Lee777 1991 LJ 78 Prado Build

[Lee777]

All finished. I took it for a drive. Its loud but I dont mind. You can hear the turbo coming out if the exhaust end. There was a noticeable improvement in acceleration. My EGT guage is on the fritz. Im pretty sure its the vibration because when I move the wire going to the probe it corrects. It doesnt read properly for very long before it shuts off. My EGTs were up at 800 at 100km on the flats. (Later it was 600 with the down pipe bolted properly) Ill know more when I drive up a pass.
This is a pic of a hanger I made. The crossmember was already present for the first one. The second hanger is on the other side of the muffler. I forgot to take a picture of the second hanger. Basically I welded some steel onto the body mount bracket and drilled a hole in it to accept the second hanger. I used the exhaust clamps to fasten the hanger to the exhaust. In this way I can remove the entire exhaust section fairly non destructively. To keep it looking nice I mounted the bracket bolt side up. To keep the exhaust looking new, I painted it with clear manifold paint. With the exhaust visible it would be sad to see it all go rusty after a year. The 3” pipe I bought is aluminized which is helpful.

 

[Lee777]

Materials were about 400$. The down pipe took about 3 hours (in the hands of a professional). The rest I did over 2 evenings (3 hrs each) and 7am - 2pm on a Saturday.

 

[JuanJ]

Hello,

Very good work.

That side exhaust reminds me of the Mercedes-Benz G Class setup.





Juan

 

[ALEXY]

on an early 2lt I do 800 post turbo at 100km/h on flats without any sort of modification...

is the 2lte a "hotter "engine then 2lt?

or simply adjusting the IP in my case equals your mods? (IP +injectors service is more expensive then an exhaust pipe as I learned)

 

[Lee777]

I was driving without the 4th bolt holding the down pipe to the turbo. I was able to get that last bolt on today. It shows 600 on the egt going flat 100km/hr which is more what I was expecting. Driving up the pass today at 75km/hr , EGTs did not exceed 800F.

 

[Lee777]

I got an upgraded fan from a 90s forrunner v6. Its one of the ring type fans. I pulled the fan and tried fitting the new one to see how close the blades come to the belts. The new fan would have to be positioned forward. I dont have access to a lathe to make my own spacer. I tried putting some washers between the blade and the fan clutch but i dont think it will create enough forward positioning to clear the belts. As well there is barely any bolt left to fix the nut securely.

Does anyone have any other ideas to push the fan forward?

 

[Nas90tdi]

How much do you need?
Maybe try a coupling nut and then a bolt into the other end to secure the fan. Red Loc-tite on all.
I agree, I wouldn't do that half nut. Too easy to destroy your radiator.

 

[GTSSportCoupe]

I got an upgraded fan from a 90s forrunner v6. Its one of the ring type fans. I pulled the fan and tried fitting the new one to see how close the blades come to the belts. The new fan would have to be positioned forward. I dont have access to a lathe to make my own spacer. I tried putting some washers between the blade and the fan clutch but i dont think it will create enough forward positioning to clear the belts. As well there is barely any bolt left to fix the nut securely.

View attachment 1810976 View attachment 1810977

Does anyone have any other ideas to push the fan forward?

Those ring fans pull a lot of air, but the offset being wrong is a total pain. I recommend you try to find a fan from a 2H diesel (HJ60 landcruiser). I have not tried one, but I've read they are literally bolt in. Or if you can find one from a early HDJ81, they are pretty good too, but require some modification to the top of the fan shroud. Just read the LJ78 Big Fan Upgrade #2 thread. Note, the latest HDJ81 part number fan is too big.

 

[AirheadNut]

Unfortunately I didn’t take any photos of it before I put it on.

 

[AirheadNut]

Redundant post

 

[Lee777]

Thanks guys, great ideas. Ill try and see if i can make the v6 fan work. I ordered up some M6 , 10mm hex , 25mm long coupling nuts (to give approximately 1” spacer) along with 10mm head x 10mm long flange bolts to fasten the fan to the couplers.

 

[GTSSportCoupe]

Thanks guys, great ideas. Ill try and see if i can make the v6 fan work. I ordered up some M6 , 10mm hex , 25mm long coupling nuts (to give approximately 1” spacer) along with 10mm head x 10mm long flange bolts to fasten the fan to the couplers.

I could also send you the spacer I made if you want. But you'll still have to modify the top of your fan shroud. If you want it, let me know. Here is the thread that shows it: LJ78 Prado BIG Cooling Fan Upgrade

 

[AirheadNut]

Sorry about that, was trying to respond from my phone on a poor connection and fat fingered it. I meant to say that on my first Prado I used a ring fan. I removed the short studs in the fan hub and used 1 inch collars and bolts to space it out. I also drew up a spacer in Solidworks that I was going to have 3D printed in ABS plastic, but I sold the vehicle before I got around to it.

 

[Lee777]

Thanks Nick I may take you up on that. Ill see how these bolts work, if its looking flimsy, i may go the spacer route. Its a pretty big fan! Im prepared to cut the shroud if needed. Airheadnut, i never thought about pulling out the studs, that makes sense. It seems to be a simple option.
Lee