yobit eobot.com

Announcement

Collapse
No announcement yet.

Rob's 1UZ swop Hilux Surf 2nd Gen

Collapse
X
 
  • Filter
  • Time
  • Show
Clear All
new posts

  • Rob's 1UZ swop Hilux Surf 2nd Gen

    Click image for larger version  Name:	toyota-hilux-surf-1uz-swop.jpg Views:	1 Size:	301.8 KB ID:	1296112

    Here is my build log for my 1uz swop in my 2nd gen Toyota Hilux Surf (2nd gen 4runner)

    This swop has been done by many before, but I thought I'd document how I've done it and hurdles I've had to overcome and pros/cons I've found from other conversions.


    CONTENTS

    1) The story
    2) The donor
    3) Removing the engines
    4) Engine harness
    5) ECU repair
    6) Firewall modification
    7) Handbrake modification
    8) Slam panel thingy mod
    9) Engine mount adapters
    10) Steering damper
    11) Under bonnet lighting
    12) Fuel filter
    13) Kickdown switch

    14) Power steering lines
    15) Wiring in the ECU
    16) LED diagnosis and information panel
    17) Fuel pump


    You may also be interested in my 1st gen hilux surf build.


    WORK IN PROGRESS! More updates to be posted soon.
    Last edited by Admin; 27 April 2021, 02:23.
    Thanks
    Rob Watson (forum owner and admin)

  • #2
    Click image for larger version  Name:	IMG_20170810_143444.jpg Views:	2 Size:	1.19 MB ID:	1296114

    1) The story



    The truck I've had for several years. It's a 1993 2nd gen Toyota Hilux Surf SSR-G, originally with a 3.0 turbo diesel 1KZ-T/E engine in it.

    It's a really nice spec and has the following mods:-
    • 2" body lift
    • 2" suspension lift
    • 33" tyres
    • Winch bumper and winch
    • Tinted windows
    • Custom speaker mounts made for all doors with 17cm speakers in front, 13cm in rear
    • 4 channel amp for speakers
    • 2 channel amp for sub
    • Twin subwoofers
    • Roof rack
    • Sound deadening
    • Leisure battery set up - split charge using a Voltage Sensitive Relay (VSR) with manual override
    • Voltmeters inside car for each battery
    • etc

    Due to a couple of cracked cylinder heads, numerous brake downs on holiday to the frustration of my wife, and having since buying a "sensible" family car after having a baby I decided that I might as well just go all out and put a v8 in the 2nd gen.

    I managed to pick up a donor vehicle, namely Lexurf VI which was a 2nd gen surf that had been converted many years ago and was rather "rough around the edges" and had been sat for many years. The wiring on the donor truck was really, really awful so rather than fix up this truck the plan was simply to use it as a donor for my big red princess.
    Last edited by Admin; 27 April 2021, 02:27.
    Thanks
    Rob Watson (forum owner and admin)

    Comment


    • #3
      2) The donor

      The donor is a 1992 2nd gen surf, which originally had the 2.4 diesel in it.

      Almost identical, apart from things like the mount points for the engine on the chassis rails being in a different place.

      The donor hadn't been on the road for years, and like I say, the wiring was very questionable at best. Wires changing colour all over the place, and run in awful places.

      Click image for larger version

Name:	20201017_162353.jpg
Views:	29
Size:	1.67 MB
ID:	1296117
      Click image for larger version

Name:	20201017_100939.jpg
Views:	29
Size:	1.59 MB
ID:	1296118


      Pictured below is the 2 surfs, together with my friend James' surf, and my 1st gen...

      Click image for larger version

Name:	20201017_220604.jpg
Views:	31
Size:	625.5 KB
ID:	1296116
      Thanks
      Rob Watson (forum owner and admin)

      Comment


      • #4
        3) Removing the engines

        We took both engines out with the gearboxes attached.

        The grills etc all had to be removed, and we had to cut a piece out of the front (the bit that the radiator and grill attaches to) to be able to get the 1UZ out. I'll later modify that so it can be simply bolted back in.

        My friend James (also on here) was in charge / directed the engine removal.

        The 1UZ was then mounted to an engine frame from SGS Engineering so it could be worked on.

        Click image for larger version

Name:	james-removing-engines.jpg
Views:	31
Size:	1.27 MB
ID:	1296120
        Thanks
        Rob Watson (forum owner and admin)

        Comment


        • #5
          4) Engine harness (wiring loom)

          The loom on the donor was in pretty bad shape. So rather than messing around with this I bought a brand new custom loom from Phoenix Engine Management. This loom is a "standalone" loom with fusebox so pretty much all you need to do is wire in 12v+, ignition, starter signal, etc. By "standalone" I mean you could use this in any car. So if I wanted to put the 1UZ in something else than I can just use this loom.
          Attached Files
          Thanks
          Rob Watson (forum owner and admin)

          Comment


          • #6
            5) ECU repair

            The ECU had some blown capacitors and this had wrecked some of the traces so this was sent away to be repaired.
            Thanks
            Rob Watson (forum owner and admin)

            Comment


            • #7
              6) Firewall modification

              The 1UZ engine is too big to fit into the surf engine bay without modifications.

              On the donor two modificiations had been done:-
              a) The handbrake had been moved back, and badly reattached. It worked, but it was a bodge
              b) The firewall had been bashed in with a hammer, then taped over with duct tape (YUP!)

              I wasn't going to do the above, so I attempted to do it properly. I'm not a professional welder, and don't have much experience welding thin metal but I cut a piece of the firewall out, welded on a 1.5cm lip, then welded it back in.

              Click image for larger version

Name:	firewall-mod.jpg
Views:	31
Size:	853.5 KB
ID:	1296129
              Thanks
              Rob Watson (forum owner and admin)

              Comment


              • #8
                7) Handbrake modification

                The handbrake, which is a very strange design anyway, has a mechanism which goes inside the engine bay. It gets in the way of the 1UZ engine so I made it so that:-

                a) The cable runs in through the floor, lower down
                b) The original mechanism that sits in the engine bay I got rid of and I made a bracket and mounted it that way
                c) I had to do some cutting of the handbrake itself to get it to work, but you can't really tell
                d) I covered the whole using some high temp (500 degrees C) special self adhesive stuff meant for firewalls
                Attached Files
                Thanks
                Rob Watson (forum owner and admin)

                Comment


                • #9
                  8) Slam panel thingy mod

                  I think it's called a "slam panel" but I'm not really sure. I'm referring to the bit in the pictures below!

                  Basically it's in the way when trying to get the 1uz in/out with the gearbox attached. So I've cut it out and welded "ears" to it and made holes so you can simply bolt it in/out whenever you need.
                  Attached Files
                  Thanks
                  Rob Watson (forum owner and admin)

                  Comment


                  • #10
                    9) Engine mount adapters

                    I bought some engine mount adapters from CarTune in New Zealand. These bolt between the 1UZ and the original rubber dampners from the 1KZ so that you can easily mount the 1UZ in the right place.

                    The CarTune company specialises in 1UZ conversions and the chap who runs it (Kelvin) has a popular YouTube channel on the subject. Details below...

                    https://thecartunecompany.co.nz/

                    https://www.youtube.com/channel/UCSn...jOh1eUIRUusqiA
                    Attached Files
                    Thanks
                    Rob Watson (forum owner and admin)

                    Comment


                    • #11
                      10) Steering damper

                      The steering damper bolts to the TOP of the steering rack. The bit it bolts onto gets in the way of the 1UZ's sump.

                      So you have two choices:-

                      a) Cut the bracket off, and live without a steering damper as per the donor. MEH!
                      b) Cut the bracket off, weld it onto the bottom of the steering rack, and then make a new bracket and weld it to the chassis for the other side

                      So I went with option (b). Pics attached of before and after.
                      Attached Files
                      Thanks
                      Rob Watson (forum owner and admin)

                      Comment


                      • #12
                        11) Under bonnet lighting

                        I did something simliar on my 1st gen, and it's really helpful.

                        I've added 12v LED lights under the bonnet which turn on automatically when you open the bonnet and light everything up. They run off my leisure battery (I have a proper 2 battery split charge setup) and are really bright.
                        Attached Files
                        Thanks
                        Rob Watson (forum owner and admin)

                        Comment

                        Working...
                        X