22R to 5VZ FE swap - Completed.

zepplin · Post by **zepplin** » Fri Nov 25, 2011 7:33 pm

I have been planning this swap for about 18 months now & finally it begins. My decision to go with the V6 rather than the more popular V8 swap was because I beleive that the V8 is too much for the SFA drivtrain in the long run. I also wanted to do what Toyota SA should have done before discontinuing the SFA range. If it was good enough for the Hilux/Surf/Tacoma in the US & Oz, why not here? (So sc%#w them!!!)

My plan all along was to keep the manual gearbox & to do as little damage to the firewall as possible. This meant having to move the motor forward a minimum of 35mm by either fitting a custom bellhousing or moving the gearbox forward. I'm not too fond of welded drivetrain components so I managed to get an original 5VZ FE bellhousing off a manual vehicle in Australia & had a mate bring it over (in his hand luggage nogal!).

This bolts staight onto the motor but does not fit the W56 box in the SFA. So it was either source a R150 box from a KZTE - which would have bolted straight on at both ends - or get it to fit the standard box. Considering the prices of the KZTE box I went the adapter plate route.
The 5VZ bellhousing is already 20mm longer than the standard 22R bellhousing & by having the adapter plate made 30mm thick, I have now moved the motor forward by 50mm without having to massage the firewall or move the gearbox. There were a few complication going this route - input shaft length, clutch fork angle etc. but these have been sorted out.

Next challenge was the sump. The standard 5vz sump is towards the front of the motor & would have interfered with the front axle travel so I had to swap it with a sump from a 3vz motor. This sump is towards the rear of the motor & gives sufficient clearance over the axle. The oil pick up & oil splash plate had to be swapped too. These two motors share the same block so no mods needed as the 3VZ parts fitted perfectly.

3VZ top & 5VZ bottom.

With this change, the dipstick also needs to be repositioned. Luckily the 5VZ block already makes provision for this with an existing hole in the casting that is plugged up. Remove plug with a punch from inside & relocate dipstick tube, then re use plug to plug up original dipstick hole.

More to follow.

ToyX4 · Post by **ToyX4** » Fri Nov 25, 2011 7:43 pm

Awesome! Can't wait for more!

Post by **Family_Dog** » Sat Nov 26, 2011 8:32 am

This is going to be one of the sexiest SFA's ever when you're finished, Steve! I think that motor will be an ideal match for your SFA and you will have a winner!

Of course, you will be married to it for life, but that can only be a pleasure :)

-F_D

Post by **FIRSTGEER** » Sat Nov 26, 2011 12:36 pm

I like what I see.The standard of of that adapter plate is great so I am sure the final result will be of a high standard.Keep us posted.

Buddie · Post by **Buddie** » Sat Nov 26, 2011 7:24 pm

Great Job, If You Good You Good

Gunta · Post by **Gunta** » Mon Nov 28, 2011 9:46 am

Steve, did you manage to get the OEM ecu for it as well?

zepplin · Post by **zepplin** » Mon Nov 28, 2011 11:37 am

No. Would have been nice though. No too concerned as the motor is from an auto vehicle & when cleaning up the wiring, I noticed a massive amount of plugs & sensors for the auto gearbox. It would have been a huge headache to get it running with the OEM ecu not connected to all the gearbox stuff. Going to go with Dicktator.

Gunta · Post by **Gunta** » Mon Nov 28, 2011 12:53 pm

Good luck, I am keen to see what your consumption is going to be with the dictator setup.

zepplin · Post by **zepplin** » Mon Nov 28, 2011 1:01 pm

I'll let you know once it's done. Even if it's the same as the 22R EFI (7 - 8km/l) I'll be a happy bunny.

Gunta · Post by **Gunta** » Mon Nov 28, 2011 1:42 pm

I think you are going to get around 5km/l with the dictator. I hope you get more but I got that with the dictator.

zepplin · Post by **zepplin** » Wed Nov 30, 2011 5:43 pm

A mile stone today. Finally got the VZ in for a test fit. The 50mm extra spacing is perfect. Loads of space at the firewall. Will most certainly have to go with a body lift or cut the bonnet. Will still decide.

Post by **Family_Dog** » Wed Nov 30, 2011 8:51 pm

Looking very good, Steve. But don't cut the bonnet, try a body lift first.

-F_D

zepplin · Post by **zepplin** » Wed Nov 30, 2011 9:49 pm

I'm with you. On closer inspection it seems I might just get away without doing either but if not, body lift first.

ismail · Post by **ismail** » Thu Dec 01, 2011 8:17 am

looking good steve

jacques kotze · Post by **jacques kotze** » Thu Dec 01, 2011 8:32 am

Looking very, very good! If I can give some advise, do a body lift, it is really not so complicated at all. I've done mine some years ago in a days time. But I got everything together before I started. Good luck

GeorgeJvR · Post by **GeorgeJvR** » Thu Dec 01, 2011 8:42 am

So laag as moontlik maar so hooeg as nodig............
COG moet laag wees

Hangover · Post by **Hangover** » Thu Dec 01, 2011 11:17 am

Very nice!!
Jou trokkie gan n klein huisie vol krag he!

zepplin · Post by **zepplin** » Fri Dec 16, 2011 8:12 am

Done! Motor in and running sweetly. Drove it for the first time yesterday & will do so around the neighbourhood for the weekend just in case. It did get a little warm on the dyna but that was running the stock 22R radiator - now changed to a aluminium unit from a 2.4D so I'll keep a close eye on it. Relieved that it all fits without a body lift or bonnet trim! A few more small things to get done then I'll post pics of the completed swap.

Post by **Family_Dog** » Fri Dec 16, 2011 9:42 am

Excellent! Now you need to test it on a long run and let it stretch its legs. A long run - say to Klerksdorp and back! ;) Would love to see/hear/drive it!!

-F_D

zepplin · Post by **zepplin** » Fri Dec 16, 2011 10:39 am

Well, I do need my radios programmed.........................

Hi-Hilux · Post by **Hi-Hilux** » Fri Dec 16, 2011 11:04 am

Verynice, baie geluk!

Post by **Family_Dog** » Fri Dec 16, 2011 12:47 pm

zepplin wrote:Well, I do need my radios programmed.........................

Now that's a plan!!

;)

zepplin · Post by **zepplin** » Mon Dec 19, 2011 6:53 pm

All done :party:

Final dyna run today - 130Kw & 311Nm at the wheels on 31's. Maybe not the best but no contest compared to the 90kw with the 22R.

Now for the consumption tests -

Mr_B · Post by **Mr_B** » Mon Dec 19, 2011 7:43 pm

Congrats, good dyno figures! Just be aware the 5VZ wasn't known for good fuel consumption, if you get around 7-8km/l I say it's very good!

zepplin · Post by **zepplin** » Mon Dec 19, 2011 7:52 pm

I'll be happy with that - what's the 4,0l getting?

Here are some pics.

Ou Legend · Post by **Ou Legend** » Mon Dec 19, 2011 9:53 pm

Dit lyk regtig baie netjies.Mooi so

Buddie · Post by **Buddie** » Mon Dec 19, 2011 10:00 pm

Well done.Hope to go for test drive soon?

ThysdJ · Post by **ThysdJ** » Tue Dec 20, 2011 7:34 am

Nice Steve!! Looks great and the dyno figures looks good. You're going to enjoy that puppy..

Do you really think the V6 ouens are going to tell you their true fuel consumption??

zepplin · Post by **zepplin** » Tue Dec 20, 2011 8:09 am

I wasn't really expecting an answer Thys.

How does that saying go...........something about a pot & a black kettle?????

GI Jane · Post by **GI Jane** » Tue Dec 20, 2011 8:17 am

Does this mean you are going to be testing your vehicle at Bergkraal on the 13 to 15 seeing you missed the Year end GTG?

zepplin · Post by **zepplin** » Tue Dec 20, 2011 8:21 am

That's the plan unless a last minute contract comes through (as they usually do just when I want to enjoy myself).

Hoppy · Post by **Hoppy** » Tue Dec 20, 2011 9:47 am

Very nice, that's the ideal dune eater, i am organising a quick trip to atlantis sometime next week, are you game?

GI Jane · Post by **GI Jane** » Tue Dec 20, 2011 11:52 am

Hoppy wrote:Very nice, that's the ideal dune eater, i am organising a quick trip to atlantis sometime next week, are you game?

Goodie, looking forward to that

Post by **Mud Dog** » Tue Dec 20, 2011 12:56 pm

Looking really good Steve!

Now for those consumption test figures!

Post by **Family_Dog** » Tue Dec 20, 2011 1:16 pm

Steve, it looks terrific! One thing concerns me is the distance between the fan and the radiator Are you intending fitting a cowling between fan & radiator?

-F_D

zepplin · Post by **zepplin** » Tue Dec 20, 2011 3:47 pm

Working on the cowling as we speak but I've just had it out on the road to check the temp & could not get it hotter than 92 deg as it is - fitting the cowling anyway. The big bonus was getting the standard rev counter to now work with the six cylinder. Took me 20 minutes & it is only out by 50rpm @3000.

zepplin · Post by **zepplin** » Tue Dec 20, 2011 3:48 pm

Hoppy wrote: i am organising a quick trip to atlantis sometime next week,

If it's next week I'm in.

zepplin · Post by **zepplin** » Tue Dec 27, 2011 3:29 pm

Cowling done. A combination of .6 & .8 galvanized plate rivited together.

This has made a big difference in temperature during normal road driving. It was running at 91-92 deg without the cowling & now at 84 deg. I'll test it properly at the dunes on Friday.

The Legend · Post by **The Legend** » Tue Dec 27, 2011 4:17 pm

Steve
That is a nice job to be proud of.Enjoy it.

oom dan · Post by **oom dan** » Tue Dec 27, 2011 4:30 pm

professional job steve are you going to fit a fan cowling, plenty off folks will be interested in the consumption figures, we have accepted our 22R for what it is, pap en dors

oom dan · Post by **oom dan** » Tue Dec 27, 2011 4:36 pm

OK did'nt see there was a second page looks like the boys have been following this one closely start taking orders steve

Post by **Family_Dog** » Tue Dec 27, 2011 6:32 pm

Looks great, Steve! You know you will now never get rid of that SFA now, don't you? ;)

Wasn't this engine an option in the USA for the model that superseded the SFA, the one not sold here?

-F_D

Post by **Mud Dog** » Tue Dec 27, 2011 8:32 pm

oom dan wrote:professional job steve are you going to fit a fan cowling, plenty off folks will be interested in the consumption figures, we have accepted our 22R for what it is, pap en dors

Slowpoke · Post by **Slowpoke** » Mon Jan 16, 2012 4:50 pm

Zeppelin (Steve?)
It seems after much searching that this is the conversion I want to head to myself. Would you be willing/able/interested in some minor assistance/pointers/advice on the process? Also any recomendations on where to find the engine?

One question. You mentioned your motor came off an auto box and so you rather went the Dictator route. Would it be a better solution to look for a manual unit with ECU?

zepplin · Post by **zepplin** » Mon Jan 16, 2012 8:28 pm

No problem in sharing info.

You'll struggle to find one from a manual vehicle but if you find one with the ECU off an auto I'm sure you can get it to run.

Slowpoke · Post by **Slowpoke** » Tue Jan 17, 2012 10:33 am

Thanks

Now it may be a ball ache but there are two sets of infor I think would be handy:
1) What extras to buy:
radiator, hoses, rubbers, electricals etc.
2) What specific mods were needed:
Did you move engine mountings, which ones? The bellhousing adaptor plate - looks like a good plan - do you have the plate lineout or can you supply? Mods to the drive train (bearing changes, shaft lengthening etc). ECU setup and lastly getting that speedo to work!

Kinda a step by step process outline? I have worked on engines (my 22R I know well by now) but have never attemped a transplant.

If it's a bit too much do'nt worry, I know I am asking a lot and if needs be can figure things out - just though it may be easier to ask ;)

zepplin · Post by **zepplin** » Fri Jan 20, 2012 1:02 pm

Slowpoke wrote:1) What extras to buy:
radiator,I'm running a 2.4D aluminium radiator
hoses, Standard 22R heater & radiator hoses except top hose
rubbers,Married so don't use them
electricals,Nothing except fitting the Diktator management etc.
2) What specific mods were needed:
Did you move engine mountings, which ones?Moved the standard 22R engine mounts on the chassis rearwards. These had to be cut as they extend outwards too much for the 5VZ
The bellhousing adaptor plate - looks like a good plan - do you have the plate lineout or can you supply?
Had this professionaly made in Cape Town
Mods to the drive train (bearing changes, shaft lengthening etc).None. Standard 22R everything
ECU setup and lastly getting that speedo to work!Haven't touched the speedo & it works fine.

Kinda a step by step process outline? I have worked on engines (my 22R I know well by now) but have never attemped a transplant.My first one too. Removed old motor, did a couple of test fits to get the new one positioned, cut & welded the engine mounts, fitted management & did the exhaust. It was pretty painless once I had all the bits together.

GeorgeJvR · Post by **GeorgeJvR** » Wed Feb 01, 2012 8:06 am

Did i miss the fuel consumption report?

zepplin · Post by **zepplin** » Wed Feb 01, 2012 8:22 am

The best I've recorded is 6.5km/l. Combination of 70% town & 30% highway @ 120km/h on 31's. There is so much torque available at the bottom I don't need to rev it past 3000 through the gears but at 120km/h the revs are sitting at 3400rpm which I could bring down a little with 33's. Very happy for the moment so that can wait. It's a little heavier on juice than the 22R but still struggling to keep the right foot from mis-behaving.

GeorgeJvR · Post by **GeorgeJvR** » Wed Feb 01, 2012 8:30 am

Thanks

Mr_B · Post by **Mr_B** » Wed Feb 01, 2012 8:31 am

6.5km/l... Steve that sounds about right! 33's will be great, but again they're going steal some more fuel!

Stef · Post by **Stef** » Wed Feb 01, 2012 9:37 am

What did the 22R consume then? I'm currently getting just over 6km/l on mine; R500's worth of fuel from empty, then 300km to Heidelberg & back (including the trail) and the needle is sitting just above empty.

Slowpoke · Post by **Slowpoke** » Wed Feb 01, 2012 11:01 am

Thanks Steve - good info to have as it influences the descisions.

On my 22R I get about 6.5km/l driving nicely. When I go hunting and I am in a hurry to get there doing 110 then I get closer to 5km/l. I stopped going 120 - too expensive.

zepplin · Post by **zepplin** » Wed Feb 01, 2012 12:38 pm

Stef wrote:What did the 22R consume then?

I was getting around 7 km/l with the EFI and driving like my gran used to.

96-Luxi 4x4 · Post by **96-Luxi 4x4** » Thu Feb 02, 2012 11:03 am

With all my extras and 33" BF's, I get between 5 and 4.5km/L

So bring on any conversion engine, cannot be worse than this, and then I have power!!

Stef · Post by **Stef** » Thu Feb 02, 2012 3:25 pm

Then mine is not that bad

The above figures were obtained while doing 120 -140 the morning and 110-120km/h back

niclemaitre · Post by **niclemaitre** » Thu Feb 02, 2012 3:57 pm

Don't suppose you'd feel like selling your EFI?

zepplin · Post by **zepplin** » Fri Feb 03, 2012 7:55 am

Already sold.

mark watson · Post by **mark watson** » Mon Feb 13, 2012 8:39 pm

steve im sure if you can get the rpm down to 2800 it should be a lot better on juice , the motor has enough low down torque so should be happy with it. even on 33,s , but for your first conversion give yourself a pat on the back it looks good.

GeorgeJvR · Post by **GeorgeJvR** » Tue Feb 14, 2012 7:32 am

Will a KZ box bring the ratios down?