MPG worktruck buildup (2WD diesel)

[denis]

This forum lacks some diesel and 2WD action, I'm going to give you both, if you don't mind something different...

SO, since DDing the LJ70 was getting old, being slow (60mph) and expensive (22mpg) I decided I had to part with it and find something more suitable for road driving. I had thought about a liteace for the room and 35mpg but the handling characteristics and engine accessibility killed the idea.

I finally found this, engineless, trannyless and bedless 
Those are quite rare around here, and much sought after, the price was right so  I jumped on it.
The body has its share of dents but is almost straight and has no rust, which fits my beater requirements perfectly !

[denis]

This is the original 2L engine from my '85 LJ70. I retrofitted the turbo one year ago, will now take it off and put the engine back into the LJ. Yes I like to do things twice at least. Doh. I thought I would put this one into the hilux but will use the '90 2LT2 -which is currently in the LJ- instead.



Last random pic, this is the camper shell I will use, this POS is even uglier in reality but the price coudn't be beat.

[denis]

Due to the lack of 2WD trannies in my parts pile I decided to build an hybrid, and bought a turbo supra for that sole purpose. (price was right, don't ask )
I'm using a supra R154 output shaft and tail housing for my 2WD application with R151F input and gearsets. This is the donor R151F with the diesel bellhousing.



R154 vs. R151F internals





Done

[denis]

Another freebie from the POS supply was a bench seat from some earlier hilux, much less torn than my original is.



It's not a direct bolt-on, I had to use the original sliders to make the bench fit the slightly wider bolt pattern.



The seat shell needed a bit of BFH adjusting.



The rearmost hole on the slider has to be moved forward about 1/2" for the sliders to bolt on the bench, and that was it.
Done

[denis]

This is where the fun begins. Test-fitting an engine block. The mounts on the block are in the correct position and the oil filter can be reached with not too much trouble. The L series engines were used in a bunch of different models. The one I'll be using comes from a 1990 LJ70 "landcruiser II".



While looking at my 4WD hilux I thought the oil pan wouldn't be a big deal, but the 2WD is obviously different. The crossmember sits much higher and the sway bar get in the way as well.
In that pic the crank points upwards a fair bit.

[denis]

This is the oil pan I'm modifying. It obviously comes neither from a landcruiser or a hilux of any kind, only thing I know is its from a 2LTE.



Torn apart since it didn't fit.



Clearance between the corresponding oil pickup and tierod = zero.



This is the point when I start thinking I might have been better off modding the stock sump.

[denis]

The stock pickup is in the right spot, but hangs down too low, the unknown pickup is the correct height but sits in the wrong spot.



Test fit.



Weld



more cutting

[boggerunner]

nice, another diesel build up, what are the specs on that motor?  get alot of power gain with the turbo?

[denis]

The stock 2L/2L2 is 70/75hp, stock 2LT/2LT2 is 85/90hp.
What I'm putting in is a 2LT2, that will get me rolling and when I find some time I'll assemble a 2LT with a couple wild mods for development. The turbo allows for some nice power gains but reliability becomes an issue sooner or later. After trying all of them I think I like the plain NA the most, nice low-end torque, unbeatable durability and simplicity. When I get tired with modding the 2LT, or when the funds lack, whichever comes first, I will probably switch back to a 2L2 which is OE for the truck, ported, long wave 4-1 headers and a free-flowing exhaust.

[kneedownnate]

I may have asked this before, but do you have the 1kz diesel available there?  Not sure what the mechanical version makes powerwise, but I know the 1kzte makes great power and has a respectably high redline.

[denis]

The KZ is great but $$$$ and I'm about as cheap as it gets 
I would skip the KZ anyway and go straight to the KD-FTV 16V direct injected, retrofitted with a mechanical pump, and 2-stage turbocharging. Then I have no idea what I could use the power for 
I believe the 2L series engine have some potential, mostly unknown and unexplored and I am willing to challenge that.

[denis]

it rolls ! the flatbed needs one more coat of paint and the wood flooring, I need to fix a couple of minor things like an oil leak and some wiring and it will be good to go. I'll post a couple pics later. With the flatbed on I managed to spin the rear tires in 4th on the wet pavement. I think I will definately need taller gears in the future with the engine mods

[79coyotefrg]

MAN  that block looks EXACTLY   like a 22R 

[denis]

really ?
I'll take more pics of the 2L engine blocks. Never seen a 22R in my life btw 

[79coyotefrg]

check here  for LOTS  of 22R pics  http://board.marlincrawler.com/index.php?topic=5628.0

[Doable]

Denis , are you related to MACGYVER ?

How do you keep everything straight to get replacement parts ? Oh and I like the work you are doing on the Truck .

[denis]

Denis , are you related to MACGYVER ?

How do you keep everything straight to get replacement parts ? Oh and I like the work you are doing on the Truck .

I don't think I need to keep anything straight, after all it's not like I'm cutting the cab or the frame. Honestly I'm spending a lot of time trying to do it the best I can withing my financial and technical resources.

[denis]

These are the only additionnal pics I have of the oil pan work.



After that it's just cutting and welding it closed.
I also had to modify the crossmember below to gain a bit of clearnace and allow the engine to move around a bit without hitting. More pics of that when I get the truck back on the lift.

[denis]

These are the only pics I have of the tranny swap mods, so use your imagination 
The tranny mount support on the truck had the same bolt pattern as the supra mount, so I only had to shorten it 1 1/2". the center bearing on the driveshaft was also moved backwards by relocating the captive nuts on the support ears about 3/4". The rear axle was also moved backwards 1", the handbrake cables are tight but it works so I just had to redrill the perches and u-bolt plates.
The driveshaft that came with the truck was a 31 spline intput whereas the R151 is a 33 spline output. I took the supra output and made it fit the hilux u-joint. I had my "machinist" turn some sleeves to make up the difference between the cup races diameters, and machine the snap ring grooves on those about 2mm towards the inside to accomodate the narrower width ot the R output. (picture below). So far it seems to work fine although I have only driven sub-sonic yet.

The shift lever ended up in a somewhat perfect location as well.

[denis]

The flatbed was made mostly out of old I beams from some barn structure we took off when we build a cinder wall (which you can see on the 2nd pic btw).
The bed size is 5'6" x 7'2" and has tilt capability accounted for, so it will be a "quick" fit when I find some suitable hydraulics.

[denis]

some engine pics for 79coyote
2LT2 engine is in plus a couple 2L block shots.

[denis]

done
It runs, and flies. I will need to make a rear hoop and some sides on the bed to maximize the utility potential, otherwise I'm pretty happy with it. Engine upgrades will come later down the road, its plenty fast as-is but could definately use a lower rear end ratio. New shocks, bigger brakes and maybe ABS would be more useful than extra HP.
The drivers door is still not pretty but opens and closes well so it's alright for now I guess. 

[blyota91]

So any idea what kind of fuel mileage your getting?

[denis]

With the supra sender the speedo and odo are way off, but I estimate about 21-22MPG daily, making short 3mi trips to and from work, and longer trips on secondary roads hauling butt for supplies.
Highway constant speed could be anywhere between 30/35.
I hoped the economy would be better, its just the same as my previous LJ70 in which I tested the engine, but I'm getting everywhere twice as fast and the fuel setting is on the smokey side at partial boost.

[denis]

OK, sorry the hosting for the old photos was suspended by the servers
Anyway, I got about 18mpg on a 1500mi cross-country trip. (60mph on the flat)
Apart from the turbo blowing a bit of oil the hilux didn't miss a beat and could almost keep up with the semi rigs uphills 

[DTB]

thats awesome...i love seeing little toyotas hauling ass 

[denis]

right now I'm debating if I should keep the hilux or get a hiace van instead. Either might get a 1KD-FT transplant (retrofitted with mechanical injection pump and supra turbo since I somehow have all the necessary part right now)
That or just quit messing with work trucks and spend some time on wheeling trucks

[kneedownnate]

Anyway, I got about 18mpg on a 1500mi cross-country trip. (60mph on the flat)

That's towing mileage with everything in the pic, right?  I hope so since my 2wd 91 w/22re gets about 30 averaging 75mph pulling a light trailer 

[denis]

Obviously, yes.
It involved quite a bit of black smoke on the hills too...
I was a bit disappointed with this figure since my fullsize iveco van would have done better and faster.

What axle ratio does your 2wd have ?
Even while towing I felt I had too much gearing with my 4.10. Unloaded I start in 2nd, then most of the time only use 4th and 5th.
In an perfect world a R152 (452 internals) with a 3.07 axle would absolutely rock 

[te51levin]

Anyway, I got about 18mpg on a 1500mi cross-country trip. (60mph on the flat)

my 2wd 91 w/22re gets about 30 averaging 75mph pulling a light trailer 

Denis, how are you figuring your miles per gallon - Imperial gallons or US gallons?  US gallons are 3.785 liters, but Imperial gallons (as used in the UK and who knows where else) are 4.546 liters.