1UZ-FE into my 93 Hilux

[v8toy]

Well I thought it was about time I started a thread bout the history and mods to my 1uz-fe powered hilux.

As of Tuesday 14th july it will be here finally after saving like mad and trying to sort transport to darwin

She started off as a stock as a rock 93 white Dualcab running a 2.8 diesel and w58 5 speed manual.

The only mods done to it was a set of 15x 7.5 white sunnys, under bonnet compressor and a steel winch bar.

Within the first week of owning it in went a cd player, 2 6’’ split in the front doors, 2 6’’ splits in the rear doors, a set of tweeters, amps and a single 12 inch sub on the back seat. Then went in the gme tx4400 uhf scanner.

In this time my 2’’ body lift also turned up so that was fitted and the steering shaft extension as well.

About 2 weeks after I got it, my v6 commo powered single cab lux **** its auto gearbox for the 5th time and the night before I was going away for a week long new yrs camping trip.

So in a mammoth effort and just 3 hrs after my old boy had just finished a 12hr shift at work we lobbed in a swapped all the suspension outa the single cab into the dualcab which consisted of 2’’ lifted parabolic springs, 3’’ homemade extended shackles, tough dog adjustable shocks, extended brake lines, rtc steering dampener, dropped drag link, adjustable torque rod and a few other little things then loaded me up for camping and all done by midnight. Thanks pa haha.

After new yrs trip

So after that trip is when the serious stuff started to happen I had already ordered all the gear for the conversion and lift so it was a matter of waiting for it to turn up.

The mods planned are as follows.

Toyota 1uz-fe v8 conversion

Swap out the w58 5 speed for a later model r154f Toyota 5 speed

New box on the left old on the right

Fit the snake racing pro rock stage 3 suspension kit which consists of crossover steering mod, 3’’ extended shackles, 3 ‘’ lifted springs, 2” dropped front crossmember ,inverted rear shock kit, rancho rs9000 shocks, front shock hoops, and a massive traction bar for the rear end.

Then drive it like I stole it.

First on the list was rippin out the old 2.8 slug and 5 speed it was a pity in the end because it was in perfect running order and not a thing wrong with it and only had 150,000 on the dial, sold it for a good price though.

Before the new engine went in I tore in and removed everything not needed in the engine bay like power steering resovoir and lines etc and just a heap of wiring not needed for the petrol engine, I also tore in and ripped the 1UZ apart and checked out the bottom end and what do ya know 6 bolt mains (didn’t know they were fitted with these standard woohoo) and nice and clean too. The inlet manifold came off so I could rebuild the starter motor (yes they are under the inlet manifold and yes it took an hr out of the car to get it out lol) at the same time I rebuilt the alternator, power steering pump and a few other little things got tidied up.

At the same time I also ripped of the traction control butterfly etc of the inlet manifold, removed the idle step up motor out of the inlet manifold and welded these areas shut.

Then there was the wiring as u can imagine there was heaps and mainly because it had an electronically controlled auto box originally so I had to separate the gearbox harness from the engine harness plus also remove the unwanted wiring that was used for the cruise control, traction control and idle step up motor.

Once done the engine was dropped in for trial fitting and engine mount and gearbox mount fabrication begun.

Originally placing the engine about 35mm from the firewall and not much higher than the 2.8 with the bodylift which also meant I had to extend gearbox mount forward 35mm which was on the money for what other people had down in there conversions.

After this was done I wired in the starter to the factory hilux starting system with plans to join into this with the aftermarket ecu to cut down on the extra need for wiring. So now my engine was cranking from the key I was getting excited. At the same time I also swapped the battery to the passenger side and rerouted all other wiring to suit new engine ancillaries.

I was finally getting close at this point I had it booked in for the exhaust system which I had planned to run a 2 ¾ ‘’ from the headers to the y piece and then 3’’ from then on flowing thru a 3’’ sports cat and 3’’ sports muffler exiting were the standard pipe originally exited.

While that was being done I had measured up the driveshafts and had them sent off to be lengthened/ shortened.

Got the car all back exhaust done, driveshaft’s fitted etc etc and had to wait acouple of days for the radiator to turn up which left me 2 weeks to get it fitted, car running and tuned before I had to move north for work and as usual working to a deadline never goes to plan.

Radiator rocked up and guess what it was 25mm to thick with thermos attached to fit in, I was fummin and swearing once or twice. Instead of sending it back east again I managed to find a local guy to mod it for me so after a few measurement I decided to go back to square one and move the engine back another 25mm to give me 10mm clearance from the firewall and also lifted it as high as the tranny would let me in the tunnel end result is much better giving me about 25mm clearance now between the engine and electric fan at the same time old mate was modding the radiator for me which involved cutting the shroud to fit closer to the core, sliding the mounting surfaces so the radiator recessed into the support panel a bit and also putting the inlet/outlets in the right spot.

So after all that I ran out of time and ended up having to make makeshift engine mounts to leave it in the engine bay and just pack it up and leave it to move north.

So now it’s time to work on it again very very soon and this is what needs to be done to finish it.

Fab engine mounts again

Fab gearbox cross member again

Fab up custom rear sump

Fit radiator and plum up

Plum up power steering

Cut and shorten exhaust (again) to refit headers

Mod and balance driveshaft’s again

Fit in ecu and related relays

Wire to run

And finally tune

After that’s done then I will re plumb aircon in when funds allow

Once running etc etc fitting of the lift kit will involve welding in the new 2’’ dropped front crossmember and fabbing in ifs steering box for x-over steering and also fitting traction bar.

Not much to do but enough fingers crossed it should be finished within a month or 2.

Cheers

Stewy

My V8 Lux Build

[v8toy]

well 5 hrs after she arrived i was gettin stuck into her heers to mud gecko (dan) for given me a hand to push her of the car trailer who needs ramps lol.

first job was to unload the mountain of crap i stacked in the cab, then just lookin at her so i had to fix the bullbar originally i just thru a couple of bolts in it to hold it to get here but as u know it either my bro (hes a little underbrained lol) or the trucking companys decided to put a winch strap around it and well it as leaning forward about 2'' turned out the nuts in the chassis had been bent out from the pulling but all good now.

tommorrow nights effort will be swap the front prings around to get her to sit level then start cutting cardboad templates for the engine mounts and gearbox mounts and fab up and if time permits remove sump and trace block mounting and CAD a new rear sump up.

if all goes to plan, all the fab work will be done within a month as well as trying to save for the rest of the ecu which is going to be a wolf v500 standalone.

hopefully by end of august it will be registered before our bub arrives.

hey dan i figured out why it wasnt flexing as much as i thought, the spring clamps are done up way tight from the factory and have bowed the tops in which means the crush tube is shorter than it should be and is restricting it so i will spread them out and put a longer crush tube in, by i reckon at least 30mm

[v8toy]

got a bit acheived tonight

swapped front springs around and she now sits level across the front

then moved onto the engine mounts and gearbox x-member, after fiddling around a bit fitting in the radiator i ended up with a 5 mm clearance of the fire wall and about 10-15mm between the thermo fan and the crank pulley with the gearbox pushed up as high as possible leaving about 15mm between that and the transmission tunnel.

positioning the gearbox in the centre

5mm spacer for firewall to engine clearance (zoom qualitys pretty crappy)

passenger side engine mount tacked up

drivers side engine mount tacked up

both mounts ready for welding

one of the mounts side view

end result of engine placement on the left were the compressor and fuse box is, is were the custom airbox wil be placed and move the other items backwards a bit that way i can fit a seconf battery in the original position.

and the gained gearbox clearance

in the end the gearbox x-member has been raised by 65mm over standard most of it is acheived my using 12mm plate instead of a big lumpy original style x member.

tomorrows effort will be send CAd drawings of the new gearbox x member once a ally trail one has been done and then remove sump and Cad up a new rear sump version ready for profile cutting.

then the tailshafts will be measured up and sent of as well as shortening the exhaust system to fit to new engine postion.

after that its just a matter of fiddling around with the small bits and peices like making sure all fuel lines etc are good and not rubbing etc anywhere.

[v8toy]

tonights effort consisted off

laying under the car for like a hr measuring and CAD drawing on the lappy until i was happy with the design of the x-member then i went and made a 2mm ally template of the x-member to double check b4 the design heads of to the profile cutters.

end result was first shot perfection 8) 8) 8) and a gain in clearance between underside of x-member of about 100mm.

in this pic the box is sitting at the right height i need with a 45mm bit of timber on top of the original x-member as u can see theres quite a gain in height. the new x-member only steps down about 50mm.

the next thing to get adjusted was the exhaust system, i removed almost the whole thing and mounted it to the headers then figured were the best place to cut the extra length from ended up cutting 32mm out and shes all sweet now.

also mounted the rear driveshaft to figure out how much it needed to be shortened by and its only 25mm which is annoyin cause originally i lengthed it by 32mm damn it oh well the job will be done right atleast.

so next thing on the list is to spend acouple hrs rubber mounting the radiator and finalizing its final postion then plumb up some hoses for it and connect the power steering.

then i reckon ill put a battery in her and and see if she turns over still.

found out some good info today from a local auto lecky after quizing him about the alternator hookup for the warning light etc. turns out ashdown ingrams sell an adaptor plug that goes from the 2.8's alternator 3 pin round plug and changes into the 1UZ's 3 pin oval plug, pinouts are the same but uses different plug styles much easier than fiddling around changing the terminals over.

cheers

stewy

[v8toy]

tonight i sorted the radiator properly and made new side mounts and cut the hold ones of and tig'd the new ones on the side redrilled them and mounted it to take a 20mm rubber bush between it and the front support panel, radiator now has about 20mm between it and the crank pully.

next i tackled the under bonnet fuse box and removed the under bonnet compressor infront of it. i needed to do this to make room for the custom ally airbox. This way i can still run dual batteries one in the original position on the drivers side behind the headlight and the other behind the headlight on the passenger side were the original deisel airbox was, which is the main battery.

at this present time im going to see if the panel filter in my aurion will be the right size if not ill find another smaller size. the reasons i want to use a panel filter is that way the airbox will be able to be made to a smaller profile seen as its going to be on the drivers guard and it will be and easier style for me to fully seal for the snorkel setup, also the inlet pipe will only be about 250mm long from the airbox to the throttle body so thats got to be a good thing.

tomorrow should be an eventfull day the plan is to measure the area for the new sump and then pull the motor out to reattach all the crap on the front (its only all sitting on there at the mo) and also remove the original sump and trace the block surface to CAD the new sump up, Inbetween all this the boys and me and DAN (Mud gecko) hehe in the W/shop will be pulling the new boat hull together so i got a busy day.

along with this i will finish of he rerouting of the drivers side harness for the fuse box and start fabbing a airbox fingers crossed.

cheers

stewy

[v8toy]

well today was a extra productive day i had the help of dan (mud gecko) and we got **** loads acheived cheers mate.

first thing was to rip the donk out and reattach everything eg aircon compressor sort out the length of belt i needed and just put some bolts in here and there. we also removed the sump base and mid section so i could make a tracing of the block to make a start on my custom sump.

at the same time dan sanded up the engine mounts and we painted them ready to go back on.

donk out

u got love this sexy looking crank and the 6 bolt mains

engine mounts sanded and painted

while the engine was out we moved the clutch line bracket out of the way by 25mm and also attach the marks 4wd handbrake relocation kit.

dan rewelding the clutch line bracket in the new location

by the end of the day the engine was bolted back in and everything tightened up.

there is only a few little things here and there that need to be done now

fab custom sump

fab custom airbox

wire ecu when i get it

drop front and rear driveshafts of to be altered

finish of handbrake assembly

fit fuel surge tank

fit gearbox x-member when it turns up

refit stereo and uhf head units

final fit radiator

not much but all little things that as we know take more time than the bigger items.

cheers

stewy

[v8toy]

I worked on her from 8 till 12 today and finished of the wiring rerouting in the drivers guard.

ive done this to allow me to put the airbox on the drivers guard and leave room for dual batterys.

some of the wiring mods

this wiring is for the indicators and park lights i used the same colour wires with traces etc and lenghtened it by aboout 500mm to exit thru another hole in the back of the guard

not the most interesting pics but all good haha

also got the bossman to double check my CAD drawings for the sump flange and gearbox x-member got both of them first shot so all good they will be email to profile cutter on monday morning. Sump flange will be cut from 10mm ally plate to allow for warpage after welding and also so i got room to mill it afterwards, and gearbox x-member from 12mm plate, reason because i can

tonight im sittin on the couch make a wiring loom up for the efi relays, fuel lpump relays and main relays ready to be fitted with connections and fittings etc.

chers

stewy

[ELEGNT]

wow that is awesome!!!!!!!!!!!!!!!!!

fantastic work on your car and great write up mate

keep us posted as you go, this is going to be a mean truck

i like you single cab too btw, probly doesnt look the same now after u stole all the stuff off it LOL

[v8toy]

hey cheers mate she will be a weapon i still cant get over the size of the rear traction bar lol must need it haha

and yeah the single cab is looking really worse for wear this weekend my brother and old man are stripping it and getting rid of what my brother doesnt want poor thing has had a floggin lol its built for it haha.

so tonight i just ***** farted around a bit getting the little obsolete things done

i fitted driver side seatbelt (removed it to fit into my single cab at one stage)

refitted all the dash panels even though they have to come out again for the ecu to mounted under them

put all my recovery gear behind the backseat

and made a sweet little polished bracket for the other side of my fuse box and for acouple of earth to attach too.

its just **** but it looked really good until i covered it up with crap and now u cant see it lol oh well it looked good to start with.

and here it is all covered up lol

i also got excited and decided to take soem of my aurion next to my lux

aurions lowered 53mm

not the the roof line on the aurion is the same level as the bottom of my windows on the lux :roll: :roll: :roll:

lastnight i made my wiring loom up ready to go in 12 wires and all done its all taped together and longer than i need but just incase i needed it to be.

cheers

stewy

[DJKOR]

Love the progress on the Hilux mate. I LOL'ed at the second photo showing the Aurion. It looks like a toy car.

[the_random_hero]

Such an awesome conversion to do mate (worked on a couple of these so far, convincing two mates to do it in the following few weeks). I greatly advise you ditch the factory intake manifold (super duper restrictive) along with the exhaust manifolds (as you can see they are shocking) - that along with an aftermarket ECU should get you close to the 250rwhp mark. After that, time to tackle the terrible cams :P

Any reason you chose the super duper expensive R154 over the cheaper R153 (from an import Surf)? Are you making/modifying a bellhousing to suit or does somebody do one off the shelf?

[v8toy]

cheers guys yeah i was quite amused of the aurion conpared to my lux u should have seen the aurion drag it on the trailer from the transport company it looked funny as .....

i think in my personall opinion its almost the only conversion to do to a hilux everything is adaptable really easy and it looks factory dont get me wrong the ls conversion would be really nice to but i couldnt go past a 1uz quad over cams 6 bolt mains what more do u want lol

later on while fab my own stainless zorst manifolds but i need to get it on the road b4 me and my partners new arrival turns up (7 oct).

what do u recommend as far as intake a custom one or aftermarket agin once bubs is here and fuinaces settle abit i will consider this cause i would mind drop a charger up there with it nothin extreme cause i still want it driveable with the kids etc, plus it will run a wolf v500 so i gotta put some good bits on her lol.

i got that box from a 03 3.0ltd prado basically cause it allready had the transfer with it the yokes have the same bolt pattern as my driveshafts and i need the rubber mount to be 15mm forward of standard. it was 2g to by from the wreckers and the car had only done 35000 so its really good nic (i did check it out still) i got the bellhousing from dellows direct fit witht he flywheel and clutch and fork etc so far its all gone on good but we'll see when i start it and go to drop her into gear haha.

plus the other reason is i wanted to make it easier to get parts for even with the 1uz but i have more chance of finding a secondhand prado box rather than inport surf one.

alot of fellas hate the 1uz for the fact u cant get parts in the outback well im in darwin and theres a few here at certain wreckers, but i thought of it as if your at oodinatta rd house and ya 08 pajero or 200 series cruiser ****s its self u aint gonna get parts anyway.

tonight im gonna start fabbing the sump body while i wait for the flange to be cut it should hold about 5 - 5.5l fingers crossed

[1stKill]

Great post mate very informative,well done...Awesome looking truck sorry i mean Hilux... :D

Did ya keep all the spotties off the old girl,and are they going on the new beast?

[v8toy]

cheers mate im tryin to make it like that so people have an idea on what needs to be done to do this conversion successfully and enjoyable.

and hellllll yeah the lights are stayin on lol i umm need them umm to see cows and stuff mr officer lol nah really i do they are awesome at night the 2 on the bar are setup for spread beam eith the blue lens (makes it appear more of a white light rather than yellow) and the 4 on the roof are pencil beams and man do they pencil lol i reckon easily 800m to the naked eye and more if u can see reflectors etc light up B) B) B) B) B)

seriously though the coppers have never had a drama with me using those lights up there one time down south in my single cab lux they actally called me up on the uhf and wanted to hang with me i thought i was in the ***** but they wanted to stick with me and use them aswell lol they were impressed and just warned me not to use them in built up areas lol but i have a secret wickedly awesome hidden switch to confuse them if i do get pulled over :P :P :P :P

Edited July 21, 2009 by v8toy

[1stKill]

cheers mate im tryin to make it like that so people have an idea on what needs to be done to do this conversion successfully and enjoyable.

and hellllll yeah the lights are stayin on lol i umm need them umm to see cows and stuff mr officer lol nah really i do they are awesome at night the 2 on the bar are setup for spread beam eith the blue lens (makes it appear more of a white light rather than yellow) and the 4 on the roof are pencil beams and man do they pencil lol i reckon easily 800m to the naked eye and more if u can see reflectors etc light up B) B) B) B) B)

seriously though the coppers have never had a drama with me using those lights up there one time down south in my single cab lux they actally called me up on the uhf and wanted to hang with me i thought i was in the ***** but they wanted to stick with me and use them aswell lol they were impressed and just warned me not to use them in built up areas lol but i have a secret wickedly awesome hidden switch to confuse them if i do get pulled over :P :P :P :P

Cool... what a farking beast this thing is,in all areas...once again well done.

[v8toy]

today i got my freshly cut x-member and i well to say the least i got quite aroused lol theres no way in this world i know of anyone that could cut that nice with an oxy.

after speakin to ash about his x-member i got into folding mine up and then onto drilling the holes (didnt get the cutter to do them because i wanted to double check my measurements).

sorry the ics are a bit shotty damn fones forgot the camera.

the freshly cut 12mm plate x-member

in the press ready for folding.

first fold

all folded

new v's old

holes drilled

the said item fitted

tomorrow night will be a night of for the first night since last wednesday the youngin is harpen on to me to watch were wally dvds lol

cheers

stewy

[the_random_hero]

Intake manifold will have to be custom made, I don't know anything off the shelf that will go straight on. In my opinion, they have more than ample torque so supercharged is a bad idea - either mod it slightly for a bit more NA grunt (cams, quads and exhaust - head flows nicely already and the engine will rev to 8k without hassles), or bolt a pair of T28's on there and run it low boost. With decompression the engine will easily run 10psi, which should see you on the nicer side of 400rwhp. Either of those will be a very nice upgrade to get you up and boogeying quicker.

[v8toy]

after ready about t28's i got highly aroused lol but ill have to control myself after all ill have to keep it reasonably suttle to drive for the missus and for the kids are inside (dont want to get outa control then). After all all its a pretty high hilux lol.

would definatly be on the to do list though if we end up with a decent family car again but for now the hilux is going to be the daily driver once finished and my sx6 aurion is gettin booted.

[the_random_hero]

after ready about t28's i got highly aroused lol but ill have to control myself after all ill have to keep it reasonably suttle to drive for the missus and for the kids are inside (dont want to get outa control then). After all all its a pretty high hilux lol.

would definatly be on the to do list though if we end up with a decent family car again but for now the hilux is going to be the daily driver once finished and my sx6 aurion is gettin booted.

They won't come on boost too hard (maybe 3000rpm you'll have full boost), tuned right it should still be VERY manageable on the road. We did not one so long ago with T28's, had a very nice powerband (stupid amounts of torque from 2000rpm all the way to 6000rpm on a dyno graph, died in the ***** from 6k onwards though).

[v8toy]

k got a little bit slack this weekend had planned to get craploads done but my laziness got the better of me and only manged a half day on saturday but still mangaged to sort half the airbox out.

tacked together with inlet and outlets holesawed in it.

the lid exciting hey lol

test fit of filter, filter is outa my aurion and the angled edge suits what i need to get around the brake master cylinder.

with lid

all tigged together

test fitted to engine bay its quite big but im tryin to think of how to make it smaller

hopefully ill get of my sphincter during the week and finish the whole lot of bar the ecu.

cheers

stewy

[v8toy]

ok so ive decided to change change my mind on the airbox it jsut to big and looks way gay lol ive decided to run a unifilter pod filter instead measuring 76mm inlet, 100mm od and about 140mm length this way i can make the airbox smaller to suit the engine bay etc and also have more room left on the drivers guard for the battery etc.

i forgot the camera today but i got my uhf and stereo all crankin again (somehow i think the 10"" sub will have to go the new born wont like it lol) and did some small touchs to the gearbox x-member.

all the things i have left to do are things i need reasonable amount of coin for things like driveshafts and the purchase of the ecu and ive been hassling my ex employer for my group certificate so i can do my tax and fingers crossed put that money towards these items but as per usall he is giving me every excuse under the sun and im starting to get ****** now.

i have the wiring harness made up for the car too run just need the ecu to finalize it b4 i seal it off and feed it into the car

also checked all my lights tonight made sure indicators worked etc etc all good.

Tomorrow night i will make a small bolt on bash plate for the transfer case and and muck around with the springs to get it too flex to the max and then measure front drive shaft length compressed and extended.

cheers

stewy

[3zzfe]

very very good work.

I love it

[v8toy]

today i got motivated after downing 2 double shot iced coffees and half a bottle of coke lol.

i went to ashdown ingrams and sorced the adaptor for the alternator plugs $15 and on the shelf (P/N 44-76440) also got a 5 bank of relay bases with a heap of crimp terminals.

adaptor plug

adaptor plug and relay block

plugged in the adaptor and instantly had all my dash warnings lights and the gauges all worked cant beat that no soldering needed.

after that decided to wire in what i could without the ecu, layed out my harness that i had prepared earlier and labeled everything.

harness layed out

mounted the fuses and relay block i only need 2 relays for the engine to run the third is for my bullbar mounted lights and i have the 180amp relay on the guard for the roof lights.

relay block

fuses

then got into wiring it after laying it into the engine bay the plan is for all the wiring to be done in the engine bay nothing going into the cab besides the ecu and the 8 wires to operate it lesson learnt after the other hilux conversion i did the dash harness cant take the extra load :roll: :roll: :roll:

fuses soldered on

fuses heatshrunk

soldered and crimped

the blue/white colour wire runs from the fuel pump relay down the the fuel pump.

ive used colours that are mostly trace wire colours to try and match the existing hilux wiring the best i can, reasons for doing this is mainly for fault finding later cause i dont have 10 red wires all going to different things and trying to follow them.

the other reason is it looks factory lol

tomorrow im going to finish what i can with the wiring and then i might even give her a wash and aluminium acid the engine and box.

cheers

stewy.

[spillige]

awsome thread good luck with the rest of the build

[the_random_hero]

That's neat as dude, wish my bay looked like that! I'm considering ditching as much of the loom as possible and running one of those new Motec CAN relay-thingers, but I think it would considerably increase my budget :( I need a sponsor!