My HJ61 Rejuvenation (1 Viewer)

[Fifty Hertz]

Mate, I registered just to say well done, shes a beauty.

I have a 1986 HJ61 Sahara high top stored away ready for a similar project rebuild! Healthy 12ht with a mere 300k on the clock

Cheers mate

I'll be packing it up and heading to the east coast soon. I'm planning to drive from Perth to My Isa through the centre, via Uluru and Alice Springs. Then down to Toowoomba. Can't wait for an epic road trip

 

[Fifty Hertz]

So this happened a few days ago



I noticed a small pool of oil on the driveway the morning after I drove home from the airport. Couldn't see exactly where it was coming from, although the side of the injection pump was fairly wet, as was the oil feed pipe. Nothing visibly leaking with the engine running though

So I wiped it all clean and gave all the fittings a quick wiggle. Nothing obviously loose. Started the engine up again and suddenly it was a gusher!

I think that pipe was fatigued from having been on and off multiple times. Each time it's undone and done up, the central bificated connection turns a bit, and this fatigues the two pipes coming out. I think that my gentle wiggling was enough to finally push it to failure.

 

[Fifty Hertz]

Unfortunately when I was removing the pipe, the whole central fitting rotated and really mangled the lines. So it ended up getting completely busted

Not what I wanted at all, being 3 days away from a 60-series meet! No options for a direct replacement turned up locally. After a bit of consideration, I decided to replace with flexible hoses. This was the only viable option to get me going again in short order. And I think it's actually a better solution z especially if it needs to be removed and replaced again for whatever reason.

I had these made up at Enzed in Welshpool. They're the same type as the ones that I previously had made for the vac pump and fuel filter hose.

 

[Fifty Hertz]

Getting in there was a bit of a mare. I had to remove the intercooler and air filter to get decent enough access. Got them on ok though.

Feed from the oil filter housing:

Feed to the injection pump:

Feed to the timing cover:

The central connection to the injection pump needed to have one banjo fitting stacked on top of the other. I needed to do a lot of calling around Perth to find a place that had M10 double banjo bolts, but I eventually located them at Perth Brake Parts.

Detail of the central connection to the pump:

 

[Fifty Hertz]

Success

 

[plink01]

Hey mate I loved ya build thread. You did an awesome job. You probably posted the most in depth detail of installing a bonnet scoop/top mount intercooler I've seen so far.

I'm looking to buy a HJ61 at the moment and trying to work out if I want to go top mount or front mount intercooler. Ideally I'd go front mount but it could get pretty squishy with a radiator, intercooler, condensor and ideally an oil cooler! So ill probably have to copy what you've done.

Keep up the good work!