Builds Tenerife to Texas: a 1997 HDJ80 Tale

[Workhorse]

That is the right attitude sir, let's get er done!

 

[bottombracket]

Ok, time to get this thing back on the road. Using the @davegonz method, tiny little bites, getting little bits done.

A couple weeks ago I replaced the totally fractured and rotten heater valve.

What am I standing on as a stepstool?

 

[OffRoadScott]

Love that "step stool".

 

[bottombracket]

Time for a good old-fashioned part number dump.

Friday night @Mr Cimarron and @shanko stopped by. We got the intake manifold cleaned and back in place with new hardware. It is a real pain to do this with the motor in the truck.

 

[bottombracket]

Injector lines were next. Again, it is a giant pain in the ass to do this with the motor in the truck.

For future reference, number 2 goes on first. I used a combination 17mm crow’s foot wrench and an injector wrench. The crow’s foot was small enough to manipulate in tight spaces.

I know this is posted everywhere, but for future reference, here is the injection pump firing order, and order of assembly of injector lines.

 

[bottombracket]

Thermostat was next, just ‘cause I was in there.

Always remember to keep @davegonz ’s jiggle joint upwards.

 

[bottombracket]

Turbo water lines and turbo drain hose next.

 

[bottombracket]

Exhaust manifold studs and hardware: I tried to torque them to the same 31 foot pounds for the nuts, as specified in the FSM but couldn’t get them much past 25. Close enough.

 

[bottombracket]

As a future reminder for myself, the blue O-rings go in the two grooves followed by exhaust rings spaced 180° apart. Manifold collar goes in between and the whole mess gets shoved together. Every time I do this I have to go back and review exactly how it goes together.

 

[bottombracket]

My good friend @Workhorse cut me out some beefy EGR delete plates. I will drill and tap them for an EGT probe later. Yes, I know it’s not in the center of the manifold but it should be good enough.

@OGBeno I confess my sins. I am using some non-OEM G turbo studs and nuts here. I’m hoping this oversight can be forgiven.

Don’t carry your turbo like a school lunchbox. The FSM tells you how to keep it real.

Entire turbo assembled and ready to drop in.

 

[bottombracket]

Interestingly, G turbo ships their turbos without a wastegate actuator hose and clamps.

I had OEM on the shelf… But my darn hose was too short. Don’t read into that.

There are 1 million choices for high temp silicone hose on Amazon. I rolled the dice and bought some of whatever can be delivered in 24 hours. Does anyone out there have a favorite silicone hose and clamp source, or am I just reading too much into this?

 

[bottombracket]

The Kroil watches over the engine bay with a slightly menacing stance.

To finish the evening, I hung the manifold and torqued everything into place. Oil lines and exhaust tomorrow.

Overall, it was a really productive day.

 

[HDJ80L]

Awesome build to follow, so many nice new parts.
As for access to the IP / fuel lines, unbolting the fuel filter housing and putting it aside helps a lot imo.
I think EGT placement is great between 5 and 6 as those cylinders tend to run hottest on an inline 6.

 

[shanko]

Man, you sure did knock out a ton of stuff last night. The new lady friend must have been out with the girls for the evening.

Everything looks fantastic. Not too much longer before it is back in action. Can't wait to see it rolling again!

 

[davegonz]

You're knocking it out. Keep the momentum going!

 

[bottombracket]

@shanko she was out of town. She has called the HJ61 as her truck to drive but I’m wondering if she’ll change her mind when she sees and drives the Cave 80.

@davegonz I am trying! One bite at a time.

Also, in case anyone was wondering, my hose is now totally long enough to get the job done.

6mm/1/4” ID silicone hose with OEM clamps.

 

[shanko]

I’m glad you got your hose problems straightened out.

 

[bottombracket]

I wonder why the grid heater didn’t work?

At least, living in Texas, I don’t need to worry about it. I could pirate one off of an FTE that is sitting here, but I think I’m just going to gut it and use it as a static spacer, which the front-facing inlet of the PDI intercooler will require to clear the intake and throttle cable.

Curiously, there is a 13 mm nut in this JIS world. It is not 12 and it is not 14. Very unusual.

I reused the 50mm bolts, two studs and two nuts from the original crossover and it is about to be intercooler and exhaust time.

 

[Workhorse]

@bottombracket
Is this bugger burning diesel yet? I want to hear your impressions since it was stock to present.

 

[bottombracket]

Not yet…exhaust and intercooler soon