocker cover gasket. I put a gentle chamfer on the case and some slightly longer bolts. Then finished blocking the vac pump hole. Removed studs, made a card template

Cut it out of 5mm gal plate. The holes are through drilled so used thread sealant. Once there's a bit of dirt on it it'll look almost factory...

Then I had a mate turn up who was busting to "skin his knuckles" so we started on the car. Got the bullbar, rad, grill (no thanks to the FPO who ran the UHF cable through it), airbox, charcoal canister, most of the wiring, PS lines, AC lines, tail shafts and exhaust out.

Unfortunately I then got a message from a randomer saying my wife had broken down in the HJ60 with no service. So went and found her, tow started and rip into it :evil:

Bloody thing had engaged while driving and totally cooked the starter. I'm guessing ignition switch but this will seriously get in the way of HD105 work as I need to make sure it doesn't do it again

 

[mudgudgeon]

The old UHF cable through the grille chestnut!
Stitched myself up with that one in the past


Why is it pesky issues come up when you're trying to sink your teeth into a project?

10 dogs! That's nearly as bad as my cousin. He was breeding kelpie working dogs and when he visited his folks for a week, turned up with 18 dogs and cages on the back of the Ute!

 

[wedgetail]

Yeah - not mine though my neighbough's... He does breed dogs for work too! I guess if I'm honest I know I'll never get a full day's work but at least life isn't boring!

So anyway finally getting somewhere - started by chucking a spare starter into the 60. Then couldn't be bothered to pull the dash apart trying to find out why it engaged, so temporary repair this is how you start it

Then got stuck in. A few more small bits to pull off and starter bringing it out

Had my mate again (pictured) it would've taken a lot lot longer on my own...

Wasn't much room to spare in front of the condenser and front brace

And it's out. Probably the hardest bit was pulling the engine loom out between the manifold and head. It might as well have been run through 1" poly pipe it was so stiff. And the plugs were very brittle - I actually broke two injectore plugs and a knock sensor plug. Took us about an hour to pull the loom out...

After about an hour of rolling the gearbox around listening to the bolt rattle around but not come out I decided it had to come apart We managed to get it onto the bench - not light this assembly!

Pulled the transfer adaptor and out this popped

Can't tell you how happy I was to find it all nice inside with no damage. Got it back together after checking the other selector bolt and cleaning the (already clean) magnet and pickup.

The TC rear output seal was leaking so now was a good time. It was a rather large amount of work compared to a 70 series and the shaft took some belting to come out of the beaing.

But I did realise changing the speedo gears would be pretty easy and something I'll pursue later to correct it and the odo

And lastly started fitting it up! VDJ throwout, HZJ75 throwout spring clip, HZJ80 fork.

All went together smoothely and now this massive assembly is almost ready to move into its new home!

 

[roma042987]

Awesome thread! Love reading about people working on cruisers in other countries. We weren’t fortunate enough to get the 105s in the states. I think that’ll make the ultimate tourer with the fte and 105 body.

 

[wedgetail]

Thanks Roma! Glad you've got some enjoyment from it. I do in fact often think the 105 really is a fantastic combo - big shame only a few markets got them. I think aus is the only developed one in fact

So I started on the fuel tank and lines tonight. Pulled the tank out, managed to do it all from underneath - really didn't feel like pulling seats out!

Then the solenoid/T. Then under the rear inner guard this is hiding

Pulled it out - contrary to other posts I've read on here it come straight out no dramas. Compared to the HDJ100 one it's almost identical in shape.

So swapped it in.

Transferred the pickup and breather over to the 105 tank. Everything on the HDJ feels and looks much newer/nicer...

Three change over assemblies - FZJ105 on right, then HZJ105 then HDJ100.

The HDJ100 uses a totally different bracket - it won't mount to the 105 body (and I thought the bodies were indentical). So used the HZJ105 bracket. But the HDJ main solenoid is bigger, so had to die grind and drill new holes.

Looks good enough though.

Then the fuel lines... I've read these are difficult, so wasn't expecting it to be easy. I pulled the petrol feed line out of its clips and bent the diesel feed line to match (the petrol becoming return). Or that's what I tried to do anyway. It's close, but not perfect. It's now in the car, but I've called it quits for the day. It still needs a lot of tweaking but will work. Hopefully tomorrow I'll have the main tank in and all lines hooked up, (optimistically) ready for the powertain on wednesday... Sub tank will be a whole nother saga as I'm using a 120 prado tank so will need to fab brackets and make the sender work. But my aim is to get this back on the road ASAP it doesn't need a sub for that right now

 

[mudgudgeon]

it doesn't need a sub for that right now

Just have to be careful filling up.
If you put the nozzle down the wrong spout you could find yourself with diesel splashing all over your boots

I used a prado sub in my HZJ105. I massaged one corner a fair bit with a FBH. can't remember why though. Might have been to get it in a good position to hook up the fill tube, or might have been trying to get better room for an exhaust system.

 

[wedgetail]

Hmm, what size exhaust? I thought the 120 sub went in without too much drama... Oh well mine can get the same treatment if needed!

Just have to be careful filling up.
If you put the nozzle down the wrong spout you could find yourself with diesel splashing all over your boots

Well I had a short night last night - need to pace myself a bit better still got a long way to go! Worked on the fuel lines and still not finished. Got them mostly shaped and mounted with a mix of metal (rubber lined) P clips on the toyota M6 studs, and the factory plastic clips.

Got the solenoids in and connected - the fuel lines weren't in an ideal place but will work...

The tank fill rubber hose is too short with the HDJ fill neck. Will probably pull this off tonight and bend it a bit.

 

[wedgetail]

So I finished the fuel lines last night and tidied up a cables etc. while the engine was still out. And then tonight - at last...

Feels very good to have it sitting at home. Now I've just got to get stuck into the wiring! Although maybe should do the intercooler first... not sure

 

[Lmp220]

Wedgetsil: By chance is the 1HD-FTE you picked up a couple months ago have Eng No 1HD0295271 ?
If so, I can give you some background and detail about It.

 

[wedgetail]

Sadly no, it's not. I would have loved some history on it though! Nothing bad allowed though.

So managed to find some time this weekend in amongst the usual...

Started with the air cleaner. The lid needs repairs - the main sealing surface is good but I need to sort the outer surface out. Might butcher the petrol lid and graft it on somehow. Can you poly weld this stuff? I've got a better base though. So I've read elsewhere the motor sits a bit higher in a 105. Clearly this is the case.

Ended up cutting the new hose down and using the die grinder with the rubber wheel (for patching tyres) to smooth it out.

Fits good now.

Found what killed the turbo too

Then AC lines. Rear line was easy bolt eh HDJ line straight on.

Front not quite so... The HDJ line almost fit, but the condensor must sit slightly lower (probably a different unit) and didn't quite fit. A bit of bending and it did but then the bolt hole didn't line up. Over an hour later and a lot of swearing it just about fits, but isn't perfect. Had to relieve the upright very slightly with a die grinder. Looks OK when everything's in. I did have to alter its bracket a lot

I got the radiator in and as I still haven't managed to find an HZJ105 shroud yet I cut the FZJ one to use as a mockup for IC lines. All needs to come out so I can tighten the front crank bolt when I get the tail shafts back in anyway.

Then I got to work on the IC. Using a second hand (unused) 600x300x76mm core, very solid unit feels well made. After a lot of thought I couldn't see how I could go through the clip without some major compromises to batteries of rad mounts so going underneath. It just fitted above the cross member but I moved it forward to clear the AC pressure sensor so it had to come down to clear the bonnet latch. It's all quite tight but actually seems made for it! So I reckon I spent a good four hours on the brackets :roll:

Got it mounted it it feels very solid

I had to relive the grill very slightly to clear my vertical brace, not the IC. I might still run a brace from the bottom bracket to the body where it meets the vertical brace. All starting to feel a bit overkill though... So hopefully tomorrow I'll start on the pipework

 

[Lmp220]

Wedgtail: Seemed possible. I put a HDJ79R RV on its side Oct 2016, Written off and sold as salvage by Pickles, Wagga Wagga. I suspect Nerranderra Wreckers bought it, but may have gone to Wodonga ? Went for around $5,600 from Memory ?

 

[wedgetail]

Wow that's quite a mess - were you OK? What happened? Mine's actually from a wagon but I but they are listing your ute as wrecking on their website. The motor is still there but he's sold all the electronics, looms etc. so no good for a conversion.

I sent some oil from the FTE off to Cat and it's come back an A sample! So feeling very happy there.

So my latest update - I've actually been fairly flat out over it and have had to back off - up till 11 each night and up at 6 for a full day's farm work hasn't been going so well for me! The intercooler and pipe work was way way more labour than I bargained for. But I've finally finished that chapter (I hope). After making the brackets last weekend I started on the piping. I'm using mild steel (can't weld anything else and I reckon even with a catch can there'll be enough oil floating around the intake to put rust at bay). I got a 3m length of 2.5 exhaust and a couple of donuts. So started off making a flaring tool.

Got the end 1/2" cherry red and tapped it on. Worked better than I thought...

Tacked it one piece at a time.

Then pressure tested them to 30psi. Tried 40 but it fired my unflared pressure fitting 8m up into the roof like a hotted up potato canon. Very glad it wasn't aimed at my face! Bent the tyre valve but still sort of works...

From the turbo to IC is one piece, I'm getting a 2-2.5 reducer from the turbo and am using a 2.5-3" elbows to the IC. It mounts to the wing and the bottom of a body mount bolt. The cool side is three pieces as it's pretty long and would have been very awkward with less pieces. The last piece was tricky and had to make a compremise. It's ended up to get to the AC ports you need to remove the final piece. Not ideal as you need to run it but it will be in a workshop and hopefully not too much crap flying around... Although it may be possible to loosen the mount and a couple of clamps and lift it up to get the pipes on.
The welds aren't the prettiest (I'm no boiler maker) but are air tight at least. Cold gal'd them and ready to fit!

Put some new rubber PS return line on, the old ones had the consistency of a dry stick. Used the HDJ pressure line. It's surprising how many of the fittings (soft lines and electrical connectors) are incredibly brittle on the fzj even with only 260k km. The HDJ parts are much nicer at 390k, makes me think the extra four years has really taken it's toll or toyota improved things a lot at the 02 update?

 

[wedgetail]

OK minor update. I started the exhaust but still waiting on more material so only have the engine pipe to front prop shaft. Have squeezed a flexi in next to it and a flange there too but it's very tight. Seriously thinking about remove the flange and putting it behind the TC - just so long as I can get it in and out...

So I moved onto the heater hoses. This was fun. I hadn't installed (and considered) the hard line on the fire wall. In fact I didn't even have it - the wrecker had to send it as it had been overlooked. Getting it in was a b*tch. To start with the engine sits higher than an HDJ100 so there's less room. Managed to squeeze it in but couldn't work how to mount it. After finding some photos of HZJ105s I realised for some reason this is missing the captured nut/hole for it's mount - there is a space in the soundproofing for it but just nothing there. WTF?! I thought bodies were the same across the board? So far everything else has had the correct studs or captured nuts and this is an anomaly... I wonder if all FZJ105s are missing this nut? So I guessed the size of a piggy back strap to mount off the AC line clip. More contortion and it was in. Even more contortion and I had all the clamps done up on the new hoses!

Then finished hooking the fuel up. Cut the return line off and flared it a bit. Blew the line from the tank to get rid of swarf.

Made a bracket for my aux fuel filter. It's a donaldson high flow truck one for very high horse power applications (eg ISX at 600hp+) the rep gave me a while ago. But I sourced a shorter filter. Still a fair bit larger than the others and factory but. This one's a 10um cat filter but might go to 3um donaldson next change. I'll run it as a secondary, should be good for 50k at least (will change every 20k as usual with all my secondary fuels) with the factory in front and possibly overkill, and makes the factory one redundant but I need the primer and the factory would be easier to get if i got stuck.

Made the bracket out of some C channel. Feels solid, just misses most things.

Bolted the damper up and fitted all the lines. There won't be a lot of room with the spill driver sharing the diff lock compressor and the size 31 1000cca cat battery that'll be going in...

 

[wedgetail]

So wiring has started! Pulled the dash out yesterday, had a fight at the end as every instruction I found failed to mention the two M8 nuts under the passenger airbag module...

Found a few unexpected accesories like an old nokia hands free unit and speaker, about 20m of open ended coax, a 6mm hot wire going back through the body (still haven't traced it) and the remnants of the gas system. Still pulling unwanted bits out but:

Fitted the HDJ ignition switch - bolted straight up and plugged in (imob. plugs different but no worries as I'm using HDJ imob).

Decided to swap it out as it came with four keys, fzj has one. Got the wrecker to send me the door locks. Those anti theft bolts on the column are interesting - decided it was quicker to remove the hole thing and weld nuts on. What do people do to replace them? I've got regular bolts in the for moment...

Then the pedal - old one out and the new one clearly uses different mount holes. Pull the sound dampening out and there's the bottom hole and a space for the top but had to drill it.

Plated the old cable hole too

Bolt the new ECU in, plugged the engine in. So now I have some questions... I'm still undecided about the dash. I want cruise control to work, and the display lights for it too. However in the wiring diagram I can't find any output from the HDJ ecu or switch for the dash - I assume it comes in in the multiplex. Does anyone know of a way of getting 02 update cruise to talk to a pre 02 dash?

I'm still toying with the idea of fitting the HDJ dash. I've been scanning the wiring diagram and the only inputs to the cluster from multiplex are two wires from the ECU and one from the body ECU. It will physically bolt up, an the plugs are the same. So "all" I'd have to do is give it the ECU multiplex wires and the rest of the inputs are analogue by pin swapping. Does anyone know what the body ecu tells the cluster via multiplex? Or if this route is possible? Have I missed something?

 

[wedgetail]

So I haven't been idle, but the wiring gives less spectacular photos I'm deep into pulling the HDJ loom apart to extract what I need. I think I'm going to give the cluster swap a go! It seems to physically fit (even though I've read reports it doesn't - hope I'm not missing anything). Yes the side plastic is broken - I'm negotiating a replacement off the wrecker. If not I'll swap my old one over the only issue is the odo reset is in a different place.

I did feel like my mind needed a quick break yesterday so quickly fitted up the finished IC pipes as I finally got the 2-2.5" silicone reducers. Unfortunately the super clamps I had for this are a size small but I'll put those on later. Super clamps put up quite a fight when fitting!

I did fab them up with shroud in place (well the altered FZJ one - still looking for an HZJ one) so it clears everything, just...

Vac pump plate mount

lift point mount

offside mount off body mount

nearside mount off body mount

Feels really nice and solid although seems to flex where it needs to. Just got to sort the filter housing out