Builds My HZJ77 Build

[ForealBoreal]

i would love to have my fuel economy back on the PZ, i fitted the turbo, cranked the fuel for fun and the fuel mileage (as expected) dropped substantially.
to be able to have my decent fuel mileage AND my power sounds like a great idea.

a nice plus will be the lack of black smoke pouring out the back that has been pissing off the locals behind me.

Yeah I loved the power but the combination of the fuel economy and black smoke was driving me nuts. I really disliked the smoke, it's just dirty coming from a cruiser. It did come in handy a few times though smoking a few people out. Lol. It's now quite civilized, I really tried last nigh trying to get it to smoke.
I am really looking forward to how this changes my fuel economy again. I have read that others after fitting have gotten the same fuel economy to 1l/100km worse than stock. Time will tell.

 

[swederic]

Man you got way more patience than I do with stuff like that!

 

[ForealBoreal]

Well I can't afford to pay someone to do it, not to mention nobody in town has cruiser knowledge and would charge me $100 an hour for something they would have to learn. Might as well learn and do it myself.

I have learned a ton from this website and hope to at least pay it forward. I am glad to help anyone on here.

 

[crushers]

that is the biggest issue that we have as a group ... most shops have no idea what they are doing ...
there are those around that have a ton of knowledge but you have to go through trial and error to find them.
if you can do the job yourself, or learn to do it, then you are leaps and bounds ahead. if something goes wrong on a trip then you have a good idea of how or what it might be.

thanks for posting up the thread and being honest in posting the flawed install. many of us would be stumped if it wasn't for your words.

 

[ForealBoreal]

Data helps me out. I was scratching my head all Saturday night with that pump. As I said if anyone needs help or advice on things just ask. I pm and get pms all the time asking questions.

Exactly Wayne, nobody knows these things up here. I am forced to learn and do it myself which is ok at time, just annoying when I want to be doing other things but I rely on the thing so I have to maintain it.

I like knowing what has to be done and seeing a clutch job, bottom end bearings, my turbo job, wheel bearings, transfer case rebuild and upgrade. I know I could deal with it. I think there are only a handful of jobs that I would have to outsource the job to get a particular part fixed.

I have a list of stuff I still have to do, waiting for shipping on some stuff from aus and funds to permit to do it though. All for the love right?!?

 

[GTSSportCoupe]

Nice work! When you get it all dialed in, I'd be interested to see an in cab video showing the acceleration.

Will you ever have the need to tow? I'm curious how the hills will be now with all the work you've done.

How does the power compare to the 1HDT in your opinion?

 

[ForealBoreal]

Nice work! When you get it all dialed in, I'd be interested to see an in cab video showing the acceleration.

Will you ever have the need to tow? I'm curious how the hills will be now with all the work you've done.

How does the power compare to the 1HDT in your opinion?

It's all dialed in, it took me roughly 15 mins to get it all tuned up in terms of proper idle speed and max fueling egt. I could probably fool around one of these nights an get a few shots.

I am currently designing an enlarged intake manifold to suit a top mount 12x12 inch intercooler core. I am hoping with a good cooler and plenum I can lower egts even more, turn up the boost to 20lbs and put some more fuel in. In theory I should be close to the max fuel of my pump and I hope to have more power running cooler EGTs. I think it's fully possible. If I have more of a power craving after that I might do meth injection but that's a ways away.

Hope to own a 16" welded aluminum skiff with a jet sometime next year. Utility trailer with building supplies. Potentially an ATV at some point. Nothing big or really long distance.

I think it is quicker than my old stock 1hd-t. But I am sure a tuned 1hd-t running the same boost and stuff will beat my truck. I am not after building a 1hd-t killer, I just want a capable and reliable truck. It definitely pulls better on the hills since the turbo and accelerates way quicker. It's a completely different truck.

 

[GTSSportCoupe]

It's all dialed in, it took me roughly 15 mins to get it all tuned up in terms of proper idle speed and max fueling egt. I could probably fool around one of these nights an get a few shots.

I am currently designing an enlarged intake manifold to suit a top mount 12x12 inch intercooler core. I am hoping with a good cooler and plenum I can lower egts even more, turn up the boost to 20lbs and put some more fuel in. In theory I should be close to the max fuel of my pump and I hope to have more power running cooler EGTs. I think it's fully possible. If I have more of a power craving after that I might do meth injection but that's a ways away.

Hope to own a 16" welded aluminum skiff with a jet sometime next year. Utility trailer with building supplies. Potentially an ATV at some point. Nothing big or really long distance.

I think it is quicker than my old stock 1hd-t. But I am sure a tuned 1hd-t running the same boost and stuff will beat my truck. I am not after building a 1hd-t killer, I just want a capable and reliable truck. It definitely pulls better on the hills since the turbo and accelerates way quicker. It's a completely different truck.

Right on man, sounds good. Keep up the good work. I look forward to seeing the intake manifold and intercooler work!

 

[Clint79]

It's all dialed in, it took me roughly 15 mins to get it all tuned up in terms of proper idle speed and max fueling egt. I could probably fool around one of these nights an get a few shots.

I am currently designing an enlarged intake manifold to suit a top mount 12x12 inch intercooler core. I am hoping with a good cooler and plenum I can lower egts even more, turn up the boost to 20lbs and put some more fuel in. In theory I should be close to the max fuel of my pump and I hope to have more power running cooler EGTs. I think it's fully possible. If I have more of a power craving after that I might do meth injection but that's a ways away.

Hope to own a 16" welded aluminum skiff with a jet sometime next year. Utility trailer with building supplies. Potentially an ATV at some point. Nothing big or really long distance.

I think it is quicker than my old stock 1hd-t. But I am sure a tuned 1hd-t running the same boost and stuff will beat my truck. I am not after building a 1hd-t killer, I just want a capable and reliable truck. It definitely pulls better on the hills since the turbo and accelerates way quicker. It's a completely different truck.

Good progress mate, just need more pics

 

[ForealBoreal]

So i got off my ass tonight and decided i should finally re-time my injection pump.
I took my ACSD (assisted cold start device) off last year and since the the cold starts were right off. White smoke, sputters. This was saying the timing was retarded.
Anyways, checked the timing and the plunger stroke of the ip was .77mm and stock is anywhere from 1.03mm - 1.09mm. Right out of wack, i advanced it to 1.09mm.

The truck ran decent highway temperatures at 600-700 degrees F on the highway off the top of my head and when I fitted the tent it shot up to 800 deg F. Way to hot for my likings.
Plus the fuel economy was in the toilet (15L/100kms). Truck's max fuel screw was tuned to 1200deg F pre turbo.

Since advancing the pump and doing a short test tonight on my way home the truck runs smoother, has noticeably more power, more responsive and runs cooler on the highway and a cooler max temperature to boot. Apparently my fuel economy should get noticeably better and my cold start sputters should be fixed.

I got 100-150 F degree lower temperatures while cruising @ 100kms/h so now its sitting back at 650-700deg F with the fxxxing tent on the roof. Nice really happy about this, I will be able to give better numbers when I can take it for a good long burn down the highway to go fishing.
Plus the max EGT is at 1000 deg F now, this means I can crank way more fuel into it.

She's going to be a monster with more fuel, intercooler, plenum, air box and 20lbs of boost.
The pull now in 3rd gear is like stepping on it from a dead stop in first gear but while your cruising ~50kms/h with enough load to slam that boost needle until the waste gate opens up. Lots of torque.

 

[FJRanger]

Did you you use Graeme's tuning guide when working on your pump?

 

[NGray]

flipping through this tonight...amazing work. That roof rack is great.

 

[ForealBoreal]

Did you you use Graeme's tuning guide when working on your pump?

His tuning guide is hard to find like unicorns apparently. I have tried asking numerous people and contacting him a handful of times here and it never comes through and is never sent.

I think I did a good enough job with my pump mods so far fitting the boost comp, tuning the fuel rod and internals, setting my timing advance correctly and tuning the max EGT nicely. Its running like a champ now.

I took the truck out for a tune tonight and drove 50k out of town to the biggest hill in the area, charged the thing at 100k and once it was up on the hill i put my foot to the floor all the way up watching the pyro like a hawk. It stopped at just under 1200 deg F pre turbo. Perfect. Truck is fully tuned now waiting for the next performance mod.

flipping through this tonight...amazing work. That roof rack is great.

Thanks for the compliment. I want do do a few other minor mods to it in terms of add-ons but its doing the job well and it fit the budget perfectly. Onward to other DIY projects.

 

[DamoPeru]

Exhaust Fabbing.

......

Routing #1
View attachment 710077

Karter,
Very similar to what I'm doing right at the minute, but i notice it appears you had very little clearance above the chassis or below the body mount support. I put an extra kink in to clear the chassis by 1 1/4" (cut the panel above as well) but I still only have 1/3" below the body mount support (which I'm going to heat and bend away) otherwise it rubs on the tyre (with suspension removed, resting on only the small stop on full right hand lock).

has this amount of clearance turned out alright for you or have you had some rattles occasionally at shutdown or offroading?

Cheers,
Damien

 

[ForealBoreal]

It's turned out alright for me.
Doesn't rattle or touch tire on full lock.
I did bend the inner fender to clear it a bit

 

[ForealBoreal]

Quick update on some stuff in the last little while.
I have been slacking a little.

New shackle bushes and grease-able pins were installed, its more plush now as alot of the grease cavities in the shackles were basically cemented shut. All fixed now.
New TREs and Drag-Links all grease-able now.
Alignment done as well.
Valve Shim Adjustment

Bought the ebay HPD top mount intercooler last year and just finished installing it.
So far I recommend a few things with the kit:

1) get t-bolt clamps, the worm clamps are s***.
2) get better silicone 2 x 2" straight works just fine. The stuff in the kit is s***.
3) make sure you have some fasteners as you will need some for the install. The center manifold bolt isn't the best design, you just need to find a really small allen cap screw to go in there.

The fellow selling the kits can take out anything not wanted in the kit and will knock off a bit of money. I opted to avoid getting their scoop and should have said no to the silicone and clamps. He did give me a 24v puller fan as it was an option. I hooked it up awhile back and it seemed to work well.

I haven't installed the STi scoop I have bought as of yet nor have I wired the puller fan or sealed the hood to the core to maximize flow to cool the core. I am up in the air if I really want to put the STI scoop on or if I should pursue a different one which is proving to be a pain in the ass.

Truck was previously tuned to 1200F pre turbo.

Results:
So far it has dropped my max EGT by 200F. I can't get the temps over 1000F. There is about a 1 psi drop in pressure through the core so its boosting 13lbs on the other side.

Headed down south next week and there are a few things in the works next week:
LineX job and Cruisin Sliders mated to the brush guards.
Few other maintenance items and mods to do after I get back from the trip.

Stay tuned!

 

[Gun Runner 5]

I would need a lot of alcohol to muster up the courage to cut my hood. : )

 

[swederic]

Gonna be ready to do the Telkwa Pass in August bud?

 

[wardharris]

I would need a lot of alcohol to muster up the courage to cut my hood. : )

Just think of it as an induction circumcision.

 

[BJ74Guy]

Turbo (Diesel) awesome write up. How does one subscribe to a topic?