1UZ at Last!

Post questions, advice and pictures of Engine conversions here
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AM Racing
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Mon Mar 04, 2013 12:10 am

Well decided to take the plunge and just do it! As you can expect any conversion has its set backs and dealing with them or resolving those issues takes time. The other issue I face is that all the components come from JHB, so any wrong or incorrectly supplied item sets you back 3 days at least. We have decided to run the Spitronics engine management system for a few reasons which we will show during the course of this build including the dyno tuning of the system. I hope this build will clear up a few misconceptions about these conversions. I will show relative costs and labour spent on the various stages of the process.
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The 195kW version with 10.4:1 compression ratio and VERY dirty
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Well after stripping and cleaning we were 6 hours down! We removed the intake manifold for sand blasting as well as the tappet covers for some steel brush cleaning. I'm not really a fan of painting aluminium (personal preference) so I want to see the beauty of the metal. We also removed the starter motor for overhauling. (1,5hrs). I also stripped the timing belt and replaced the oil seals and refitted a new belt.(2,5hrs).
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Removal of the existing 1KD engine (3hrs).
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By the way, there will be a rebuilt 1KD engine available shortly for those that are interested.......
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Mon Mar 04, 2013 12:21 am

You eventually gave in to that itch, I see! :D: Will be watching the progress with keen interest, since I imagine I will be going this route as well in time. ;-)

Oh. BTW, what time did you finish on Friday .... thought I saw the workshop was still open at about 6.30pm (was attending a hunting club function at the Bushbuck Inn), and imagined I heard the whine of a turbo from somewhere outside a little later on. :think:
When your road comes to an end ...... you need a HILUX!.

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Mon Mar 04, 2013 12:25 am

Finished about 7.30 but 1.30am the morning before! so I was brittle by then....... I like the sound of the 1UZ in the Mud Dog. It will give it a growl with some bite!
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Mud Dog
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Mon Mar 04, 2013 12:28 am

No doubt, but I definitely want to go manual. What box / x-fer and diffs are you using?
When your road comes to an end ...... you need a HILUX!.

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Life is like a jar of Jalapeño peppers ... what you do today, might burn your ass tomorrow.

Don't take life too seriously ..... no-one gets out alive.
It's not about waiting for storms to pass. It's about learning to dance in the rain.
And be yourself ..... everyone else is taken!

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Mon Mar 04, 2013 12:42 am

I am keeping it manual with existing diff's. It is a 3.9 ratio so its plenty! Just changing the bell housing and using the existing clutch albeit a new clutch!
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Mud Dog
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Mon Mar 04, 2013 1:17 am

I can see a stripped box somewhere in the near future! :lol: :lol:
When your road comes to an end ...... you need a HILUX!.

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Life is like a jar of Jalapeño peppers ... what you do today, might burn your ass tomorrow.

Don't take life too seriously ..... no-one gets out alive.
It's not about waiting for storms to pass. It's about learning to dance in the rain.
And be yourself ..... everyone else is taken!

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AM Racing
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Mon Mar 04, 2013 8:06 am

The box will hold plenty. Not looking to drag it, just move a few taxi's :twisted:
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Mon Mar 04, 2013 3:27 pm

Good Luck Dylan!

I have to agree with you on the "all metal' look if you were to sandblast the aliminium!
Kaspaas's 7MGE is all natural ali! :twisted:
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Mon Mar 04, 2013 3:39 pm

Looks good. Going to follow this thread. :thumbup:
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Mon Mar 04, 2013 8:40 pm

Ali3n wrote:Looks good. Going to follow this thread. :thumbup:
Me as well, looks good. :thumbup:

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Thu Mar 07, 2013 10:43 pm

Firstly this week was a waste due to ANOTHER incorrect bellhousing.
IMG-20130306-00164 (360x270).jpg
Spot the correct one....
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So after the 3rd one it was eventually right but still not without issues. There was some contact between the edge of the clutch and the bellhousing an easy fix with the motor out, but a gearbox out scenario if not properly checked. CHECK AND CHECK AGAIN!
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Tonight we did the first trial fit of the motor (3hrs). Don't be fooled into believing that everything JUST goes in. From the next two pics it looks looks its ready to go in and its in. Not the case! Nearly in and discovered we needed to move fuel pipes, heater pipes, clutch fluid accumulator, a/c piping and the exhaust manifolds had to come off the motor before it would slip in.
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With the motor mocked up I could see that there will have to be calculated use of the space around the mountings together with the manifolds. As I don't want to use the earlier log type manifolds I will be making up a set of custom headers to fit.

I tried getting the motor to sit level in the bay this would mean modifying the metal sump to clear the steering rack. So I jacked it up to where I was happy with the clearance. This ended up with the motor cantered up 6* and sufficient clearance between the motor and the firewall. I will be doing a 60mm body lift as well.
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Just some German engineering in the shop at the moment. BMW M5 trumpets in a plenum chamber.....
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The next stage is engine mountings and headers.....
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Fri Mar 08, 2013 12:35 am

Does this mean that it won't be ready for Sunday!?? :o: :wth: ................. :twisted: :lol: :lol:
When your road comes to an end ...... you need a HILUX!.

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Life is like a jar of Jalapeño peppers ... what you do today, might burn your ass tomorrow.

Don't take life too seriously ..... no-one gets out alive.
It's not about waiting for storms to pass. It's about learning to dance in the rain.
And be yourself ..... everyone else is taken!

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Fri Mar 08, 2013 7:18 am

No, not quite yet :(
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malwheat
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Fri Mar 08, 2013 7:22 am

Hey Dylan, good to see you have started with the muscle transplant! The learning process is going to be very interesting, I am very happy that you are sharing it with us. I am still keen to go the same route when you get it right! The more muscle you have under the bonnet the less effort needed under the foot..... Provided the rest of the senses are not too demanding.. Yeah right :mrgreen:

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Fri Mar 08, 2013 8:34 am

Hmmm... So what will you charge to chuck that rebuilt D4D into my KZ?
Nothing is impossible - it just costs more

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Fri Mar 08, 2013 9:42 am

Dodging wrote:Hmmm... So what will you charge to chuck that rebuilt D4D into my KZ?

I was thinking the same thing but just into my SFA..... :beg:
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Fri Mar 08, 2013 7:27 pm

Dodging wrote:Hmmm... So what will you charge to chuck that rebuilt D4D into my KZ?
It is a 2.5 1KD and complete with a/c pump, flywheel, alternator, mountings and for a little bit extra an intercooler which was on my motor. It also has the flywheel for the bigger clutch which was std on the 4x4. I have a bellhousing as well...I sold my existing engine to a client and took his on exchange. The turbo IS uh um, broken. The motor was running in that state, so whether you will get away with just replacing the turbo I'm not sure. I would take a chance. These motors are bullet proof! Mine did 384 000km without being opened and he was happy to take it! I'm to involved in getting my project completed as well as the other work in the shop.

I am open to reasonable offers. you guys can pm me for pics and further particulars.
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Cheetah Drakie
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Sat Mar 09, 2013 8:38 am

:thumbup: Serious question. I have seen many posts for the 1UZ-Fe, but nada for the 2UZ-FE. Isn't the 2UZ-FE more suitede to the SUV/4x4 applications?

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Sat Mar 09, 2013 8:54 am

The 2UZ from my research is a cast iron block and a whole lot heavier. They don't like to be revved and from what I have seen there are guys in the states changing to the 1UZ or the 3UZ. They also cost more and are not readily available as they came out in the Landcruiser. I have never enquired about the the 2UZ but the 1UZ R6500 inc box, 1UZ VVTi inc box R8500, 3UZ inc box R16500. My first choice would have been the 3UZ but this would have pushed the project WAY out of budget. The 1UZ is the best bang-for-buck conversion option in my opinion. Maybe the next one I do will be a fuel inject Chev V8.
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Sat Mar 09, 2013 8:59 am

Looking good Dylan, was there on Wednesday with Tony to take a look see, but you were out testing a customer vehicle. Will see you Sunday Brekkie
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Sat Mar 09, 2013 9:06 am

Haboob wrote:Looking good Dylan, was there on Wednesday with Tony to take a look see, but you were out testing a customer vehicle. Will see you Sunday Brekkie

I would bring the Lux but my wife doesnt want to push......
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Sat Mar 09, 2013 1:34 pm

Well, motor is in on its mounts and with some fettling got the stock manifolds in. I may just have to massage them a bit on the front primaries, but nothing major. I ended up using BMW 5 series engine mounts. I used the Lexus brackets on the block and fabricated new brackets on the chassis. This freed up all the space for the manifolds. I did not want to use the shacklebush type mountings as I feel these are a bit to rigid and create some vibration in the vehicle. I want it smooth.....
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Hiluxfan_111
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Tue Apr 30, 2013 3:05 pm

Hi Dylan
Please give a bit of feedback on your conversion.

I have wanted to do this for a long time.
Ive already baught a 3UZ and may have found a suitable 2.5 D4D.

Does the 2.5 D4D use the same R151F gearbox and diffs as the 3.0 D4D?

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Tue Apr 30, 2013 7:27 pm

Well just a follow up:

My motor is in AGAIN! Yes it had to come out! On start up it had a BAD tappet noise with a corresponding misfire/zzzz. A leakage test found it blowing straight out the exhaust valves on the lh bank. Seized valves were the culprit. My supplier supplied another motor but I was not happy with its condition. So I removed the heads from my existing motor, stripped them, reseated valves and fitted new seals. So add another R4000 for another motor (reduced price to "compensate" me), another R1000 for transport, R1700 for a gasket set. The second motor supplied ws also a first generation 1UZ which has a lower compression ratio a few less horses. I will strip it later and give it a once over for the next project.

Well it started tonight and purrs like a kitten. Tomorrow will see me finish off the small bits so I can get it out on its own steam.....
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Tue Apr 30, 2013 7:32 pm

Hiluxfan_111 wrote:Hi Dylan
Please give a bit of feedback on your conversion.

I have wanted to do this for a long time.
Ive already baught a 3UZ and may have found a suitable 2.5 D4D.

Does the 2.5 D4D use the same R151F gearbox and diffs as the 3.0 D4D?
You dont say if you are running a Gen 6/Vigo Hilux. I'm not sure of the diff ratio's between the 3.0 and 2.5 but the 2.5 has 3.9:1 diff and the gearbox is the same for both.
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Wed May 01, 2013 8:02 am

Hi Dylan

Thanks for the update. Sorry to hear about the setbacks. Hope you get it sorted soon.

I own a 2.7 IFS and been wanting to do the conversion on that.
However I need a reliable manual gearbox and will need to change that too.
After seeing your post I’ve been thinking of buying a KZTE or 2.5 D4D to do the conversion. I’m looking for one with a broken engine. :think:

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Wed May 01, 2013 6:57 pm

You will need to run the KZ box for sure. You will still pay for a KZ even if the motor is broken. BUT, you will have the diff's you need. You shouldn't sit with your 2.7 if you must move it. Goodluck with your build!!!
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Thu May 02, 2013 3:24 am

Well it moved on its own steam today!!!

Still some issues to sort out like the GPO output for the radiator fan, air filter piping, a/c piping and final dyno tuning.
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Sun Jul 07, 2013 10:57 pm

More Pics......posting.php?mode=reply&f=98&t=29827#" onclick="window.open(this.href);return false; :celebrate:


Would love to see the progress.


http://www.spitronicsengineconversions. ... conversion :boss:
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AM Racing
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Mon Jul 08, 2013 4:51 pm

Lost a lot of my photo's will take more tomorrow.
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Mon Jul 08, 2013 4:52 pm

Checked out your "Terms and Conditions". Flippen classic bru!!!!
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Tue Jul 09, 2013 10:07 pm

totally agree , very good must send this on to some of the finnicky guys

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Thu Jul 11, 2013 9:27 pm

OK an update is in order! Unfortunetly I lost a lot of photo's on the build but I will fill you in as I go.

Ok well I got sent the other motor and the capion say's it all.
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Here are some pics of the exhaust system. It is a 63mm s/s system running 2 resonators into a 76mm "silencer" existing 76mm. I used mandrel bends throughout the whole system. I went for a h-pipe set up for the simple reason that it clears the gearbox nicely. A y-pipe would be equal length but would get smacked in the bush. It is a 4x4 after all! At some stage I will do up a set of branches which will free up some power at the top. For those thinking "Go dual pipe it will sound good and go like hell!" Not quite. We just did a drift car that went that route and he lost nearly 15% at the wheels! :shock: It also didn't have the bark anymore. So his old system went back and we will do a progress sum's system.
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Thu Jul 11, 2013 9:56 pm

Well in the past 3000km I have had to change the following:

Clutch
Gearbox bearings
:evil: BeLLhOuSiNg :evil: :punch: :punch: :blackeye: :banned: :( :thumbdown: :cry: :aggresive: :evil:

The bell housing supplied was skew as I suspected after being assured that it was straight and I wouldn't have any issues. Well after inquiring I got "Well if you bought your bell housing between x & Z then yes it is skew. We had a faulty batch. Just send it back and we'll gladly exchange it for you." :punch: So more money spent on freight because they don't cover freight. So do yourselves a favour and make sure your supplier is reputable!
I stripped the gearbox as a precaution to find the case hardening coming off the cluster shaft bearing so I replaced the bearings as a precaution. The clutch plate began to separate due the the input shaft running skew. Surprisingly, the motor never went in tight at all! I fitted it by myself and it just fell in.

On a more positive note it is awesome to drive! :twisted:
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Besides the bell housing issue I have had the following teething issues:

P/S Oil leak (minor)
Exhaust flange leak
Slight water leak from a water hose (clamps needed a tweak after 1000km or so)
Basis setup and tuning issues (tuning on going for development purposes)
Alternator voltage regulator

The van on the left is mine. The one on the right has come in for a suspension upgrade and a few other bits
front.jpg
front.jpg (76.54 KiB) Viewed 1886 times
rear.jpg
rear.jpg (113.67 KiB) Viewed 1886 times
side1.jpg
I have found a restriction in the stock airbox and have done some mods to rectify this (no pics yet, will follow) but so far it has 136kW ATW.
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AM Racing
LR4WD, Lockers, Crawler Gears
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Vehicle: Range Rover Classic V8
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Thu Jul 11, 2013 9:57 pm

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Mud Dog
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Vehicle: '90 SFA Hilux DC 4X4, Full OME, 110mm lift. Brospeed branch, 50mm ss freeflow exhaust. 30 x 9.5 Discoverer S/T's on Viper mags. L/R tank. (AWOL) '98 LTD 2.4 SFA, dual battery system. Dobinson suspension, LR tanks, 31" BF mud's.
Real Name: Andy

Thu Jul 11, 2013 11:03 pm

Hey! Stop experimenting with my motor ..... look after it! :D:

Nice Dylan, pity about that damn bell! (Hope the bell you're keeping for me doesn't have the same issues .... :eh: ) I've also been wondering if my std airbox / ducts / snorkel are going to choke the motor. :think:

;-)
When your road comes to an end ...... you need a HILUX!.

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Life is like a jar of Jalapeño peppers ... what you do today, might burn your ass tomorrow.

Don't take life too seriously ..... no-one gets out alive.
It's not about waiting for storms to pass. It's about learning to dance in the rain.
And be yourself ..... everyone else is taken!

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BlumTRD
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Thu Jul 11, 2013 11:07 pm

Hi Dylan

Looking good .

Who is the supplier of belhousing

Fana van Zyl (conversion man)
Turbo toys
Or the place in nelspriut .


Sent from my GT-I9300 using Tapatalk 4 Beta

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AM Racing
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Thu Jul 11, 2013 11:08 pm

I would do up something custom there. At least with the Lexus you can swing the intake around to get the intake pipe on the left hand side.
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AM Racing
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Thu Jul 11, 2013 11:09 pm

BlumTRD wrote:Hi Dylan

Looking good .

Who is the supplier of belhousing

Fana van Zyl (conversion man)
Turbo toys
Or the place in nelspriut .


Sent from my GT-I9300 using Tapatalk 4 Beta

TT. :punch:
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Mars
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Fri Jul 12, 2013 8:26 am

Very entertaining thread thanks Dylan and a great job. I really like it when it looks like it has come out of the factory. When are we going to see a breakdown of the costs?

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AM Racing
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Sat Jul 13, 2013 4:07 am

ENGINE (INITIAL) 5500
BELL HOUSING 2250
FLYWHEEL 2200
CLUTCH KIT 2750
FUEL PUMP 1000
ENG MOUNTINGS 500
SPITRONICS 3500
TIMING BELT 950
V-BELT 185
A/C 1800
EXH SYSTEM 4000
CLUTCH SLAVE 200
SPIGOT BEARING 25
TRANSPORT (VARIOUS) 4000
WATER PIPES 500
INJECTOR SEALS 50
RADIATOR FAN 350
CLEANING MATERIAL 400
STARTER O/H 600
ALTERNATOR 350
SERVICE KIT 650
SUBTOTAL 31760

2ND ENGINE 4000
TRANSPORT 1000
GASKET SET 1750
SUBTOTAL 6750

GRAND TOTAL 38510
LESS SALE OF MOTOR -20000
TOTAL COST 18510

Allow +- 2000 for smalls///

I reckon I could have cut an additional R8000 off with the extra costs incurred with the seized valves in the first engine! But school fees. I must say suppliers feel nothing for the extra costs you incur due to incorrect/defective components supplied. It is a lot easier if you are in the GP area as you can drive and pick your engine, check the components and be happy with what you are doing.

To the guys wanting to do this type of conversion, pick someone reputable and stick with them. Rian from LexusV8Conversions' Terms and Conditions couldn't say it any better! The majority of guys become hard@rse because of the "new vehicle" perception.Dis nie n blikkie Ricoffy nie! These things tend to be ongoing until its all sorted. Would I get in my van and do a 2000km round trip now? Yes! Would I go do a trans Africa tour? No! Maybe in 6 months time. So when you get a quote for R50+K it is easy to get there. Anything else is going to be a compromise IMO.
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Real Name: Tumelo Thebe aka Baas John
ORRA Call Sign: X122

Sat Jul 13, 2013 4:52 am

Lovely read and project, thanks for sharing. When I grow up I want to be like you :thumbup: :subscribed:
Tumelo Maketekete
Donkey, simple and often misunderstood.
We don't stop playing because we grow old, but we grow old because we stop playing!

2002 - 3.0KZ-TE Toyota Hilux (Letebele)
1994 - 1.6i Gl Toyota Corolla (Platkar)
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Sat Jul 13, 2013 7:33 pm

That will take a loooong time Tumelo. Why have you faded for the Saturday the 20th Drive in Stutterheim ?
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AM Racing
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Sun Jul 14, 2013 8:20 am

Does Donkey need a carrot? :twisted: Maybe you could demo the Lexus :wink2: Or maybe a stick :lol:
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Real Name: Tumelo Thebe aka Baas John
ORRA Call Sign: X122

Mon Jul 15, 2013 7:20 pm

Haboob wrote:That will take a loooong time Tumelo. Why have you faded for the Saturday the 20th Drive in Stutterheim ?
Something happened beyond my control, and had to redirect the money there :( , but such is life, sorry guys - I had to.
Tumelo Maketekete
Donkey, simple and often misunderstood.
We don't stop playing because we grow old, but we grow old because we stop playing!

2002 - 3.0KZ-TE Toyota Hilux (Letebele)
1994 - 1.6i Gl Toyota Corolla (Platkar)
1990 - Gli TwinCam 16v (ZuluBoy)

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Rian
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Real Name: Rian
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Mon Jul 15, 2013 9:34 pm

AM Racing wrote:ENGINE (INITIAL) 5500
BELL HOUSING 2250
FLYWHEEL 2200
CLUTCH KIT 2750
FUEL PUMP 1000
ENG MOUNTINGS 500
SPITRONICS 3500
TIMING BELT 950
V-BELT 185
A/C 1800
EXH SYSTEM 4000
CLUTCH SLAVE 200
SPIGOT BEARING 25
TRANSPORT (VARIOUS) 4000
WATER PIPES 500
INJECTOR SEALS 50
RADIATOR FAN 350
CLEANING MATERIAL 400
STARTER O/H 600
ALTERNATOR 350
SERVICE KIT 650
SUBTOTAL 31760

2ND ENGINE 4000
TRANSPORT 1000
GASKET SET 1750
SUBTOTAL 6750

GRAND TOTAL 38510
LESS SALE OF MOTOR -20000
TOTAL COST 18510

Allow +- 2000 for smalls///

I reckon I could have cut an additional R8000 off with the extra costs incurred with the seized valves in the first engine! But school fees. I must say suppliers feel nothing for the extra costs you incur due to incorrect/defective components supplied. It is a lot easier if you are in the GP area as you can drive and pick your engine, check the components and be happy with what you are doing.

To the guys wanting to do this type of conversion, pick someone reputable and stick with them. Rian from LexusV8Conversions' Terms and Conditions couldn't say it any better! The majority of guys become hard@rse because of the "new vehicle" perception.Dis nie n blikkie Ricoffy nie! These things tend to be ongoing until its all sorted. Would I get in my van and do a 2000km round trip now? Yes! Would I go do a trans Africa tour? No! Maybe in 6 months time. So when you get a quote for R50+K it is easy to get there. Anything else is going to be a compromise IMO.


Dylan

The conversion looks great.

Thanks for the positive input..

I believe Honosty is the way to go, since we started doing these conversions in 2005 we learned. Since the new Consumer act forced us to set terms & conditions in place we decided to pack the bull by the Horns. Every thing you see there is based on facts, no Bull............s.

How much time did you spend on this project? I did not see that added or did i mis it?

Rian :surrender:

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AM Racing
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Real Name: Dylan
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Tue Jul 16, 2013 8:40 am

I reckon I lost a month :shock: due to incorrect/defective components due to suppliers and transport time. The rest is due to having to see customers vehicles first and working when there was a gap between jobs and after hours. And with a 6 month old colicky/reflux baby, this didnot make mommy happy! But I reckon all things being right it should have taken 4-8 weeks! Not 4 months!

As for labour I stopped counting after the original motor had its issues. Thereafter was just damage control!
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Rian
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Location: 396 Gerit Maritz street Pretoria North
Contact:

Sat Jul 27, 2013 10:03 pm

Dylan


4 to 8 weeks is So true, time flies when you are having fun.

Some people think it takes a day or 2!

:dance1:

Tommeetippee
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Posts: 2
Joined: Thu Aug 27, 2015 12:10 pm
Town: Cambridge
Vehicle: Hilux D4D
Real Name: Tom

Thu Aug 27, 2015 1:19 pm

This build is great have just purchased a 1UZ-FE to go in my 06 Hilux, still wrapping my head around the things need to do, luckily a lot of the parts I require can be bought from a shop that is local (been reading about your freight nightmares) though so far the most daunting thing has to be the wiring. While I want to do a nice job, I also would like to keep the costs down. Initially I thought factory ecu would be best but now I am on the fence about it, can you tell me a bit your wiring, pros and cons ect. I found this on the web but its not exactly step by step but it does contain a ton of info http://www.clublexus.com/forums/build-t ... -vvti.html

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AM Racing
LR4WD, Lockers, Crawler Gears
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Thu Aug 27, 2015 3:45 pm

Send me your number. I can't type that fast now......
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Drifter X
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Real Name: Ranesh
Location: Fourways

Thu Aug 27, 2015 9:58 pm

Very Nice. Thanks for sharing

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