MATERIALS, PARTS, TOOLS AND SUNDRIES
After conducting months of research I spent up to a year obtaining the following materials:
PARTS
• 1UZFE engine from a Toyota Celsior, 100,000 Km approx, gearbox, wiring harness and ECU from SSS Automotive (an engine importer in Girraween, Sydney, NSW). It was originally a Japanese Domestic market (JDM) motor. Its advantages were it didn’t have the EGR system (which would have complicated the plenum reverse I was hoping to do), and no Trac Control butterfly in the throttle (simpler).
• A complete Toyota Surf gear box with transfer, adapter/extension housing, levers, control box and loom.
• A SC400 throttle from the USA (ebay is your friend and ally), without the Trac Control. I reversed the intake plenum to fit the snorkel and LPG gas system, so this US spec SC400 throttle would pull the throttle and kick-down cables from the correct (right) direction. This throttle also did not have the Trac Control butterfly in its throat and was therefore simpler.
• Rancho 4runner steering damper and damper relocator kit (product numbers RS5402 and 5573 respectively) 4wd1, Castle Hill, NSW, Australia. This relocator clears the sump of the 1uzfe. The original factory setup does not.
• 1uzfe Toyota Crown exhaust manifolds – needed in this swap due to the restricted space in the 4runner engine bay. The crown manifolds are a simple (if restrictive) log design that hugs the motor closely and gives clearance to accommodate the steering column. There are reports of some guys fitting other manifold types to a 1uzfe in their Hiluxs and 4runners, and there are even some reports of guys fitting after markets extractors with various degrees of success (I think the intrepid – Nemesis – has done this successfully). But at this stage I was trying to keep things as simple as possible and just get the motor in.
• Modified alloy Afco radiator from Venom Cobras, QLD, Australia. This radiator had the input and outputs modified by Scott at venom. He is great to deal with and apparently has done heaps of 1uzfe 4runner conversions. This radiator had the brackets fixed half way along the tanks so it could actually be recessed forward into the radiator support panel. This created an extra few centimetres of precious room in the engine bay.
• Fan idler bracket off 3uzfe motor (this bracket has no hydraulic fan mechanism). I got this from the Lextreme website and these are also commonly available on E-Bay. This replaces the hydraulic setup on the Celsior motor, which I did not need due to the installation of thermo fans.
• V8 Landcruiser fan bracket idler pulley to suit the above mentioned bracket: (Australian) Toyota Part Number 16371–50040 (AUD$78). The pulley was the same size as the original hydraulic one but bolt pattern was different so this new pulley was needed (a revenue raising exercise?). I read this swapping pulleys trick from Cebby’s posts on Lextreme.
• Accessory belt - $60 from an auto parts store.
• New 1uzfe distributor caps and rotors and leads.
• Timing belt and timing idler pulleys
• Oil pressure sensor off V6 4runner – so that the oil pressure gauge in the dash is compatible with the new motor.
• Water temperature sensor off V6 4runner – so that the water temperature gauge in the dash is compatible with the new motor.
• Rubber hoses of various types for rerouting coolant and air intake hoses.
• PCV valve grommet in the valve cover, Australian Toyota part number 90480 – 18001 (AUD$6.95). The original one was hard and cracked.
• Fibre glass resin
• 1 x 1mm spacer washer for speed sensor
• 4 x 6mm grub screws for speed sensor rotor on transmission output shaft
• 8x Spark plugs: NGK BKR6E-11
• Battery leads from alternator
• 2 x VN V6 Commodore air boxes
• 2 x VN V6 Commodore intake hoses
• New Thermostat
• Transmission cooler
• Transmission cooler hoses
• Vacuum line hoses
• Various wires for patching wiring loom
• Kick down cable from LN hilux
• Tacho from sr5 2.4 litre Hilux or 4runner
There is probably other stuff too but I have forgotten about them at this stage.
TOOLS
10mm coarse thread hole tapper
14mm spark plug socket
15mm drill bit to drill speed sensor hole in transfer case adapter
4.5mm drill bit
6mm hole tapper for grub screws on speed sensor rotor
8.5mm drill bit
Alan keys (including a 10mm key)
Angle grinder – Something for cutting the metal output shaft
breather / mask and filters
Drill press
Ear Muffs
Engine crane
hand drill
Jigsaw
Jigsaw bits
pliers
Safety glasses
Soldering iron
Screwdrivers
Sockets
Spanners
Stanley knife,
Torque wrench
Vice
wrenches
Again, this is not an exhaustive list and is all I can think of at the moment.
SUNDRIES
Bolts
Electrical tape
FIPG or three bond 1281 sealant
Gumption and steel wool
Never-seize
Small screws and washers
Tarps
solder
Thread lock red
Copious amounts of WD40