injected 5Lt into diesel Hilux, have lots of questions

[DUDELUX]

Hey guys.
Im replacing the old 2.4diesel engine with a injected 304 from a Statesman.
I have done a search and look through the yota tech section, but havent found any info.

Im pretty much after any advice and info on what to buy, what not to buy for the conversion.

I have the engine, it has engine mounts from Marks Adaptors, custom extractors, the speedo correction thing, a new harmonic balancer.

I also have a Supra 5speed gearbox, with a CRS bellhousing, bolted to a Hilux trans case, a new clutch, custom front and rear driveshafts, 2 different radiators, 1 came from a 75series and has been modified to suit the Lux, the other is an alloy Commy one with twin thermos.

I was looking on the site for Marks Adaptors, there is a heap of stuff on there I didnt think about, and now I have alot of questions.
- petrol tank,
Can I get away with giving my diesel tank a good clean??
Or am I better of fitting a petrol tank from a V6 or something??

-fuel lines,
Should I get some off a V6 or something similar??

-fuel pump,
When I was going with the 3rz engine, I was told that I would need to fit an external high pressure fuel pump from a VL turbo Commy, should I still get one of these??
Is there something that will work better for this engine??

-wiring loom,
Should I get the wiring loom from Holden, or Marks Adaptors??

-BCM,
I was told by the guy that sold me the engine, that the factory ECM has been modified to bypass the BCM, is there some way I can get it checked to see for myself??

-power steering,
The engine has no power steering pump on it, I have a complete power steering set up from a 4runner, someone mentioned to me that I can get a pulley made up to suit the 4runner power steering pump, is this true??

-airbox,
The engine currently has a pod filter on it, Im not going to be using this, the plan is to run some sort of airbox to the snorkel(I am planning on getting a 4inch snorkel made up after the engine is in).
Should I get the airbox from a Commy??

Other things Im unsure about are.....
- handbrake running via passenger side??
- clutch slave cylinder??
- running an engine driven fan??
Is there anything else I need to know, or have forgotten about??

Please, school me on this.
Thanks.

[Ashley_bmx]

Fuel tank wise, i would just be using your tank, save making brackets etc, buy an unleaded filler neck off a later model lux (you wont get it engineered without an anti splash neck). You will need an External Fuel surge tank and a 5-15psi goss fuel lift pump to transfer the fuel from your fuel tank to the surge tank. Then between the surge tank and the engine you will need a fuel pump. A bosch 044 pump would be plenty. Just use the original steel fuel lines on the hilux, just cut the pipe about halfway down the chassis for the fuel pump, and just link it together with rubber fuel line. If you have a marks adaptor, just ring them for the slave cylinder to suit your application, also they make "plug and play" wiring harnesses. I can get you a 5 litre Commodore P/steer pump for cheap off one of jeremy's engines. That should get you started and keep you busy for awhile !!

[DUDELUX]

Cheers Ash, you do realise that you have been recruited to help with this??
But Ill start buying stuff.

[Ashley_bmx]

also you will struggle to run a belt driven fan as the front of the w/pump will only just clear the radiator let alone with a fan bolted to the front of it. Run a 16" davies craig thermo fan with an electric thermo fan controller on the back of that 75 series radiator

[stilivn]

Cant offer any real help but you doing a build thread on this? I did do a petrol engine in diesel ute but was from same model car so had all the bits an pieces so swapped tanks and lines, not sure on how you would clean. Also $ on engine mounts from marks? Could splice a commodore wiring harness with the 4runner but would be a pain in arse. You really need to weigh up price against time it will take you to do. And if you stuff it an shorts out could cause possible fire hazard.

[DUDELUX]

also you will struggle to run a belt driven fan as the front of the w/pump will only just clear the radiator let alone with a fan bolted to the front of it. Run a 16" davies craig thermo fan with an electric thermo fan controller on the back of that 75 series radiator

Struth mentioned that I should run a serpinetine belt and there should be enough room for an engine driven fan.
I have the 2xthermos here anyway.

Cant offer any real help but you doing a build thread on this? I did do a petrol engine in diesel ute but was from same model car so had all the bits an pieces so swapped tanks and lines, not sure on how you would clean. Also $ on engine mounts from marks? Could splice a commodore wiring harness with the 4runner but would be a pain in arse. You really need to weigh up price against time it will take you to do. And if you stuff it an shorts out could cause possible fire hazard.

Im not going to do it half assed mate.
The engine came with the engine mounts already on it.
As for build thread, check members section for my poolux.

[georgey]

If you don't mind me asking how much was the motor? Looking for one myself.

[Struth]

also you will struggle to run a belt driven fan as the front of the w/pump will only just clear the radiator let alone with a fan bolted to the front of it. Run a 16" davies craig thermo fan with an electric thermo fan controller on the back of that 75 series radiator

Struth mentioned that I should run a serpinetine belt and there should be enough room for an engine driven fan.
I have the 2xthermos here anyway.

Cant offer any real help but you doing a build thread on this? I did do a petrol engine in diesel ute but was from same model car so had all the bits an pieces so swapped tanks and lines, not sure on how you would clean. Also $ on engine mounts from marks? Could splice a commodore wiring harness with the 4runner but would be a pain in arse. You really need to weigh up price against time it will take you to do. And if you stuff it an shorts out could cause possible fire hazard.

Im not going to do it half assed mate.
The engine came with the engine mounts already on it.
As for build thread, check members section for my poolux.

No no no mate, read your pm's again

You need to ditch the serpentine.

Fit a 308 short water pump and run 308 vee pulleys and belts, use a VK commodore 6 cylinder steel fan, you can source a vee pulley to fit the 304 pump from Bursons or anywhere that can get Bosch parts. Can find the pulley number for you if you like.

Then have a pulley made for the toyota p/steer pump to accept the vee belt from the 308.

When positioning the engine ensure you have 10 1/4 inches clearence between the panel that the radiator mounts to and front face of the drivers side head (the heads are offset with the passenger head set further back on the block than the drivers head) this will allow you to fit the steel fan and have 20mm clearence between fan and radiator fins.

[DUDELUX]

Struth, I have the feeling that my engine doesnt have a serpinetine belt, if you check the pics on page 15 of my build thread, there seems to be 2 big pulleys, and there is another that came with the engine.
Also, does my engine already have the short shaft water pump??

And I have moree questions now..

And I will be talking to my mate at the 4x4 wreckers over the next day or 2 about getting hold of......
- unleaded fuel filler neck with anti splash neck
- handbrake setup from V6 4runner/Surf(Im told the cable and links run inside the cab)

I was looking at the Marks site, and it says they sell a clutch slave cylinder, which seems to be from a petrol Hilux.
And a clutch master cylinder, which seems to come from an 80 series Cruiser. Can I just get these parts from the wreckers too??
What model petrol Lux do I get the slave cyl from??
Does any 80series clutch master cyl work??
So I would only need to get the clutch hydraulic line to run to passenger side??
Remember I am using the Castlemaine Rod Shop bellhousing.

What size surge tank shoild I be getting?? Would 1lt be enough??
I assume that a low profile one would be best so its out of the way.

Again, Marks wiring vs Holdens wiring?? Where should I go for it??

Im already going to be buying a Bosch 044 fuel pump and the Goss fuel lift pump(I found a guy thats local on ebay selling stuff).

Im sure there will be more questions as I progress through this.
I really appreciate you guys helping me out. Thankyou.

[Struth]

I will take a look in your build thread, early model 304s had vee belt systems.

Cheers

[brad 93hilux]

Doesn't killalux on outers make the plug and play wiring harnesses?
I know he does the ls1 ones and have heard of him doing other ones.

Just a thought
Brad

[DIRTY ROCK STAR]

as far as fuel tanks etc.
i bought a 100 series sub tank on ebay.(i needed a tank anyway)
then got a VN commodore fuel pump (it fit perfectly in the tank)
diesel fuel lines are solid and handle the pressure (well mine did. i got a HJ60 chassis which was lucky)
and that and some wiring made it go.

the filler neck i think was from a V6 4runner because it was the shape i wanted and right diameter hose for the tank.

total spend about $40 and some luck.

the steering i just used commodore v8 pump and had lines made up to adapt to 80 series landcruiser steering box.

cant help with the gearbox though.

[Zuri92]

go for a 2 litre surge tank, and dont mount it in your engine bay, just mount it besides your tank, or anywhere where it is not going to get hot. it needs 4 pipes welded into it (go stainless) one comes from your lift pump into the pot near the top. the other goes from pot back to tank (overflow) needs to be right at the top, but can be on the side, just at the top. next is one that is normally larger, same size as inlet onto your high pressure fuel pump, comes out of surge at the bottom, can also be on the side, just at the bottom, of side. last is the return from the efi pump that comes in about 3/4 the way up. idea is that engine gets fuel from bottom, and overflow to tank is at top others in middle

as for wiring, it depends on how much work you want to do, and how cashed up you are.

[pig 83]

The belt set up on the front of your engine in not serpentine nor is it V belts its called a gilmore drive and they are useless in 4wd applications .

[DUDELUX]

Gilmer belts??
Are they the ones that give the supercharged whine??

[simkell]

sort of.

[johnsy86]

Gilmer belts??
Are they the ones that give the supercharged whine??

yes

[DUDELUX]

OK, so now I know what pulleys are on this engine, I can start thinking about buying the right ones for me. Im going to write up a list here for my own use, and anyone that comes searching for info, as well as for anyone that has better ideas for me.

The vee pulleys and belts from a 308.
Bosch 044 external fuel pump.
Fuel surge tank(around 2litres).
Full engine harness and under bonnet wiring for this engine.
Goss fuel lift pump.
VK 6cyl engine fan and shroud. Somebody today told me that the VK 6 and 8cyl engine fans are the same, is this correct??
V6 fuel filler with anti splash neck.
V6 handbrake setup(runs inside cab)

According to the Marks website, I need to buy new....
clutch slave cyl, they sell a petrol Lux unit.
clutch master cyl, they sell an 80 series unit.
Can I get these items from my local 4x4 wreckers??

Also, Struth and others in the know, can you tell whether the water pump on my engine is the short shaft one or not??

I dont want to buy stuff that I dont need, thats all.

Thanks guys.

[tezza88]

Ashley_bmx wrote:
also you will struggle to run a belt driven fan as the front of the w/pump will only just clear the radiator let alone with a fan bolted to the front of it. Run a 16" davies craig thermo fan with an electric thermo fan controller on the back of that 75 series radiator

..... You said you rnt gonna do this any way, but 4 any 1 else considering this, DONT. i just recently tried to convert from an engine fan to a thermo on my 79 series cruiser ( has same radiator as the 75 series) using the 16" davis graig thermo. because of the shape of the radiator the thermo didnt cover enough area to pull air through the entire thing with out custom making a tighter hugging shroud, and i was also very unimpressed on how much air it actually pulled.... it just doesnt spin hard enough. any way so i ditched it and went back to a engine fan as the engine kept over heating with the thermo

[Ryan_006]

Ashley_bmx wrote:
also you will struggle to run a belt driven fan as the front of the w/pump will only just clear the radiator let alone with a fan bolted to the front of it. Run a 16" davies craig thermo fan with an electric thermo fan controller on the back of that 75 series radiator

..... You said you rnt gonna do this any way, but 4 any 1 else considering this, DONT. i just recently tried to convert from an engine fan to a thermo on my 79 series cruiser ( has same radiator as the 75 series) using the 16" davis graig thermo. because of the shape of the radiator the thermo didnt cover enough area to pull air through the entire thing with out custom making a tighter hugging shroud, and i was also very unimpressed on how much air it actually pulled.... it just doesnt spin hard enough. any way so i ditched it and went back to a engine fan as the engine kept over heating with the thermo

60 series 4 core diesel radiator + AU twin thermo (the ones with the moulded shroud) cover very well, just a thought.

You will definatley struggle to fit an engine fan, my 304 is nearly touching the firewall and i struggled for clearance between pulley and radiator, before moving the radiator to the tray.

[DUDELUX]

Ryan, can you please post up a pic or 2 of you engine bay for me??

I have a couple more questions,

Will my diesel fuel lines handle the pressure, or will I need to upgrade them too??

Ive had a 2L surge tank donated by an outers family member, so Im going to use it.
Should I buy a petrol tank from the same model Lux, or give mine a good clean??
Ill have to clean out the lines too, whats the best technique for cleaning out tank and lines??

I think thats it for now.

[Struth]

You will definatley struggle to fit an engine fan, my 304 is nearly touching the firewall and i struggled for clearance between pulley and radiator, before moving the radiator to the tray.

Is this a Gen 1 problem only, I easily fitted an engine fan with 20mm clearence to the radiator in a Gen 2.

[Ashley_bmx]

Ryan, can you please post up a pic or 2 of you engine bay for me??

I have a couple more questions,

Will my diesel fuel lines handle the pressure, or will I need to upgrade them too??

Ive had a 2L surge tank donated by an outers family member, so Im going to use it.
Should I buy a petrol tank from the same model Lux, or give mine a good clean??
Ill have to clean out the lines too, whats the best technique for cleaning out tank and lines??

I think thats it for now.

If you can get a V6 fuel tank for cheap enough, then definetly go for that option. But your tank should be fine, just remove your tank , put 2 or 3 liters of Metho in it ( as it absorbs water) and roll the tank over a couple of times, shake it as best you can drain the crap out and refit, as for the fuel lines, just blow the old deisel back through from the engine bay. And yes, They will easily handle the fuel pressure. Another option... Is maybe buy a donor (blown up) v6 MANUAL 4 runner or surf. You can get them for around the 1g mark. Not only for the tank and neck. Stronger g/box which your going to need anyway, the widetrack rear diff ( make yours coil in the rear) the front hubs and rotors. All the interior. Just a thought

[Ashley_bmx]

You will definatley struggle to fit an engine fan, my 304 is nearly touching the firewall and i struggled for clearance between pulley and radiator, before moving the radiator to the tray.

Is this a Gen 1 problem only, I easily fitted an engine fan with 20mm clearence to the radiator in a Gen 2.

What radiator are you using ??

My brother inlaw is fitting a 5lt into his gen 2 lux and is having troubles clearing his radiator with the water pump, So we are thinking of removing the water pump. Gutting the pump, slicing it in half (removing the 'snout' ) and Tig welding a plate on the front of the pump, fitting a davies craig electric water pump, a SPAL 16' (3000cfm) thermo fan and an electric fan controller.

[Struth]

You will definatley struggle to fit an engine fan, my 304 is nearly touching the firewall and i struggled for clearance between pulley and radiator, before moving the radiator to the tray.

Is this a Gen 1 problem only, I easily fitted an engine fan with 20mm clearence to the radiator in a Gen 2.

What radiator are you using ??

My brother inlaw is fitting a 5lt into his gen 2 lux and is having troubles clearing his radiator with the water pump, So we are thinking of removing the water pump. Gutting the pump, slicing it in half (removing the 'snout' ) and Tig welding a plate on the front of the pump, fitting a davies craig electric water pump, a SPAL 16' (3000cfm) thermo fan and an electric fan controller.

It's a standard V6 radiator with an extra core.

The tricksa are,

1. Set the gearbox and engine back far enough to get 10 1/4" between the radiator mount panel and the front face of the drivers side head. (This requires minor firewall massaging behind the passenger side head)

2. replace the twin bearinged 304 water pump with a 308 single bearing pump.

3. Fit 308 vee pulleys and belts in place of the 304 serpentine pulleys and belts.

4. Use a VK Commodore 6 cyl steel fan.

Cheers

[Ryan_006]

You will definatley struggle to fit an engine fan, my 304 is nearly touching the firewall and i struggled for clearance between pulley and radiator, before moving the radiator to the tray.

Is this a Gen 1 problem only, I easily fitted an engine fan with 20mm clearence to the radiator in a Gen 2.

What radiator are you using ??

My brother inlaw is fitting a 5lt into his gen 2 lux and is having troubles clearing his radiator with the water pump, So we are thinking of removing the water pump. Gutting the pump, slicing it in half (removing the 'snout' ) and Tig welding a plate on the front of the pump, fitting a davies craig electric water pump, a SPAL 16' (3000cfm) thermo fan and an electric fan controller.

It's a standard V6 radiator with an extra core.

The tricksa are,

1. Set the gearbox and engine back far enough to get 10 1/4" between the radiator mount panel and the front face of the drivers side head. (This requires minor firewall massaging behind the passenger side head)

2. replace the twin bearinged 304 water pump with a 308 single bearing pump.

3. Fit 308 vee pulleys and belts in place of the 304 serpentine pulleys and belts.

4. Use a VK Commodore 6 cyl steel fan.

Cheers

I have a Gen2 (LN65) still useing standard 304 pulleys with the gearbox set back about 3inches, which is enough to just get the dizzy cap to clear the firewall. Struggled to get thermos or engine fan to clear standard hilux rad in standard position. But hey it was shit at keeping it cool so ive gone 60 series.

Your diesel tank and lines should be fine, still using mine its sweet. With no surge either, but if you have scored one may as well use it.
Ill try n get some pics to you this week DUDELUX

If your still running front rad then ^^^ Struths suggestions there are probably the go, shroud and engine fan are gonna work 100 times better than a little thermo which you will have to compromise on size for due to lack of space, i tried to run 2 8 inch thermos with shroud and they failed to stack up, but struggled to fit much else.

[DUDELUX]

Thanks for the advice guys.

Ash, the reason Jeremy is struggling to fit his rad in is because its one of those big ass desert cooler ones, Jimmy was telling me the other day.
And Ash, Im using a Supra box, not a Lux box, and Im not planning any coil rear changes.
Id like to get all this done before I plan anything else, I have my hands full with the engine and steering/suspension.

And My plan is to go with what Struth is saying, run the 308 pulleys/belts, 308 water pump, and VK engine fan.

As for radiator, I have one off a 75 series that has been modified to suit Lux, and I also have the alloy Commy one with twin thermos.

And mine is the same as Ryans, LN65, except mine is a dual cab.

Keep the advice coming please, I need all the help I can get.

[DUDELUX]

Ok, about the serpintine belts.
Someone just told me that the serpintine belts came out on the V6s, and the 5lt V8s had veepulleys.

The same person has quoted me $350 for all of the following...
- all engine wiring and computer
- ignition module,
- alternator
- pwr steering pump
- and all vee pulleys.

To me, it seems like a good buy.

I still need to buy..
- fuel lift pump, about $80 off ebay(Goss to suit VN-VS V8)
- high pressure fuel pump, about $215 off ebay(Bosch 044, including brackets and fittings)
- unleaded fuel filler neck(probably from the wreckers)

Some things Im still wondering about are...
Marks Adaptors sell the kit to relocate the handbrake, it seems to befrom a V6 4runner, could I just get this from the wreckers as well??

They also say to relocate the clutch slave and master cylinders to the passenger side, they sell the slave and master cyl, and a crossover pipe, from what I can see, what they sell is a petrol Lux slave cyl, an 80series master cyl. Could I also get these from the wreckers??

Id be interested to know what you did with the clutch slave/master cyls, and the handbrake Ryan.

[Ryan_006]

Ok, about the serpintine belts.
Someone just told me that the serpintine belts came out on the V6s, and the 5lt V8s had veepulleys.

The same person has quoted me $350 for all of the following...
- all engine wiring and computer
- ignition module,
- alternator
- pwr steering pump
- and all vee pulleys.

To me, it seems like a good buy.

I still need to buy..
- fuel lift pump, about $80 off ebay(Goss to suit VN-VS V8)
- high pressure fuel pump, about $215 off ebay(Bosch 044, including brackets and fittings)
- unleaded fuel filler neck(probably from the wreckers)

Some things Im still wondering about are...
Marks Adaptors sell the kit to relocate the handbrake, it seems to befrom a V6 4runner, could I just get this from the wreckers as well??

They also say to relocate the clutch slave and master cylinders to the passenger side, they sell the slave and master cyl, and a crossover pipe, from what I can see, what they sell is a petrol Lux slave cyl, an 80series master cyl. Could I also get these from the wreckers??

Id be interested to know what you did with the clutch slave/master cyls, and the handbrake Ryan.

Ive never heard of the clutch slave and master being relocated to passenger side? Not saying its not done but when i originally bought my ute it had a 308 carby fed motor in it with a standard g52 drive train still all in the standard usual setup, inlcuding master and slave clutch setup. Not sure why you would move this across?

Im using T700 auto with g52 gear driven transfer on the back now so no slave/master cylinder for me, as for handbrake its still bog stock standard, it should all still fit and work.
I have a turbo pattern to G52 bellhousing for sale if your chasing one? Anyway, are you staying drum rear brakes? Either way your standard handbrake should still be fine where it is

[DUDELUX]

Thanks Ryan, but I have a bellhosuing to suit engine and gearbox.

Heres another one, I was looking at this.
http://cgi.ebay.com.au/Bosch-044-700hp- ... 2264wt_905" onclick="window.open(this.href);return false;

Which fittings do I order??

They have Speedflow screw on fittings, and Proflow barbed fittings.