KZJ78 Radiator replacement?

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Hey Max,

Been closely watching your journey, most impressive! Please keep the videos coming 😀

I don't have a direct radiator experience with 70 series. But I once replaced a radiator on an HDJ80 with an aftermarket aluminum with lasting success, dare say, improvements. But there were two caveats:

1. The 'cheap' aftermarket aluminum radiator was TIG reenforced and pressure tested prior to installation. Using an AC TIG and filler wire, I was able to 'reflow' and double the beads at all the strategic spots (tube-tanks, tanks-ports, tanks-mounts). I then ground up the beads and made everything look neat. A thin coat of radiator mat black finished it all.

2. Instead of more cores, I went with less cores more passes. I know this might sound counterintuitive but hear me out: With more cores, coolant can flow from the upper tank to the lower tank faster, which means that the the outer extremes of the matrix (tubes further away from inlet) will potentially see less volume, reducing efficiency. Of course this is not always the case as this is highly dependent on the overall setup.
There are other disadvantages to more cores, such as the heat reabsorption by the rear cores, the reduced overall matrix cavity to factor in the wall diameter of the additional tubs (compared to an equal depth matrix with less cores), and the fact that the typical coolant flow rate would limit the time for coolant to shed its heat while vertically traversing the matrix.
Less-cores-more-passes radiators (think: dual core three pass) would permit better dwell time for the coolant, nearly eliminate reabsorption, and obtain a closer to ambient coolant temp at the outlet. Of course there are some disadvantages to this setup too, such as potential for the need to have a higher pump rate, a reduction in matrix structural integrity (at least compared to equal depth higher core number matrix) and, in the case of dual/quadruple passes: reversal of outlet side (triple pass don't have that problem, obviously).

Having the coolant traversing the matrix laterally in three passes can substantially increase its temp-drop efficiency as long as your flow rate can take advantage of this setup, in most applications, the OE pump rate is suitable for this setup.

On that HDJ80, I acquired a generic two core three pass radiator that roughly matched my needed size L,W,D (that unit was advertised as a Volvo diesel charge air cooler for a big truck IIRC).

Again more cores is not always better. I invited you to read more on this topic. Best of luck!
 
Hey Max,

Been closely watching your journey, most impressive! Please keep the videos coming 😀

I don't have a direct radiator experience with 70 series. But I once replaced a radiator on an HDJ80 with an aftermarket aluminum with lasting success, dare say, improvements. But there were two caveats:

1. The 'cheap' aftermarket aluminum radiator was TIG reenforced and pressure tested prior to installation. Using an AC TIG and filler wire, I was able to 'reflow' and double the beads at all the strategic spots (tube-tanks, tanks-ports, tanks-mounts). I then ground up the beads and made everything look neat. A thin coat of radiator mat black finished it all.

2. Instead of more cores, I went with less cores more passes. I know this might sound counterintuitive but hear me out: With more cores, coolant can flow from the upper tank to the lower tank faster, which means that the the outer extremes of the matrix (tubes further away from inlet) will potentially see less volume, reducing efficiency. Of course this is not always the case as this is highly dependent on the overall setup.
There are other disadvantages to more cores, such as the heat reabsorption by the rear cores, the reduced overall matrix cavity to factor in the wall diameter of the additional tubs (compared to an equal depth matrix with less cores), and the fact that the typical coolant flow rate would limit the time for coolant to shed its heat while vertically traversing the matrix.
Less-cores-more-passes radiators (think: dual core three pass) would permit better dwell time for the coolant, nearly eliminate reabsorption, and obtain a closer to ambient coolant temp at the outlet. Of course there are some disadvantages to this setup too, such as potential for the need to have a higher pump rate, a reduction in matrix structural integrity (at least compared to equal depth higher core number matrix) and, in the case of dual/quadruple passes: reversal of outlet side (triple pass don't have that problem, obviously).

Having the coolant traversing the matrix laterally in three passes can substantially increase its temp-drop efficiency as long as your flow rate can take advantage of this setup, in most applications, the OE pump rate is suitable for this setup.

On that HDJ80, I acquired a generic two core three pass radiator that roughly matched my needed size L,W,D (that unit was advertised as a Volvo diesel charge air cooler for a big truck IIRC).

Again more cores is not always better. I invited you to read more on this topic. Best of luck!

Hey Tigris yeah thanks man I'm stopped for a little while now so going to push out all the videos on a weekly basis. Going to do a whole little 4x4 movie on Honduras as well.

Turns out the seller for 5 row doesn't ship here anyways so I ended up going with the 2 row with more passes. Your post is an interesting read, I never really went that in depth with rad knowledge so I've been doing a fair bit of reading. Anyways latest estimated ship time for the rad is July 25th so fingers crossed it gets here by then. I just threw in a new water pump so I don't really want to go the stop leak route with this rad. That means hand bombing all the groceries up hill to where we're staying hahaha.

Other than that really hoping to be shipping the truck to Columbia in August, gotta make a bit of $$$ in the meantime. Thanks for your help.
 
Hey Tigris yeah thanks man I'm stopped for a little while now so going to push out all the videos on a weekly basis. Going to do a whole little 4x4 movie on Honduras as well.

Turns out the seller for 5 row doesn't ship here anyways so I ended up going with the 2 row with more passes. Your post is an interesting read, I never really went that in depth with rad knowledge so I've been doing a fair bit of reading. Anyways latest estimated ship time for the rad is July 25th so fingers crossed it gets here by then. I just threw in a new water pump so I don't really want to go the stop leak route with this rad. That means hand bombing all the groceries up hill to where we're staying hahaha.

Other than that really hoping to be shipping the truck to Columbia in August, gotta make a bit of $$$ in the meantime. Thanks for your help.
Max,
Fantastic! I look forward to the weekly videos. I already got a few people hooked on your channel, one of them (a couple) are doing a pan American trip now as we speak. Although they are using more traditional modes of transportation 😆

Yes I went down the radiator rabbit hole back when I worked on that HDJ80. Honestly, a typical leak free two core one pass will do perfectly fine if the rest of the cooling system is in the right shape. Going with more passes add a little complexity but it's worth contemplating if you are in that boat. Obviously your circumstance are quite different from the usual, you need a reliable truck while traversing practically uncharted territory with little access to reliable shipping and e-commerce.

I'd say get the best radiator you can get/afford and deal with things nice and proper once you are back home. BTW, I hope your revving/power issues are resolved by now, if not. I'll be glad to rebuild your ECU once you are back. On the house 😀

Stay safe!
 
Max,
Fantastic! I look forward to the weekly videos. I already got a few people hooked on your channel, one of them (a couple) are doing a pan American trip now as we speak. Although they are using more traditional modes of transportation 😆

Yes I went down the radiator rabbit hole back when I worked on that HDJ80. Honestly, a typical leak free two core one pass will do perfectly fine if the rest of the cooling system is in the right shape. Going with more passes add a little complexity but it's worth contemplating if you are in that boat. Obviously your circumstance are quite different from the usual, you need a reliable truck while traversing practically uncharted territory with little access to reliable shipping and e-commerce.

I'd say get the best radiator you can get/afford and deal with things nice and proper once you are back home. BTW, I hope your revving/power issues are resolved by now, if not. I'll be glad to rebuild your ECU once you are back. On the house 😀

Stay safe!

Hey thanks so much! Yeah it's tough finding anyone who's willing to ship to central America so ebay it is for now. And thanks for the support! I did get everything resolved with the rig, it all ended up being a bad MAF sensor that worked fine at idle but when the throttle was increased it didn't change values causing the air/fuel ratio to be way out of wack. And hey I'll definitely take you up on that ECU if I come back around through the area haha.

Max
 
Any feedback on installing one of these Chinese aluminum radiators? My KZJ78 radiator is showing some aging signs. I'm not in a hurry to replace it, but have this near the top of my list for important preventative maintenance, and it's becoming apparent there isn't an obvious solution at hand... other than maybe going to a racing shop and having a radiator custom built. I'm sure that would work great but would be 3x the cost vs one of these $325USD radiators. I'm also leaning towards getting one of the manual transmission versions and separately installing a transmission oil cooler as it would add net cooling capacity.

I did a radiator very similar to these on an HDJ81 and installation was somewhat difficult. We needed to modify the sides to allow the brackets to attach plus fab a bracket to get the shroud to correctly attach. In the process of modifying the sides, we got sloppy with the angle grinder and cut into the core... ended up scrapping one radiator. Luckily the ones for the HDJ were about $100 cheaper than for the KZJ78, so the cost of that slip wasn't quite as bad (still was $225 and a couple hours of time literally thrown into the dumpster). I can't comment on how that radiator performed over the long run as I sold the car not too long afterwards so I never got a report on its longevity or function. It worked fine while I had it.
 
I have installed the Chinese eBay aluminum rad after springing a leak in my copper core original. I have been running it for a while and have no deformation etc. I had originally planned to get my stock one re cored with expectations of my aluminum failing but so far haven't felt the need. Will probably re core my copper and then keep it as a spare. Make sure if you're using engine cleaners that you keep it off the aluminum or it will etch.
 
I imported another KZJ78 recently - just picked it up from the dock a few days ago. It has what appears to be a new or newish radiator (at least relative to the 29 years on the rest of the car) closely matching the OEM in appearance. I'll attach a photo of the top section with model numbers. I've searched and cant find what it is, or at least exactly what it is or where to get another. The sticker says it's from Daiwa Radiator Group and has a model number dbp-154036-m00 but I cant find record of it (I also tried searching using the scan code and also assuming the m00 is actually moo). I also tried the pa66-gf30 imprinted on the plastic... No hits. Anyone have any idea what this radiator is? By all appearances it looks to be a complete drop in replacement using the same mounts, tranny cooler, etc as the OEM radiator.

I'm perfectly happy with it for now as it shows no evidence of problems and appears to be in good condition. What I'm hoping for is I can find what this really is, whether it is actually any good / reliable over the long term, and whether it solves anyones problem of where to source a decent replacement radiator.


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I imported another KZJ78 recently - just picked it up from the dock a few days ago. It has what appears to be a new or newish radiator (at least relative to the 29 years on the rest of the car) closely matching the OEM in appearance. I'll attach a photo of the top section with model numbers. I've searched and cant find what it is, or at least exactly what it is or where to get another. The sticker says it's from Daiwa Radiator Group and has a model number dbp-154036-m00 but I cant find record of it (I also tried searching using the scan code and also assuming the m00 is actually moo). I also tried the pa66-gf30 imprinted on the plastic... No hits. Anyone have any idea what this radiator is? By all appearances it looks to be a complete drop in replacement using the same mounts, tranny cooler, etc as the OEM radiator.

I'm perfectly happy with it for now as it shows no evidence of problems and appears to be in good condition. What I'm hoping for is I can find what this really is, whether it is actually any good / reliable over the long term, and whether it solves anyones problem of where to source a decent replacement radiator.


View attachment 3598079View attachment 3598111
Aluminum core? That's a very tidy engine bay!
 
I imported another KZJ78 recently - just picked it up from the dock a few days ago. It has what appears to be a new or newish radiator (at least relative to the 29 years on the rest of the car) closely matching the OEM in appearance. I'll attach a photo of the top section with model numbers. I've searched and cant find what it is, or at least exactly what it is or where to get another. The sticker says it's from Daiwa Radiator Group and has a model number dbp-154036-m00 but I cant find record of it (I also tried searching using the scan code and also assuming the m00 is actually moo). I also tried the pa66-gf30 imprinted on the plastic... No hits. Anyone have any idea what this radiator is? By all appearances it looks to be a complete drop in replacement using the same mounts, tranny cooler, etc as the OEM radiator.

I'm perfectly happy with it for now as it shows no evidence of problems and appears to be in good condition. What I'm hoping for is I can find what this really is, whether it is actually any good / reliable over the long term, and whether it solves anyones problem of where to source a decent replacement radiator.


View attachment 3598079View attachment 3598111


They are an aftermarket radiator company based in Japan. They fill OEM gaps.

They have a sales office in the US.
 
In my personal experience, this radiator is very dependable. I have one on my KZJ78 now and driven a Hilux with a similar unit. OE fitment and performance ( based on how that Hilux was put through hell and back without issues). I drive my KZJ78 routinely at highway speeds (70-85 mph) in the Florida heat and never had any cooling system issues, including at heavy traffic etc. You'll likely be happy with this unit.

Iirc the tanks are glass reinforced plastic just like the OEM ones.
 
In my personal experience, this radiator is very dependable. I have one on my KZJ78 now and driven a Hilux with a similar unit. OE fitment and performance ( based on how that Hilux was put through hell and back without issues). I drive my KZJ78 routinely at highway speeds (70-85 mph) in the Florida heat and never had any cooling system issues, including at heavy traffic etc. You'll likely be happy with this unit.

Iirc the tanks are glass reinforced plastic just like the OEM ones.
Where do I get one from? Do you have a link for NA? Cheers!
 
@Lomoski

That I do not know. My truck came with it and so did the Hilux. I would certainly be interested in getting one if I am ever in the market for a radiator. Quality stuff.
 
@Lomoski

That I do not know. My truck came with it and so did the Hilux. I would certainly be interested in getting one if I am ever in the market for a radiator. Quality stuff.
I am sort of beginning to look for a replacement for my aluminum rad. If this is an OEM drop in I'd be stoked. I'll do some digging and if I find anything, I'll share.
 
I am sort of beginning to look for a replacement for my aluminum rad. If this is an OEM drop in I'd be stoked. I'll do some digging and if I find anything, I'll share.
It is. Judging by the mounting points, shroud fitment, and the additional tapped holes and captives moulded into the tank to attach other things just like the on OE radiator. Here are some pics.

PXL_20240404_222704720.jpg


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I can almost guarantee the top and bottom tanks are manufactured by T.Rad.— one of Toyota’s oldest suppliers and basically handles all thermal control products…. At least for Land Cruisers.

Daiwa is most likely an assembler of radiators from various Japanese industry part suppliers. Which is a good thing.
 
I think I found it - link below. Looks like it would be $420ish at current exchange rates plus shipping. Maybe it can be found cheaper elsewhere.

PLEASE - do some research. I did not buy or install this radiator myself and have owned the car for a week and driven it maybe 500 miles. It made it across the desert from Long Beach to Phoenix just fine and sure as hell looks like it was a drop-in solution, but I can't say squat about it's quality other than it looks good in the engine bay and hasn't failed me yet :). It's difficult to judge the quality with it mounted as so much of it is covered up. It very much appears to be a near exact duplicate as I haven't noticed any modifications in how it was mounted.


You could try calling Daiwa USA directly. If they don't sell direct to consumer, they might be able to point you to resellers, so maybe it's available cheaper elsewhere. Daiwa's contact info:

If anyone gets one new, I'd love to hear a report back. I have another 95 Prado where the top of the radiator is very brown, so the smart thing for me to do would be replace it before it cracks. Someday, I suppose.
 
I think I found it - link below. Looks like it would be $420ish at current exchange rates plus shipping. Maybe it can be found cheaper elsewhere.

PLEASE - do some research. I did not buy or install this radiator myself and have owned the car for a week and driven it maybe 500 miles. It made it across the desert from Long Beach to Phoenix just fine and sure as hell looks like it was a drop-in solution, but I can't say squat about it's quality other than it looks good in the engine bay and hasn't failed me yet :). It's difficult to judge the quality with it mounted as so much of it is covered up. It very much appears to be a near exact duplicate as I haven't noticed any modifications in how it was mounted.


You could try calling Daiwa USA directly. If they don't sell direct to consumer, they might be able to point you to resellers, so maybe it's available cheaper elsewhere. Daiwa's contact info:

If anyone gets one new, I'd love to hear a report back. I have another 95 Prado where the top of the radiator is very brown, so the smart thing for me to do would be replace it before it cracks. Someday, I suppose.
Thanks so much! I'm going to contact and see what they say. I have an aluminum chinese rad in currently that I replaced my stock pin holes rad with in 18 or 19. But it's not working as well as stock so I'll definitely check it out and give it a try if I can get one. Sounds like Tigris has had good results already.
 
Thanks so much! I'm going to contact and see what they say. I have an aluminum chinese rad in currently that I replaced my stock pin holes rad with in 18 or 19. But it's not working as well as stock so I'll definitely check it out and give it a try if I can get one. Sounds like Tigris has had good results already.
FYI - I ordered one of these Daiwa radiators just over a week ago and it arrived today. With shipping (and with the exchange rate in the low/mid 150 Yen/usd), the total cost was $671 usd. Unfortunately I'm still waiting on a bunch of cooling system hoses and then I have some traveling scheduled, so it will likely be 1-2 months before I can give you any feedback on the actual radiator. At this point all I can say is ordering and shipping went well.

I'll post back sometime this summer when I have a chance to install and test the radiator and give a report on how closely it mimics the OEM radiator.
 
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