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Joined
Dec 15, 2019
Threads
13
Messages
238
Location
Colville Wa.
Hi everyone im Mike signing in from Colville Wa.
Just got a new to me 91 LJ78 wagon with a 2lte and a 5 speed manual trans.
It only has 25K miles and is very sound and completely rust free.
I have been working every day for the last 3 weeks getting it road ready.
I want to make sure everything is working at100% before I start driving it regularly.
A 28 year old rig in the best of condition is still 28 years old. The interior was still pretty much like new.
Under the hood was all original and low miles but aged.
The auto hubs had broken brushes. The tire were mostly new were a heavy lug pattern not good for winter ice driving.
Here is what I have done so far.
Replaced electric hubs with Aisin manual lockers with adapter rings.
Replaced Yokohama geolanders with 31/10.5r15 BF Goodrich All Terrains.
Replaced all fluids and filters.
Repacked all bearings and greased drivelines.
Flushed cooling system with thermo cure rust desolver and blew out all hoses and cooling circuits.
Replaces all hoses and belts.
Checked brakes and replaced brake fluid. Brakes had no wear.
Shocks were recently replaced and still looked new.
Replaced wiper blades.
Replaced glow plugs.
Removed and cleaned injectors.
Sea foamed the fuel system
Removed and blocked EGR.
J-hooked turbo waste gate.
Increased pump pressure 1/2 turn.
I stall 4.3v Zener diode boost fooler on map sensor output.
Re-routed oil breather hose to catch can and open air.
Rotated coil springs to correct body lean.
I have a full set of air intake hoses coming soon and thats about it.
I think that with all that and spare belts, hoses and glow plugs i spent $2000.
The first time i drove it I was rather underwhelmed with the power of the 2lte.
Now with the improvements its quit the goer. Gets up to and hold Hwy speed no problems.
Cruis 70mph all day. Never have to down shift. I might be able to pump a little more power out of it with
More fuel and an intercooler but for now Im good with it the way it is.
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Looks great! You’ve got the exact double of mine; same color and manual trans. That’s an impressive list of maintenance and upgrades, good work. If you haven’t installed a pyrometer yet I would strongly recommend doing that soon.
 
Nice truck and nice modifications! Congratulations!

I agree with what everyone else is saying: Pyro should be a high priority. Turning up the fuel without a pyro is definitely a risk. Although higher boost helps to reduce EGT's, the factory turbo produces some very high intake air temps (which contribute to high EGT's). Generally I'd recommend not touching the fuel screw until intercooled, but that's just my two cents...

Second thing, the low km LJ7x's are a mixed blessing. Nice because they're clean and low km. The problem (as I'm sure you've read), is the first rev cylinder heads have a serious fault and fail within 100,000km. From what we saw 10+ years ago when these trucks first came into Canada, the low km LJ's usually have the original heads still. There is no avoiding an eventual failure on those heads. However with the sort of modifications you're doing, the second generation (upgraded) heads do pretty well. Any idea if the truck has the original head still? If not, make sure to save for a new one....
 
The engine does not appear to have been worked on so im guessing it still has the original head.
It may last or it may not. I was reading some aussi posts from another forum. They mostly claimed it was hit and miss on the heads cracking and usually not till after 200kms. Ill just drive it and not worry about it. This spring once the weather warms up and i can drain the antifreeze, ill run thermo cure through the cooling system for another week to get out any remaining rust. I think rust build up in the head contributes to the heat
Cracking problem.
One more item I would like to buy for the truck is a brush guard. It had ben removed before i got it.
I have so far been unable to locate a replacement.
 
The engine does not appear to have been worked on so im guessing it still has the original head.
It may last or it may not. I was reading some aussi posts from another forum. They mostly claimed it was hit and miss on the heads cracking and usually not till after 200kms. Ill just drive it and not worry about it. This spring once the weather warms up and i can drain the antifreeze, ill run thermo cure through the cooling system for another week to get out any remaining rust. I think rust build up in the head contributes to the heat
Cracking problem.
One more item I would like to buy for the truck is a brush guard. It had ben removed before i got it.
I have so far been unable to locate a replacement.

The rust is also because the Japanese are lazy about using a proper coolant mix and often run straight water! I've seen a number of these trucks/motors now where the coolant looked like rust soup! Definitely does nothing to help the cooling situation, that's for sure.
 
I think its turning around 31-32. Very smooth at 31-32. I also normally drive like a granny. Im that jerk whose only going the speed limit. Usually never over 60 trying to get the best mpg.
 
If you want to sort the logistics i have a brush guard in my garage- New Zealand that I'm happy to sell off.

8/10 condition (one small scratch on it and a paint scuff from something, also small)
 
If you want to sort the logistics i have a brush guard in my garage- New Zealand that I'm happy to sell off.

8/10 condition (one small scratch on it and a paint scuff from something, also small)
Thanks Ill try to find one in the states. The shipping from NZ would be a killer.
 
I forgot an item on my work completed list.
I also removed the throttle plate. Diesel engines should not have throttle plates.
I think thats it. There was a lot of stuff. I was quite busy. If I wasn't retired I never would have had the time.
 
@Houser , I just noticed you're in Colville WA. I grew up right on the Canada/US border just north west of you a bit. Midway BC. Had relatives in Spokane, so passed through that area quite a bit as a kid. We did some family camping trips in Washington, Idaho and Montana too. Nice country.

I'd like to come visit again when someone more predictable is in charge of your country. :D (no offence intended; just the way I feel)
 
@Houser , I just noticed you're in Colville WA. I grew up right on the Canada/US border just north west of you a bit. Midway BC. Had relatives in Spokane, so passed through that area quite a bit as a kid. We did some family camping trips in Washington, Idaho and Montana too. Nice country.

I'd like to come visit again when someone more predictable is in charge of your country. :D (no offence intended; just the way I feel)
Yes its a very nice spot. Im just 6 miles south of the border. Moved here from Alaska when I retired 3 years ago.
 
Is this the brush guard you're looking for? I took it off when I started the engine swap and am planning on building my own bumper, so I no longer need it. I have all of the brackets to mount it. Located in NW Montana, so just a bit closer than NZ...
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