My turn to introduce myself to the 70 series crowd. I purchased this rig back in January and started immersing myself in this forum. I was particularly interested in learning about the 1HZ and any upgrades/limitations it has or needs. So the journey began...I have owned 2 FJ40's and an FJ60, but always wanted a diesel 70 series for some reason. This one popped up for sale and after some investigation I found out it was originally a member of this forums' that had lots of top notch work done to it in the past. I am pretty sure there is a build thread documenting this work on here.
'91 HZJ77 RHD with 163,500 km on the odometer
Work performed in the past consisted of:
3 gauge pod in radio bin
Transmission cooler
3 row aluminum radiator
Pro Terrain Tamer adjustable shocks and lift
ARB roof rack
Smittybuilt rooftop tent
ARB front and rear bumpers
12K warn 24v winch
ARB 24V compressor
ARB rear air locker
Front LED spotlights
LED interior light conversion
Dorkel
33" BFG KO3's
Manual hub conversion
All this work was top notch, but we all know its never done and maintenance has to be kept up with. I received it and started driving it to see what modifications if any I would want to do. I have always liked my projects to be as close to OEM as possible but with comforts. LOL. The concerns that showed up and took me down the rabbit hole I went down are as follows:
1. EGT's were very easy to get to 1300
2. Coolant temp was easy to get to 220 ( I felt this was hot, but am learning others think that's fine)
3. Timing belt cover had no maintenance sticker on it indicating when it had been changed
4. Unknown filter and fluid intervals
5. Inadequate power to pull itself on any road other than a backroad - this really degraded the experience of driving it - it was work to get it above 55 and keep it there
6. The undercarriage looked like a pristine black undercoat, but on inspection it was all soot from all the black smoke leaking out the exhaust system that was completely rotted through along the top side. This is the ONLY rot/rust I have found on it.
7. The rear air locker has a leak that keeps the compressor running when engaged
8. After a drive I decided to use soap and water to find the leak and first squirt sizzled on the rear diff, it is hot to touch after a long drive
With the help of several threads on the forum and some PM's with different members (thanks
@davegonz and
@Gun Runner 5) I got pointed in the direction I felt best for my needs on the cruiser. The order of events over the next few weeks to address my concerns kept snowballing, but went as:
1. Timing belt (what a bastard of a tensioning spring)/new toyota belts (Thanks Cruiser Outfitters)
Yes, I skimped and didn't replace the water pump as it wasn't weeping. More later....I like doing things twice apparently
2. Dropped the oil pan to put a bung for turbo
3. Might as well do BEB since the pan is dropped - Installed OEM standard ConRod bearings (pics on BEB thread) with new OEM ConRod bolts (Thanks Back 40 Imports) and installed oil pan with new bung
4. Sourced adapters (Ebay and Mamba) to mate my Holset HX30W turbo (Thanks Rodney and BenzForce) to my current exhaust manifold without replacing it with one from a 1hd-t
5. Fabbed 3" stainless exhaust (Ebay for pipe, V-Bands and flex joints)
6. Replaced engine oil, oil filter, fuel filter, air filter, and front and rear differential oil (Filters from Cruiser Outfitters)
7. Fabbed silicone hoses from turbo to stock intake crossover to see if I could keep egts normal without an intercooler as I really didn't want to cut the hood unless absolutely necessary. I wasn't looking for max power with the turbo, just drivability so to speak.
Decided to drive it for a while after all this. Left fuel screw alone at this point and max EGT's under long pull of 950. Drivability was enjoyable now. I was amazed at how much cooler the turbo kept the egt's although now I noticed the coolant temp was still bumping 220-230 on long pull, which I thought was a bit hot....after a few PM's I decided cooling system update and intercooler were in order. So...
1. Remove fan/new belts/new timing belt/valve cover with new gasket.....Replace water pump/thermostat/new red Toyota 50/50 coolant.
2. Wait a minute, the valve cover is off...lets check the valve clearances. 8 of the 12 were too tight. s***. Measured them, did the calculations, ordered new shims from Partsouq and an OEM valve tool. DONT buy a knock off ebay one - piece of junk.
3. Ordered a HPD Series 2 overhead intercooler from Australia. Very good and helpful people, highly recommend. Very prompt in answering any questions. Arrived in about 10-12 days via DHL.
4. Put on the valve cover, mocked up and installed the HPD Intercooler, cut the hood (um bonnet), installed the scoop, will paint later maybe
5. Shims arrived. REMOVE the intercooler and valve cover, replace valve shims as required. Put back on valve cover and...then reinstall all the new timing stuff (what a bastard of a tension spring) and belts I had done a few weeks ago, and then REINSTALL the Intercooler. Im getting pretty good at taking things off and on...
After intercooler and cooling system upgrade and without touching the fuel screw again, I had egts maxing at 700 and coolant at 180-190. From there I started turning the fuel screw in 1/4 turn and dive a few days, then repeat until now I am running max egts of 1150, no black smoke, coolant is 180-200, boosting 18psi max, and so much less work to drive now lol.
In retrospect if I were to give out advise I would have definitely decided on a turbo and set that in stone and worked my way backwards. I started off going with a 1hd-t type stock turbo and bought all flanges/kit etc and then changed my mind (I will start putting some of this on the classifieds soon). I probably would replace the stock manifold with one from a 1hd-t and not have adapters, it would have been cleaner but I HATE dealing with broken exhaust studs. The difference the intercooler made was night and day and I tried to short cut it, no way would I consider a turbo without it now. I love the Holset turbo so far. There are no shortcuts and nothing is cheap adding a turbo. Every single shortcut I knowingly made I had to re-address it. Most all of this tech was available on the forum and easily found as far as directions, I just wanted to say thanks for that and share my journey to a now very fun ride. Ill close with a couple of pictures from this weekend touring Big Bend National Park with my wife and kids.
