1971 FJ40 Landcruiser converted to Toyota 1HDT diesel engine

[Ob1]

It all started 15 years ago, when my daughter got her license. We figured she need to build her car, that is, if she want to drive one...

We purchased a 1971 Toyota Landcruiser with engine issues ($2500). The car has been neglected and was not drivable. But it did not need smog in CA, so could be modified easily. We ended up towing it home.
View attachment 164846
View attachment 164847

We figured we will build it again (from scratch), starting with a bare frame. A friend owns a paint shop and helped out with all the finish work.
View attachment 164866

View attachment 164848

The tub had rust damage, and needed some part to be grafted. The quarter panels came from a shop in Texas that stamps all the 40 series parts. This is where she learned how to weld.
View attachment 164864View attachment 164865
We ended up taking the tub to the paint shop on the roof of the 60 series.
View attachment 164867

Meanwhile, the engine (2F) was rebuilt and the rolling frame put together.
View attachment 164880
View attachment 164868
The parts came back from the paint shop after a few weeks, and at that point the rig got it's name - Kermit.
View attachment 164869
View attachment 164879
It was time to start putting the 'kit' together.
View attachment 164873
View attachment 164881View attachment 164882
View attachment 164874
And.. this is how the rig looked for 15 years.
View attachment 164878
View attachment 164877
View attachment 164875
And now...
We have come across a Toyota 1HDT 4.2L Turbo diesel, and figured that needed a new project. The engine has good compression and came off a running 'buggy'. At this point, we will replace all the seals, and send the injectors and pump for rebuild. We still need to find a H55 5 speed transmission and a TC.
View attachment 164883View attachment 164884
Injector Pump and injectors were sent out to Portland to a shop. They were in bad shape.View attachment 164885

Stay tuned. I'll keep you posted on the progress... :)

 

[Ob1]

Just got the injectors back. This weekend will be an install and also Con Rods bearings and oil pan. The diesel shop is located in Portland, and Mark Singleton, the owner is a great guy. 503.235.1947. ACSD (Automatic Cold Start Device) was removed and replaced with a plate.View attachment 166873

 

[EXPO_D1]

beautiful 40!

 

[Ob1]

This weekend, installed the rebuilt pump, and con-rod bearings. The bearings were in great shape, but figured, since I don't know the total history of this engine, might as well while it is upside-down... Sooo much easier. I replaced the main oil seals and harmonic balancer. Also, used the CT26 turbo, from the 24 valve engine. Managed to damage one of the seal, so the oil pan will need to wait until I get a replacement.View attachment 167224View attachment 167225

 

[Scott_Milk]

I am excited to see how this turns out! Awesome project

 

[Ob1]

Main seals and oil pan is on. Today, I welded a small frame so the engine can sit on it and I have access to mount the flywheel, clutch, bellhousing and starter. Intake manifold needs the gasket (on order), and once this is done, I hope I can start it on the bench. I always remember the first time I start and engine after major work.
View attachment 167920View attachment 167921

 

[Ob1]

This weekend was productive. First start. Took a while to get the fuel into the injectors, but after that is starts in a touch. Still need to tune the injector pump timing.

View attachment 168827

 

[Ob1]

I've been helping my daughter installing the drivetrain in the car. Radiator relocated, engine mounts, fuel system, electrical, etc. Fuel system is hooked up and we almost finished the electrical. Still need to install the rear driveshaft, and the heater core. Can wait to drive this thing...

View attachment 202822View attachment 202823View attachment 202824View attachment 202825View attachment 202826

 

[GLOCKer]

Wow! This thread started out pretty awesome but then you doubled down on awesome with the diesel swap!

 

[Ob1]

I shot a photo of the drive train before installing. Almost like a statue to put in your living room. I think my wife will not object. mmm... maybe not.

And a photo of the 2F compared to the 1HDT.

View attachment 202890View attachment 202891

 

[Ob1]

Been busy with other projects, but this is moving on. We installed the engine and managed to connect fuel, electrical and vacuum. Driveshafts length was modified because the transfer case sits a few inches back. We had to modify the hump in order to accommodate the 5 speed gear box. Also had to relocate the radiator, otherwise the fan would hit the bottom outlet. All connections of the 3" exhaust were 'V' Bands.

View attachment 205477View attachment 205478View attachment 205479View attachment 205480View attachment 205481

 

[Ob1]

A bit more progress... All bolts are torqued, and electrical connected. It is time to crank.

View attachment 206247View attachment 206248View attachment 206249
View attachment 206251

 

[Ob1]

At this time we decided to add an intercooler. The exhaust manifold was cracked because this engine has no electronic protection. It will burn as much fuel as you dump in. The intercooler lowered exhaust temperature by a bit over 200F. That makes a huge difference on the climb. We had a PDI adopter, so ended up buying a set of 2.5" pipes on Amazon, and an intercooler and silicone hoses from JEGS. Total cost was less then $400. Considering that the PDI 80 intercooler is over $1000, it was a no brainier.

We had to modify the front bib, because the metal screen in front of the radiator did not leave the 3" for the intercooler.

View attachment 214247View attachment 214246View attachment 214248

View attachment 214250

 

[suzuguru]

Your project makes me wish I lived in Palo Alto so I could badger you into helping me with mine. I've just bought a 1HDT, and hope to put it in my '72 FJ40 in the near future. Looks like you and your daughter do excellent work. It turned out fantastic. I must say... I'm jealous! Where did you source your rear transmission crossmember?

 

[Ob1]

Your project makes me wish I lived in Palo Alto so I could badger you into helping me with mine. I've just bought a 1HDT, and hope to put it in my '72 FJ40 in the near future. Looks like you and your daughter do excellent work. It turned out fantastic. I must say... I'm jealous! Where did you source your rear transmission crossmember?

Hey Eric,

Thanks for the kind words.

Move west. Much better weather. . I made the cross member myself. It’s simple. You plan to use an H55? Also we had the diffs changed to 3.73 and geared the TC otherwise the 1HDT will be revving. Other option is bigger tires.

Also she just got married and rode to the altar with Kermit. Husband on a motorcycle. They both came out of an aspen forest near Flagstaff.

Where did you find the 1HDT?

 

[Andony]

We Have the same Project what changes do I have to do between 1hdt and h55f transmission to make work

 

[Ob1]

We Have the same Project what changes do I have to do between 1hdt and h55f transmission to make work

All you need is the right bellhousing and the correct clutch. For the 40 series you need to change the frame motor mounts and cross member and also modify a bit the transmission hump. If you need part numbers, I can dig it out.

The gas pedal is different and also the throttle cable.