HDJ100 swap

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Get a hold of the parts department at Sidney City Toyota in Sydney Australia and get a "GXL" badge (it is a trim package there). Tell them what you are looking for and they should know exactly what you are talking about. It is a stick-on type deal but is puffy (at least my 80 series one is). See the photo of mine. They aren't very expensive IIRC. Your 100 series will be slightly different than my 80 I believe. The "multi-valve" and "turbo" decals are an 80 series exclusive in Australia.

You're project is looking good!
rearbadges.webp
 
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I think i had to weirdest Dealer experience, i went and pickup the AHC fluid and plastic trim under the wheel column at a lexus dealer. I went and spoke with a technical advisor about calibrating and adjusting the AHC. I ask if i could bring in the truck and ask them if they could do that. I think he though i was some kind of Yo kid who just bought a big ass Lexus SUV and didn't know s*** about the cost involved. First thing he warn me was that those active suspension cost HUGE amount of dollars; tens thousands etc... In a attempt to make the Yo kid regret right away buying the big ass lexus SUV. Anyway the discussion obviously went on and i had to explain why i needed this adjustement and calibration....i think i lost him right there....lol...seriously i think he didn't beleive anything about what i was saying.

I better stick with the truck in the garage when i go there in case they decide to fxxx some AHC parts...
 
Awesome news.
Gbentnik recently completed his swap of a HD-FTE into a lexus also.
 
For the record to who ever want to do this, here is a few things that will help you save some time.

- Do not install the piping going to the intercooler until; you have the front grill engine harness all back in place and the alternator wired.
- Install the AC piping going to the rad before you install; fuel filter support.

Here is a list in order.

- Brake pump, with brake pedal
- firewall piping, AC, Heater hose and brake pipe
- AHC
- Fuse box /relay
- AC piping to front rad
- Front AC radiator
- Engine radiator
- Engine fan
- Radiator shroud
- Steel Piping for Tranny cooler on left side of radiator
- Hose piping for Tranny cooler between engine block and shroud
- Install Radiator overflow bottle on the shroud
- Place the wiring harness running on the shroud back on top of shroud
- Place the harness on the Right side wheel apron, reconnect connector where they go.
- Reconnect alternator.
- Reconnect the engine ground wire located on the right side of the engine mount (nasty place).
- Install bottom hose of radiator.
- Install intercooler piping in the right side wheel apron, between body and frame. and pipe protector
- Install piping between turbo and intercooler pipe.
- Install pipe between intercooler pipe and engine intake.
- Reconnect piping between AC pump and radiator.
- Install intercooler rad
- Install tranny radiator cooler.
- Install top engine radiator hose.
- Install air filter box.
- Install fuel filter assembly


I didn't do it exactly like this and had to back track a few times. I may be missing something here in the list
 
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Next is to change the rear brake pads bleed the system.

Then i'm going to tackle things, that i notice, do not work.

AHC, off is blinking, i'Ve read that the doors needs to be close for the pump to operate. I'm going to try to use a by pass un the DLC1 or DLC3 and see if i can get it to spin, so that i can fill the system. Since the doors are not installed. Does the AHC operate when the truck is off the ground on a lift?

Moon roof does not work, simply because the HDJ didn't have any. There is one connector with one wire in the drivers side pillar not connected, my guess is that this wire only need current to operate the moon roof ecu. Somehow i didn't find any trace of this harness joining connector in any EWD.

Also the climate control (Manual) doesnt light up at all. But the time clock does. Hazard does work. Maybe this is due to a connector not hooked up. But i fear that i may need to swap the dash pad harness. I tried to hook up the HDJ and UZJ climate control but no luck. Next would be to swap the instrument ECU located right over the radio screw on the dash pad. Looking at EPC the dash pad harness is the same for a 1999 HDJ and a 1999 Lexus, so that harness might be required for AHC...but i couldn't find any hint in the EWD that anything about the AHC goes throught the dash pad harness.

Still alot to do! But i hope i can get it running for Christmas!
 
You can use these or something similar to squeeze the door sensors shut while you do the work. Wont work for the tailgate so just close that up.
Q-G59100.jpg



Lexus dealerships in the states have laptops that connect to the OBDII system and allow all sorts of operations and adjustments via the computer that bypass all the safety things built in (like doors closed and such). The system probably has a feature to help you fill up the AHC system, not certain.


As far as the climate control not lighting up, did it light before? You are using a older vehicle for the swap maybe the bulbs are out? Did you connect the black rectangular plug to the dimmer switch that is on the trim at the base of the gauge cluster?
 
I haven't even check if the door switch are in the door or pillar, probably in the pillar if you recommand using this.

I tried to hook up a ODBII reader on the HDJ100 when i received it and it can't connect or does not reconize communication language. I cannot imagine going on the road with the AHC empty, hopefully i'll find something.

I tried to connect both climate control, HDJ or UZJ none would start the fan or do anything, and none had lights, but you are correct the dimmer wasn't hook. Neither the TC lock button would work.

1loudLX said:
You can use these or something similar to squeeze the door sensors shut while you do the work. Wont work for the tailgate so just close that up.
Q-G59100.jpg



Lexus dealerships in the states have laptops that connect to the OBDII system and allow all sorts of operations and adjustments via the computer that bypass all the safety things built in (like doors closed and such). The system probably has a feature to help you fill up the AHC system, not certain.


As far as the climate control not lighting up, did it light before? You are using a older vehicle for the swap maybe the bulbs are out? Did you connect the black rectangular plug to the dimmer switch that is on the trim at the base of the gauge cluster?
Click to expand...
 
Ok, i've got the brake bleeded, but i'm missing the pin between actuator and brake pedal, will ask Philippe tomorrow where it is.

The AHC Off has stopped blinking but i still haven't been able to start the pump. Even using the procedure explained here
https://forum.ih8mud.com/100-series...-ahc-pump-bleed-air-system-2.html#post2293322

I have 4 blown fuses, probably why the climaite control is not working, will get those tomorrow.

Eric
 
Has i was leaving the shop i notice the clamp on the right side holding the door switch had slided off the switch! So i correct this and was successfully able to bleed the AHC and everything is working number one! Glad this is solved. Hopefully tomorrow i'll get more things working!
 
Well, today progess....not much even tho i work from 8 to 5 and even didn't take time for diner.

I tackle the rear heater that didn't want to work. The heater from the UZJ is the same from the HDJ but does not operate the same, in the hdj it is manual (cable operated), dial is in the back of the center console, with switch for off/low/hi. So the heater has a cable, a resistance for low and high, a connector for motor AND a relay. The UZJ heater has not cable, instead a small motor to actuate the heat level, plug for a differente type of resistor, connector for motor, connector to temp sensor.

With the center ecu, climate control and rear heater fan from the Dual AC UZJ nothing would work. Keep in mind we changed engine 1 and 2 harness, firewall harness and the floor #3 harness, this last harness is the one joining left and right floor harness going from front to rear of truck, we had to change that one in order to have AHC.

So after loosing most of the morning trying to test different things and looking at EWD i was able to get the UZJ rear heater fan going, by using the HDJ center ecu, climate control AND the relay on the HDJ rear heater fan. BUT only on speed, kinda normal since the UZJ climate control only has a button "rear Heat". So i decided to swap the whole rear heater assembly from the HDJ to UZJ, a pita to do because you need to pull the carpet, so more plastic trim to remove and fold that carpet backward.

After plugging the rear HDJ heater with center ecu and climate control of the HDJ i got it to work high and low speed...but the fan housing of the hdj was very badly rusted, probably due to water and bearing in the motor housing were toast. So i dismentled the heater and built a new one using the UZJ motor (they are the same). Finally everything was operating normally using center ecu and climate control of the HDJ.

But i still was puzzled why it wouldn't work with all the UZJ parts. I'm going to make a long story short. The dual A/C has a ECU in the rear right. And the rear heater and rear AC are controlled from that and the roof controller. By changing the wire in the back going left and right we remove 8 wires necessary for it to operate. Also now with the HDJ firewall (dash) harness a connector was missing to connect to the right side harness going in the back, but it only had 2 wires, one is current for the rear AC ECU and the other one for Radio amplifier, easy fix. We decided to give it a go, unskin the UZJ rear harness and install the missing wires on the truck. But sitll it was a no go. I only have the 2002 uzj EWD, I'll look at this when i get the EWD, for now i decided i'll tackle to rear climate control later snd move one, since i can have a rear operating heater.
 
Hi Eric,
While everything is open, try to figure a way to blow warm air on the rear, that would be a huge improvment.
In (Canadian) winter, LC100 is not efficient enough to blow the condensation away from the rear windows
 
OursSauvage said:
Hi Eric,
While everything is open, try to figure a way to blow warm air on the rear, that would be a huge improvment.
In (Canadian) winter, LC100 is not efficient enough to blow the condensation away from the rear windows
Click to expand...

The rear heater will be working just like in a Stock HDJ. i cannot imagine that not being enough to keep the rear without condensation. It it just that instead of using the roof climate control of the UZJ i'll be using the center console rear climate control of the HDJ.

Today i will be lengthing the connector in the pilar that goes to the moon roof, then i'll put the dash back, and try to completely assemble the inside of the truck. i need the truck out of the shop ASAP.
 
the heat on mine comes out at the floor of the 2nd row. when you've got gear on and two or more people in the vehicle, the windows fog up pretty well.
 
OursSauvage said:
Hi Eric,
While everything is open, try to figure a way to blow warm air on the rear, that would be a huge improvment.
In (Canadian) winter, LC100 is not efficient enough to blow the condensation away from the rear windows
Click to expand...

Use the air-conditioning to lower the humidity and stop fogging. It works very well when it is cold and wet or warm and wet or just humid.
 
Dougal said:
Use the air-conditioning to lower the humidity and stop fogging. It works very well when it is cold and wet or warm and wet or just humid.
Click to expand...
Yep, but as 1LoudLX said, behind the 1st row, warm air is only provided on the feet level... nobody on the 2nd or 3rd row is agree to use the AC from the roof when temperature is around 0°C or even worst -15°C
They don't want to understand why it's usefull :hillbilly:

After a while, this condensation turns into ice.
Let's say it's not something expected in this kind of vehicle
 
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