HZJ40 RestoMod v3.0 (New, improved, and now with fewer sparkplugs)

[lelandEOD]

... I fabbed up a little throttle cable bracket to work with the stacked throttle cam (just two cams welded together) needed for the cruise control addition:

 

[lelandEOD]

Once more unto the breech...

Hopefully out for the last time.

 

[lelandEOD]

The engine/empty tranny assembly was pulled from mock-up duty and, now that The IP has been rebuilt, I set to work actually finished the engine assembly.

I also think I finally managed to get the cam/injection pump timing done. It was more complicated than it should have been because I’ve never done it before and my only guide was the FSM. While I get that the factory service manual is pretty much the bible, it's frustrating that the manual is broken into subassembly groups and lacks a chronological sequence to engine assembly. I had to hunt for topics to put together a step by step to setting the cam and pump timing.

With the crank at BDC, I installed the timing gears and cam pulleys.

The first hand cranked revolution of the engine had me on pins and needles; I was more than a little unsure of myself and whether I had goofed anything up. I had to rotate it 720° before the crank TDC notch finally corresponded with the TDC marks on both the injection pump and camshaft pulleys.

 

[lelandEOD]

Interestingly, when you buy a new 1HDT intake tube from Toyota it shows up as a rough casting with no “TURBO” red paint.

I set out to remedy this; filled the lettering with enamel, hit it with a 120grit orbital to knock it flat, then used a polishing disc to get it perrdy.

Speaking of perdy... freshly rebuilt IP by Bryan at Omega Fuel Injection.

 

[lelandEOD]

Started on the transmission rebuild and quickly learned that it was not my day. The input shaft got bumped and rolled off my workbench.

Ka-ching, there’s $200 out the door.

 

[lelandEOD]

Made some progress with the H55 build today.

Check out the wear pattern on the reverse idler compared to the new:

Mmmmmmm... new parts.

I was able to get the counter shaft and output shaft (full of shiny new parts) into the housing.

I put the intermediate shaft bearing in my 0°F freezer for about an hour and tapped it onto the output shaft with a length of pipe and a hammer.

I supported the opposite end of the shaft with a piece of brass round stock.

 

[lelandEOD]

Worked like a champ.

Now I just have to wait for the new input shaft to show up and I can press on (pun intended) with assembly.

 

[lelandEOD]

Thanks to Georg at Valley Hybrids @orangefj45 , I got the replacement input shaft installed two days after I ordered it. The H55 is done now; I just have to order an extended input gear to replace the chipped one that came out of the mine truck and I can finish the transfer case.

 

[lelandEOD]

Got the fuel pipes back from zinc and got them torqued down with the rebuilt injectors.

As soon as I pick up an alternator and rebuild the starter, the engine will be done-done.

 

[1Fine40]

Wow! Attention to detail is impressive as is the quality of your work .

Cheers !

 

[orangefj45]

Great work and attention to detail!

 

[lelandEOD]

Thanks for the kind words, guys.

The mounts are now burned in for good.

I’m also finally starting on the bits I’ve not looking forward to doing. ...body work.

Since this rig has been through several iterations, there are many little things that need to change. Specifically, lots of small holes, weld-nuts, and holes in the firewall and frame rails that are no longer needed.

I started on the driver’s fender. Now that the steering box has been relocated, that hole is no longer needed and will only let debris into the engine bay. I also wanted to mount a small power steering cooler on the fender skirt but wanted to add louvres to improve airflow.

Bang.

 

[lelandEOD]

Hackery ensued...

 

[thecrazygreek]

That welding is just terrible.
Those louvers are terrible.
Your skills are terrible.
I hate you....

 

[lelandEOD]

Ouch, man!
I'm just learning as I go!

 

[lelandEOD]

Also, here’s the cooler mounted up.

 

[Jordan85]

Very envious of your skill set! Is the louvre from the passenger side of a FJ40? Just about finished with my 60 series power steering swap.

 

[lelandEOD]

Thanks!

I had actually hoped to use a panel from a totaled -40 tub since it would have been a heavier gauge than what I was able to pick up commercially. I think I found the panel I used on eBay or Amazon.

 

[lelandEOD]

Made a little bracket for the washer bottle.

 

[lelandEOD]

And test fit my little homemade warning panel. This one was only the proof of concept. The finished version will actually have one more light for the charge circuit. I’m going to have a lasersmith buddy engrave the final version soon.

You can never have too many warning lights!