Builds Project F u k u s h i m a... my 1990 HZJ73 build thread

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Make sure you install a boost comp. these engines are sensitive to low AFRs. The boost comp will allow a tune for fuel delivery if set correctly.
 
Ive been reading your posts. Thank you for sharing the info on the boost compensator. I'll look into it further. I have a lot to learn when it comes to turbo charging...!
 
Axle rebuild is complete... and nothing fell off during the first test drive. :) Overall it drives better.

I ended up replacing the front brake rotors and pads with the following parts.

43512-60100 Front brake rotors
04465-60030 Front brake pads

Front rotors...

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Also installed the manual hub conversion. I bought a set of hub adapters and some Aisin lock outs.

Adapters... from Radd Cruisers

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Used these Aisin lock outs...

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The hub adapters worked fine, but they were slightly larger than the outer diameter of my front hubs and I was unable to get my wheels to go over over the adapters. I ended up turning the adapters down a little, so that they would fit the center of my wheels.

Here is the adapter installed... pretty easy installation. There are 4 hex head bolts holding it in place, along with the pins and 4 studs. They come with two studs that screw into the adapter.

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Going to drive the 73 this week and make sure everything is good. I also ended up replacing the batteries... after two weeks of sitting one of the batteries died. I tried to charge it, but it was dead. Installed two new Deka Gold batteries.

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Trying to finish off the maintenance stuff this weekend, so I can start on the 12v house battery setup. New tie rod kit arrived as well as some new Siberian Bushings for the front swaybar. I also got a chance to try out my pressure gauges while I adjusted the lspv. I did a garage alignment and set it for slightly less than 1/8" toe in, but I think I'll take it down and get it aligned next week.

The guys at Cruiser Outfitters hooked me up with the Japanese 555 tie rod end kit. These made a huge difference in the steering post install. TRE69100 or 45040-690100x is the part number on the tie rod end box.

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I ordered these polyurethane bushing off ebay. They are from a company called Siberian Bushings. Yes they came from Siberia. They are a nice quality bushing, we'll see how well they work out. As you can see the original ones were tired. :)

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I followed the instructions in the fsm for setting the rear brake pressure and adjusting the lspv. I opted for a little higher pressure in the rear.

Rear pressure before adjusting the lspv...

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Rear pressure after adjusting the lspv down about 1/4"... then fine tuning by adjusting the bracket at the axle.

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New rod ends and bushings all installed...

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I noticed a big difference in the tightness in the front end post install. The new rod ends and bushings really tightened things up. The brake are really nice right now with the lspv adjusted to proper settings. Truck is driving great after all this basic maintenance.
 
I ordered a Safari Turbo kit a number of weeks ago. Finally finished the maintenance work and decided to tackle the turbo install this weekend. The Safari kit contained everything I need except for a few thread taps. so I ordered those items. Other than the taps the kits contained everything I needed to complete the install.

The kit came complete with everything I needed...

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You have your choice of either drilling an oil return hole into the block order punching a hole in the oil pan. I opted for drilling and taping a hole in the block. I also had to drill and tap two holes for the turbo mounting bracket.

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I ordered an air driven angle drill. I think this is my new favorite tool. Made quick work of the drilling. Start with an 1/8" drill bit and worked my way up to 15mm. I ordered a 3/8" bspt tap to thread the oil return hole.

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Oil return installed...

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Turbo unit assembled and ready to install...

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The installation was pretty easy (once you get past drilling holes in the block)... Turbo mounted...

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The kit comes with a new exhaust dump pipe... I will be installing a 3" exhaust system with an aeroturbine muffler.

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I had to drill two additional holes that were used to mount the turbo bracket.

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Installed the oil lines and wastegate lines along with the new silicone intake tubes...

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Installed the final bits...

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Firing her up for the first time...



Install complete...

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Took the HZJ for a quick spin around the block... hard to notice and real difference at 25mph. :) I will drive the truck on my commute this week and see how things go.

Next I plan to do a 3" exhaust from the turbo back with an aeroturbine muffler. I will also be adding the EGT and Boost gauges and will be doing some tuning. I'm not tuning for max output... more for longevity, so the boost will remain low.
 
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Looking really good and I can't wait to hear about the performance of the kit - I am planning to do something just like this to mine 1HZ.

Great explanation and pictures - thanks :)
 
Thank you for the nice comments. :) The install went smooth and the kit was VERY complete.
 
Took the HZJ for a quick spin around the block... hard to notice and real difference at 25mph. :) I will drive the truck on my commute this week and see how things go.

Next I plan to do a 3" exhaust from the turbo back with an aeroturbine muffler. I will also be adding the EGT and Boost gauges and will be doing some tuning. I'm not tuning for max output... more for longevity, so the boost will remain low.

Beauty job on the install. That 90 deg drill is perfect for that spot.

You will not notice anything not touching the fuel.

I highly highly highly recommend you install a boost compensator to your fuel pump. You seem like a very mechanical person, this shouldn't be a hard thing for you to install and tune.

Best to have a pyrometer pre turbo and get an AFR gauge to tune. If you were to just turn up your fuel the off boost fuel would be too high causing a low AFR and risk hurting your Pistons.

Remember boost doesn't kill these engines fuel does. You could pump 25lbs no problem into the thing and it wouldn't hurt it. But the wrong AFR and high EGTs can kill your engine. You could run that thing 15lbs on the daily and it wouldn't hurt it.

It's worth your time and money to do it properly and safely the first time to avoid headaches.

Good job on the build
 
Beauty job on the install. That 90 deg drill is perfect for that spot.

You will not notice anything not touching the fuel.

I highly highly highly recommend you install a boost compensator to your fuel pump. You seem like a very mechanical person, this shouldn't be a hard thing for you to install and tune.

Best to have a pyrometer pre turbo and get an AFR gauge to tune. If you were to just turn up your fuel the off boost fuel would be too high causing a low AFR and risk hurting your Pistons.

Remember boost doesn't kill these engines fuel does. You could pump 25lbs no problem into the thing and it wouldn't hurt it. But the wrong AFR and high EGTs can kill your engine. You could run that thing 15lbs on the daily and it wouldn't hurt it.

It's worth your time and money to do it properly and safely the first time to avoid headaches.

Good job on the build

Thanks...! I've been reading more about the compensators and it sounds like they help out a lot. I need to source one still. The turbo has a place to install a pyro pre-turbo (right at the outlet flange from the exhaust manifold) that is temporarily blocked with a set screw.

I'm definitely going to tune it. Going about it methodically and after all the reading I'm paranoid about too much fuel and too much heat. :) I found a place in town that will throw it on the dyno and tune it, but I want to have everything installed and ready to go before starting to tune. I need to get the gauges, exhaust and a compensator installed then I'll start playing with the AFR and boost. I feel like I'm flying a little blind w/o the gauges.

Any recommendations on gauges...? There seems to be a million choices for gauges.
 
ISSPRO EV2 Series.
I love my setup as I like seeing a gauge not just numbers like a digital read out.
The gauges are instant unlike the VDOs I have seen.

I bought mine from Diesel Manor and I have the green backlighting. They work with 24v power.
 
Still the quintessential overachiever, I see.....

I'm still hunting the box knife. :flipoff2:

I can't wait to see gauge pod and intercooler....so hurry up!!

Why'd you opt for the block return instead of the pan, Sol?
 
Still the quintessential overachiever, I see.....

I'm still hunting the box knife. :flipoff2:

I can't wait to see gauge pod and intercooler....so hurry up!!

Why'd you opt for the block return instead of the pan, Sol?

Did your Safari turbo kit arrive?

I opt'ed for the block return because I had to drill holes for the turbo bracket. My motor did not have the bosses drilled and tapped from Mr T in Japan. Given I had to drive two holes for the bracket I figured why not add another one for the return. Also gave me an excuse to buy more tools. :) I have to admit that drilling the holes was way easier than I expected.

RE: the gauge pod... there are about a million choices to go along with the gauge choices. I've looked through everything on amazon and ebay and nothing is speaking to me. I was thinking about trying to source and OEM altimeter gauge pod, gut it and put the ISSPRO gauges into it. If anyone out there has an OEM one please PM me. Intercooler... is not on the short list of things to do. I did order a boost compensator today from @Akella (thank you btw).

I also made an appointment at the exhaust shop to get the 3" system and aeroturbine installed. Overachieving...I just grew up in a competitive family. :)
 
"I was thinking about trying to source and OEM altimeter gauge pod, gut it and put the ISSPRO gauges into it. If anyone out there has an OEM one please PM me. "

It took me some time to find one for my turbo gauges, but I needed a brown one. Contact @joekatana, he can get the blue/grey ones.
 
It took me some time to find one for my turbo gauges, but I needed a brown one. Contact @joekatana, he can get the blue/grey ones.

Awesome... thank you very much. I just did a little searching and it looks like the cover is available via dealers in North America. All I need is the cover (part # 55403-90K00-13) in blue/gray. I can make the face plate for the gauges. I'll do a little more digging and see what I can come up with. Thank YOU again for the info. Super helpful.
 
Why don't you make one that goes in the din slot below the stereo. Simple and clean. You can operate a demel to make it look very clean:)
 
Also if you are planning to run 15lbs of boost max I wouldn't bother with an intercooler.
Front mount would be the only way to go, yet again it would require a ton of fabrication to fit and do clean.
 

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