Howdy Yotatech-ers!
Although I already have a sought after diesel engine that came stock in my rig (2004 Hilux); Ive been lusting after the common rail variant (the 1KD) ever since i drove a manual one 2 years ago. The manual gearbox attached to the 1kd reminded me very much of the power of the V6 engine in my previous 2007 Tacoma X-Runner.

Anyhow... I found a rolled 2007 Hilux and purchased the salvage... and so the swap begins!

Engine and wiring loom is out of the donor truck, now to go through and do leakdown test. will at minimum replace oil seals, check intake for EGR soot, cleanup, block EGR... and go from there before stripping my current 1KZ from my rig.

 

It's been a task and a half with this engine. Since there was so much oil on the engine and in the engine bay, and the oil pan and head seals didnt look great; my mechanic and i decided to go ahead and do a rebuild. This engine has over 200,000KM on it. (my current 1kz has 168,000km)
Certainly is best practice to make sure the engine is in top condition before it is put into the rig eh? Since the motor is out any way we stripped it down; and boy what a good thing we did!
There was so much sludge and carbon everywhere!
Sadly what is common in Jamaica is that people know the Toyota engines are so strong. In dact the saying is "the hilux can't done". So often times a vehicle owner will skip on the oil changes and only add oil. This seems to have been one of those engines!

After buying the conrod bearings, new rings, sleeves, oil pump, water pump, and head rebuild kit; we also found that the crank was already cut before so I had to source another crank as well... Oh well this is how it goes!

The good news is I sold the shell and chassis so that is not a worry anymore. Minus the rebuild I spent about $700 to get the engine and wiring, computers, etc... So I cant complain too much.





Gunked Valves!


Clogged intake ala EGR and copper injector seals and lack of oil changes

The clean head

 

Whoa! That's some nasty stuff!

 

Yea man!
Because of all of this i will certainly be installing the Provent catch can / filter. They swear by these in Australia:
http://www.diesel-filters.com/393107...l-off-highway/

I will likely also block the EGR but I think the Provent will be more beneficial.

 

Engine is mostly rebuilt now! Injectors have been checked / serviced and look good, so I am very relieved there. I did have to replace the glow plugs, but found those for a deal: $100 for the set of 4 (genuine Toyota).

the only uncertainty I have at the moment is that of the new airbox. My main concern is to fit a proper airbox on the drivers side so that a safari snorkel can be installed (current snorkel is on the passengers side). The stock box from the 2006 is broken, and wouldn't fit. SO... I did some picture research and have ordered an airbox from a 2002 V6 Tacoma... Its a little bit of a gamble but hopefully it all works. If it doesn't fit it wont hinder the swap, just the snorkel.

Now to schedule the installation / swap in the next few weeks.

Picture update below:

 

lucky. I could only wish.

 

Subsribed, I hate being last....

 

OK just read thru the build so far. I'm really jealous.
Couple suggestions:
-get techstream and dongle for your laptop. Super cheap and diagnose everything thru the obd2. You can calibrate your injectors and this is necessary for the ecu.
-if the egr is water-cooled you cannot block the egr more on this later.
-if the tacoma box fits I'd be weary it can provide enough air for the diesel(but I'm guessing)
-slow your build down so I can catch up..Haha
-Google team oilybits the guy has a very informative blog

About the egr...
I have a 2006 1kd that is the last of the air cooled egrs, which is the easiest of the egrs to defeat. Notice these engines do not have blow-off valves for the turbo? That's because the egr acts as the blowout. So not only does it let exhaust gas in but it also releases the pressure off boost. I have read on the prado forum someone makes a plug in device to trick the egr and people have had good success. However, there are a few guys that have blocked the head from the egr and rerouted the hose back the the air box with a little filter. This allows the intake to pull in fresh air and still release excessive manifold pressure, keeping the soot out or the intake. Now to keep the oil vapor out use the Provent the aussie are using.
I hope the immobilizer doesn't give you an issue.
Edit: looks like you have the simpler non water cooled egr.
Good luck keep us posted

 

Well? What's the status?

 

Hope you are well, how badly did the hurricane hit you?

 

Just curious if your mechanic knows of anyone down there has swapped a 1kz for a 3L, And what would be involved? How much different are the two blocks from each other?
Cool project by the way!

 

Thanks for the tips RBX.

Yes it is the air-cooled EGR, as its the 2006 1KD.

Have I slowed this build down enough for ya? haha... (I'm going to go and read your thread now)

The biggest holdup on this project has been the electrical. the electricians are damn impossible. I have had 4 different electricians promise to come and work on the vehicle and not shown up, and the one and only guy who has shown up and been doing the work isn't able to give this project the constant attention it needs.

Anyhow, I was missing some plugs for the fuse / junction box under the steering wheel, and I was able to find a scrapped police Hilux and get the plugs. So as things stand right now the wiring should be done just after Christmas (We'll see). I can't manage to get my hopes up to be disappointed anymore.

After that is sorted and the engine is started there's a lot of clean-up to do in the engine bay, relocating the battery, and fitting the new airbox, downpipe, and to button up the dashboard... If all goes well that should be it! fingers crossed and making sure I am patient....

Some Photos:


The dusty rig


The wiring nightmare - had to hybrid the existing and the new dash loom so that I can have power windows and EVERYTHING working as they should


Latest donor vehicle


the missing plugs obtained from the doner vehicle (from floor harness). We also took the roof light plug.



The engine in the bay


Tight clearance between steering shaft and electronic turbo manifold. (shimmed the motor mount to create this clearance)

 

Hey Rustbucket... Sorry. no one has experience here that I know of. I can say however that i've seen some threads out of South Africa, New Zealand, and Australia where items have been swapped. most differences are with wiring. Sorry i have no concrete info!

 

None at all! not even rain.

The whole country panicked however. But best to be prepared and not need than to have no preparation and get hit. So we got very lucky!

Thanks for looking out!

 

glad to see this thread is still living.
Thanks for the wrecker/breaker linky.

 

That's alright. I'll have to look for some of those threads. Thanks anyway!

 

Today the electrician plugged up most everything and tried to start the engine to no success.
I got the Techstream running and went over to the garage to see what error codes came up and we get a "u0001 - High Speed Can Communication Bus" error; which seems to e related to the ECM and TCU. Also spoke to one of the lead mechanics at Toyota who also told us what to look for and report to him so we can get the engine started. Also, it turned out the fuel pump had a leak, so to tighten up those lines ( i hope that's what is keeping her from starting). In techstream the fuel rail pressure values are 50 kPag when sitting still, and 350 kPag when cranking.

Thanks again for the recommendation RBX!

 

Tech stream may need to register the bus system. Might be a Burton in there somewhere but I haven't played with it too much. I was able to connect and check for errors but that is all I've done.

 

Great news...
My 1KD started yesterday! I wasn't there to see it unfortunately but will go and take a look hopefully today. Will see if I can post a video.
Progress has been too slow because of the wiring and removal of the dashboard. But what a relief!
Now that we have passed this milestone we can make the final change in the engine bay (moving battery and airbox to opposite sides), and be back on the road hopefully in the next 4-6 weeks. That 4-6 weeks should include A/C as well.
Still, I know better than to get my hopes up... but we should have steady progress now.

 

My engine started yesterday!
Hopefully I can go by the garage today and get a video to share.
Huge milestone, now I really hope we can be back on the road with running A/C and everything in 4-6 weeks.