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1990 HDJ81. RHD, 1-HDT.
Builds Ikarus' HDJ81 Offroad Build (5 Viewers)
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My 1990 HDJ81 had different flares to Aussie spec 80s. Different shape, different width.
Early Aussie spec 80s had a narrow flare. I think mid '93 onwards the flare width increased along with the change to 16x8" wheels.
I'm not sure how that correlates with US models.
Also not sure if there was a change for JDM models over the years
There are 3 variants of flares and fenders.
- Thread starter
- #126
Parked the cruiser for what could be a few weeks of work.
Started to prep for the intercooler install by dismantling the front end. Cleaned up the bugs and rocks on the AC condenser and straightened out bent fins.
I have a slow coolant leak from the silicone hoses that came installed on the cruiser when I bought it. I'll be refreshing the coolant hoses with all OEM and I'm tempted to switch the aluminum made in China radiator to an OEM radiator at the same time.
Started to prep for the intercooler install by dismantling the front end. Cleaned up the bugs and rocks on the AC condenser and straightened out bent fins.
I have a slow coolant leak from the silicone hoses that came installed on the cruiser when I bought it. I'll be refreshing the coolant hoses with all OEM and I'm tempted to switch the aluminum made in China radiator to an OEM radiator at the same time.
- Thread starter
- #127
I'm also considering deleting the JDM headlight washers since I never use them. I'd leave the nozzles on the front since they're a part of the housing, but remove all the hose behind the grill. Just trying to simplify things.
This is standing in front of the bumper looking down. The hose is outlined in red and connects to the bottom of the headlight housing.
Additionally, I need to do some digging in the EWD and figure out what this wiring harness is tucked behind the grille. It has two unused white plugs and runs back up to a connection underneath the airbox + a ground. I've removed it for now but will hang on to it.
I'm thinking fog lights? I don't have fog lights in the bumper but I do have integrated fog lights in the headlight housing.
Disassembly continues - I hadn't removed the airbox before and was interested to find this little dirt/dust/debris catch can at the bottom. Seems effective. How often are people cleaning these out?
This is standing in front of the bumper looking down. The hose is outlined in red and connects to the bottom of the headlight housing.
Additionally, I need to do some digging in the EWD and figure out what this wiring harness is tucked behind the grille. It has two unused white plugs and runs back up to a connection underneath the airbox + a ground. I've removed it for now but will hang on to it.
I'm thinking fog lights? I don't have fog lights in the bumper but I do have integrated fog lights in the headlight housing.
Disassembly continues - I hadn't removed the airbox before and was interested to find this little dirt/dust/debris catch can at the bottom. Seems effective. How often are people cleaning these out?
- Thread starter
- #128
Ran into my first snag. The glow heater relay assembly is positioned exactly where the driver's side intercooler pipe is supposed to go.
This is standing in front of the bumper on the driver's side looking down.
The relay is right behind the circled panel. PDI instructions are to cut a 3" hole in that panel to run the piping through.
I'll post in the diesel section as well but curious to hear what people think. Move the relay? Delete the glow heater system altogether?
This is standing in front of the bumper on the driver's side looking down.
The relay is right behind the circled panel. PDI instructions are to cut a 3" hole in that panel to run the piping through.
I'll post in the diesel section as well but curious to hear what people think. Move the relay? Delete the glow heater system altogether?
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When I installed my DVS bumper I didn't realize they had one specifically for the JDM rigs and deleted all my headlight washer setup except for the button inside
- Thread starter
- #130
Nice. How did you plug up the system? At the windshield fluid reservoir?
Ya. I'll grab a picture in the am. Pretty sure I just put a rubber cap on it. I kept all the parts in case I wanted to restore it. But I'm moving soon and foresee them in the trash.
Disassembly continues - I hadn't removed the airbox before and was interested to find this little dirt/dust/debris catch can at the bottom. Seems effective. How often are people cleaning these out?
That's the tuna can.
Empty each time you change your oil so it doesn't get forgotten
- Thread starter
- #133
Continuing the intercooler installation. First, removed the intake heater power. I'll have to get a pic at the end with all the stuff I'm removing from the engine bay. Feels good to simplify things.
I now have two 10mm holes on each fender. I need to figure out a way to plug them up to keep dirt and mud out. Bolts, nuts and washers would be easy but I was thinking maybe a plastic body clip too.
From there it was time to cut. 3" hole saw on each side.
I now have two 10mm holes on each fender. I need to figure out a way to plug them up to keep dirt and mud out. Bolts, nuts and washers would be easy but I was thinking maybe a plastic body clip too.
From there it was time to cut. 3" hole saw on each side.
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- Thread starter
- #134
Next, cleaned up the holes and painted. Probably could have gone with something that matched the color a little better but oh well, no one's gonna see it.
PDI put together a well thought out kit. The only annoyance so far was the center intercooler support bracket. The top mounting hole was just a few mm too far to the left so it didn't line up with the other 2 hood latch bolts. I just had to extend the hole a bit, clean up and paint, and I was good to go.
Once that was ready to go, it was as simple as bolting up the hood latch, dropping in the intercooler, then bolting up the hood release and horn brackets.
PDI put together a well thought out kit. The only annoyance so far was the center intercooler support bracket. The top mounting hole was just a few mm too far to the left so it didn't line up with the other 2 hood latch bolts. I just had to extend the hole a bit, clean up and paint, and I was good to go.
Once that was ready to go, it was as simple as bolting up the hood latch, dropping in the intercooler, then bolting up the hood release and horn brackets.
- Thread starter
- #135
Small note on the horns. The right horn had to be moved up a little to clear the intercooler bracket, but that put it up too high and the hood couldn't close.
On the back of the horn, there's a 17mm nut holding the arm. I loosened that and rotated the horn to fit under the hood.
And wrapped up the night with some trim (provided by PDI) around the intercooler pipe holes.
On the back of the horn, there's a 17mm nut holding the arm. I loosened that and rotated the horn to fit under the hood.
And wrapped up the night with some trim (provided by PDI) around the intercooler pipe holes.
This is looking great! On the growing list of stuff I need/want. PDI looks like good kit. Did you by chance source it over here in the US or from Australia? Thanks!
- Thread starter
- #137
Bought it straight from them in Australia. They’re great to work with via email and ship stuff to the US regularly
Excellent, cheaper price as well. Would you mind listing the part numbers when you get a chance. Might as well follow your lead. Thanks.
- Thread starter
- #139
Yeah no problem. I ordered this:
Buy 80 Series Top Mount Intercooler Online in Australia | PDI
Get your Landcruiser 80 Series Front Mount Intercooler from Performance Diesel Intercoolers. Order now for 1Hz, 1HD-T, 1HD-FT engines.
www.performancedieselintercoolers.com.au
You just have to pick your model and transmission type from the drop down. They include the transmission cooler for the automatics. They also now seem to have a color option (black or silver) but they didn't have that when I bought mine.
When you order they'll ask you what size piping you need for the turbo. I emailed and they told me to pick 3" for the stock CT26.
I also bought an airbox from them but I won't have that for a couple months.
Excellent, thank you. I will check it out.Yeah no problem. I ordered this:
Buy 80 Series Top Mount Intercooler Online in Australia | PDI
Get your Landcruiser 80 Series Front Mount Intercooler from Performance Diesel Intercoolers. Order now for 1Hz, 1HD-T, 1HD-FT engines.
You just have to pick your model and transmission type from the drop down. They include the transmission cooler for the automatics. They also now seem to have a color option (black or silver) but they didn't have that when I bought mine.
When you order they'll ask you what size piping you need for the turbo. I emailed and they told me to pick 3" for the stock CT26.
I also bought an airbox from them but I won't have that for a couple months.
