back to the beginning......
the owner had installed a turbo and a snorkel. truck runs and drives great but engine runs a little warmer than it should and doesn't get the fuel economy he expected. all this work was done before he brought it with him to the USA.
he brought it to me for a few things over the last couple of years. I've been trying to tell him that the air intake system is too restrictive and that he should dis-connect the snorkel when driving around the USA to get better air flow. he didn't think that would help so he bought and installed an aux engine oil cooler kit instead. that made little to no difference.
he brought it back last week and I told him that we should still try to get better airflow to the engine.
ultimately I came up with the idea of creating another opening for the air cleaner but we decided to make it "closeable" for deep river crossings or extremely dusty conditions. I don't think he'll ever see either of these but he insisted ......
so we took an air cleaner assy from an FJ60 and chopped the intake snout off. it's got the hot-air flapper valve in it that actually seals pretty well. we cut off the down-tube and welded it shut. had to trim the snout a little here and there and ultimately got it to fit just right. welded it to the air filter housing, cut the hole from the inside, painted it and bolted it in. then we grabbed a VSV from a 60 as well, hooked it all up and it works beautifully.
first test drive is today although there are no major hills within 20 miles so i'm not sure how much load we'll be able to put on it.
time will tell.
I think it turned out pretty well and certainly can't hurt.
georg @ valley hybrids