1983 FJ-60 Land Cruiser Diesel & WVO Conversion
I've always wanted an FJ60. To me it has most the rugged aspects of the FJ40, but more comfortable.   I finally found one, made the deal and brought it home. A decent family owned, non abused or modified, original paint, never off road beauty. A good solid body. A couple very small rust spots, a few dents.
It had sat, and not been started in over a year. Nice enough so I won't be spending many hours on the body. 

I wanted a vehicle that is economical and practical to drive, one I can take on long trips. FJ60's are heavy, and in stock form came with a four speed, 3:70 gears and gas mileage is typically in the 12 MPG range. All the Land Cruisers I've been around growing up were diesel. At that time a Land Cruiser just didn't seem like a Land Cruiser to me unless there was a diesel under the hood. So decided to go diesel and 5 speed.  It is currently running on WVO (waste vegetable oil), the kind I can get free from restaurants. 



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The Land Cruiser
(Click on pictures to enlarge)

First arrival home

After a a color change, 3.5" lift, 33" tires and roof rack.

The 6.2 diesel after it was first installed.
Never to be this clean again.

Fuel mileage:  It's currently getting 16 Mpg city driving, and 18 MPG highway.  A definite improvement over the gasser MPG’s.

Power: It has more acceleration than I expected. I don't have to put my foot into the pedal much to accelerate up grades or keep up with traffic.  It doesn't accelerate like a gas V8 for passing situations, but feels similar to the 2F. Even though it's horsepower specs are the same as a 2F, but it feels slightly more powerfull, although in a stoplight race a 2F powered 60 did slightly beat me.  I've driven some 6.2 diesel vehicles that were sluggish, and others that were ok. Mine is fine. Luck of the draw I guess. I can cruise down the interstate 75 MPH without having my stomped to the floor. Not something you can count on with all light duty diesel engines. I had originally planned on adding a turbo, but now feel I'm ok without it. 

Noise: The 6.2 is slightly louder and doesn't have the smooth purr of a Toyota 6 cyl diesel like the 2H or 1HZ. But it's not bad either. Not that quietness was a big concern, but it's probably the 2nd quietest diesel that could be installed. It's quieter than a Toyota B series 4 cyl engine, Cummins, Isuzu or others. No vibrations are felt inside at idle or driving. Quieter inside than expected.  I bought Dynamat sound deadener before the conversion anticipating high interior noise levels. Didn't need it. It was just put it on the floorboards/lower firewall area. It didn't reduce noise level all that much. 

Driving: First gear doesn't get used at all. It feels like a granny gear. Engine is turning 2200 RPM at 65 MPH (speedo not corrected for larger tires). The 5th gear is 27% OD. It has 3:70 gears with 33" tires, so it's geared perfect. An overdrive is a MUST have for a diesel conversion like this that will be driven at interstate speeds. 

My opinion on these conversions is: You do it because you like diesels or want something different. Not because you expect to recoup the cost of a conversion in fuel savings. I doubt my fuel savings will recoup the $5K plus time & labor I have invested in this project even if I were to get 25 MPG.  At least not for a long time. Most conversions cost substantially more than $5K. Diesels aren't for everyone. If you don't like the smell or noise, a diesel isn't for you.

The engine runs fine on veggie oil. Just a very, very slight loss in power. The first time I flipped the switch, I couldn't believe it was running on WVO. I had to go go out and pinch off the the diesel fuel line off to verify it was in fact really running on the WVO. It felt like instant success! 
 


New Drive Train
Getting the 6.2 diesel engine, NV4500 tranny, AA adapter & transfer case ready
(Click on pictures to enlarge)

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The new (used) 6.2 gets pulled from donor truck. A good running 1982 County school board utility truck with 101K miles. Bought the truck for $75, what a deal!

Ok, spent the money here. Bought a brand new NV 4500 5spd tranny and AA adapter to mate it to the stock Toyota transfer case.

Replaced all seals, gaskets and water pump, and painted the engine. 
(Chevy orange of course!)

Ready to drop in!


Installing the new engine and drive train
 I made some engine mount supports out of 3/16" steel and welded them to the frame. Found some rust spots on the radiator support and inner fender wells. Welded some new metal in, sandblasted the frame & rad support, and painted. I positioned the engine over to the drivers side like the original engine was.  I did this not so much to keep drive shafts at original angles, but it makes room on the passenger side for a turbo if I get one in the future and it kept from cutting the floorboard for the transfer case shifter. Left exh manifold was close to the steering shaft. I probably could have left it, but put a half inch steel plate between the steering box and frame to space it. The right exh manifold's stud hit the firewall,   had to do a minor mod there.  Drive shafts had to be shortened/lengthened 3 1/2". If my cruiser had been an 85 or newer, no drive shaft mods would have been needed at all. Welded a patch over the hole where the original throttle linkage came through the firewall. Put a square hole the size of Chevy's throttle cable higher up on the firewall even with the end of the accelerator arm. The Toyota accelerator arm even had the extended rod with a cable hookup just like it was made for using with a cabled throttle system.
Caution:Frame rails will bend way easier than you think when heat from welding is applied. Go easy! I've learned this from vehicles previously worked on. The front of the frame rails will move up from the weight of the vehicle. If you have the vehicle supported by jack stands behind the front axle, the rails will bend down. Temporarily bolt in your radiator support while doing any welding and weld a little bit at a time to keep the heat down! I knew this before I started and thought I was careful and still got a 1/3" movement on one of the frame rails. Next time I will bolt in my radiator support before doing any welding.

I preferred to keep the truck brown so I wouldn't have to paint door jambs. My wife wanted a Champaign color. Too girlie for me. So went with a lighter different brown. It will also keep my friends from putting toilet paper globs on it. Or putting on TuRD stickers on it.

I cut the back part off an old Toyota booster that had had the studs and used it as a mounting plate for GM Hydro Boost. Clutch cyl is a Wilwood 3/4 bore unit. Skinner valves are for anti theft. Without 12v applied all wheels are locked.

I managed to keep my heater. Just won't have ducting directs heat to the driver & passengers feet directly due to shifter being forward. I live in Florida. Don't use it anyway.The cover will need modifying.
I
Engine fits. Now  in the process of wiring and plumbing

Transmission cross member out of 1" X 2" rectangular tubing

Getting close. Just need cooling system and exhaust


Got some mandrel bends, 2 into 1 collector and made the exhaust system myself. 2.5" primary pipes, 3" tailpipe and Dynomax 3" muffler


Veggie Oil, Cooling and Plumbing
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So much for simplicity. Many oil and cooling lines were run. Not much room in the front to put a large oil cooler. I'm put a race car heat exchanger type oil cooler between the frame rail and rocker panel on the drivers side to cool the engine oil. I also put one at the back of the vehicle to heat the veggie oil I'll be using for fuel. Hot water goes through a loop of three heat exchangers  I ran 5/8 marine hose for the coolant to get to the heat exchanger in the back. Hot water is directed there first. Then somewhat cooler, the water returns to another heat exchanger near the front of the vehicle to cool the motor oil . Then passes through another smaller Sen-Dur heat exchanger to heat the veggie oil once again before the inj pump. I scrounged all the fittings I could from friends that are plumbers or Gas line repairmen, but still had to buy some. I've spent lots of $$ at the Good Year hydraulic store on just hoses and fittings.  Hope to only do this once so got marine reinforced water hose and Parker 836 hi temp pushlok hose for oil lines. It really wouldn't be much more for aeroquip SS oil lines, but they don't bend as easy and the added pressure against the fittings on the engine with the vibration can cause the pipe nipples & fittings to eventually break. It seems like pipe fittings & nipples are made in China now and I don't trust them. I put ball valves at both ends of my frankenstein water system, so they can be shut off in event of say leaks or problems and I can still get down the road.
 . 
The stock radiator is pretty big. The 6.2 runs plenty cool with it. Even here in Florida. 
I modified and repositioned the fan shroud opening to accommodate a GM 7 blade fan and fan clutch assy. Towing a 3,500 lb car there is no overheating.
The Chevy's hyd line from the steering pump to Hydro boost worked, but I had to have a high pressure line made to go from the hydro boost to the steering box.
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I put a race car oil cooler near the back of the vehicle near the tank. I'm using it as a heat exchanger. It has a tremendous heating capacity.
Before I flip the tank switch, I turn on the WVO electric fuel pump , I heat and circulate the veggie oil through all the filters and lines first.
I put a solenoid valve just before the tank switch up front between the supply line and return line that allows veggie oil to return to the tank via the return line. That way there isn't any cold pockets of WVO.
When I flip the tank switch, the solenoid closes at the same time.
I put a temp sensor on the solenoid that connects to gauge in the vehicle that lets me know what the WVO temp is warm enough to switch tanks. It also lets me know the temp at  all times.
I have a 30 micron Racor filter before the electric fuel pump, then a 10 micron and another 6 micron filter after that under the hood.

1 year review: I would encourage more than discourage anyone wanting to do this. But there are some obstacles.For something so simple, it sure can be time consuming. At times it seemed like it was consuming my life. If your life is filled with activities and hobbies, one of your other hobbies will have to take a back seat. It's not hard work, but interesting, fun and rewarding if you don't mind getting your hands dirty. I now feel most of the hard work is over. Before starting this project, the WVO conversion route seemed like it would be easier and less hassle than going the biodiesel route. Now biodiesel doesn't look quite so bad. It still looks like lots of work too, but less vehicle risks, and no pulling over for filter change outs. But now with all the time involved with WVO behind me, it is the course I'll maintain.
I haven't ran on WVO as much as I had originally thought I would. Not practical for short trips because it has to be heated first and shut off and run on diesel 5 min before stopping or parking somewhere. I always run it on WVO if I will be driving more than 30 min or taking a road trip. I had beginners luck the first three months and had no problems. Mainly because I had a supply of WVO saved up that I got from friends and coworkers. Usually the oil had only had something fried in it once. Once I started getting the WVO from restaurants the problems began. I tried WVO oil from 15 different restaurants before I found a good source. Good clean grease will save you LOTS of work. I filter my WVO down to two microns before it goes in the vehicle. My primary 30 micron filter on my had been clogging with lard every 100 to 150 miles. How does WVO that's been filtered super fine down to two microns clog a 30 micron filter on the vehicle??!! I guess because the 30 micron filter is on the suction side before the pump, and I filter the WVO under pressure to get it through the two micron filters. I attempted to run without a primary filter on the vehicle and just filter it through both a 10 micron and then a 6 micron filter near the engine. I didn't have to change filters as often, but I noticed more smoke and fuel consumption. Even when on diesel. I was sweating it that Inj pump or engine damage had occurred for a little while there. I ran exclusively diesel for a month, and I think I finally got the lard deposits out of the fuel system and engine is nearly back to normal.  I prefer the added safety of the 30 micron suction side filter and leave it on now. I've learned to adapt. I carry extra filters, rubber gloves and ziplock bags with me. I also have all my filter housing mounted with wing nuts for easier roadside change outs. When driving down the interstate, and a filter clogs, I just flip the switch to run on diesel. I don't have to pull over or stop. I just keep going on diesel until I decide to pull over and change a filter. All the hard work is out of the way. It is getting easier and less time consuming. After changing my pre filtering methods many times, reconfiguring my vehicles system a few times, heat source and filter placements and getting my WVO at a good source, I can now go 400 to 450 miles before a filter change out.
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3 year review: Due to better WVO sources and better filtering technics, can now go 3,000 miles before a filter changeout. Not having to spend so much time collecting and filtering the WVO. Everything has gotten much easier and less time consuming. Life is good.....almost. The Stanadyne injection pumps suck. 3 1/2 years and just put on my 4th pump. I guess when you run fuel through it that's different from what it's designed for, I shouldn't expect miracles, but I hoped for better than this. 


 


Race car oil cooler works great for heating veggie oil.They are pricey new, but can be found on Ebay for around a $100

A friend gave me this Harvard bypass filter.  Extra oil filtering can't hurt. It filters down to one micron.  I'm running out of room under the hood for all this stuff.

Parker Hi temp oil lines and marine coolant hose lines & fittings

Using a 15 gal stainless tank for now. Will try to come up with an external tank later. Racor 30 micron filter

2nd heat exchanger is a Sen-Dur marine after a 10 micron and a 2 micron filter

Pumping & filtering station


Electrical & Wiring
Not that much to wiring. Just have to wire up the glow plugs, sender units, alternator,starter and a 12v wire to the inj pump. That's about it. Not much electrical for an older diesel. The alternator needed a larger gauge wire for voltage sensing. The original 16 or 18 gua wire was too thin and source too far away. Alternator would overcharge to compensate for what it thought was low voltage. A 14 gauge wire cured that.
I'm using a push button momentary switch to heat the glow plugs. I'm using a Ford type starter solenoid for a glow plug relay. I ran the wire that goes from the momentary switch to the relay through a coolant switch that goes open when the engine is hot for people not familiar with glow plugs & diesels that might be driving it. I also wired up the choke light to light when the glow plug button is pushed. The choke light is actually the glow plug lamp on an HJ60. Kind of factory like. I have a GM factory automatic glow plug controller I could have used, but I don't like them. The toyota oil pressure sender screwed right in, but I had to get an adapter to use the Toyota water temp sender. Man-A-Fre sells the adapter for $6. 


Adding a tach pickup so the factory in dash tach works. Click on pic


Diesels and the 6.2 GM Diesel
I was originally very much wanted to find a 12HT or 1HZ Toyota diesel.  Searched for 6 months, but was unable to find any at a price I was willing to pay. I've had earlier Toyota diesel Land Cruisers in the past, and am a big fan of them. But Toyota diesels are very expensive and scarce in the US, especially in the southeast. Diesel Land Cruisers were never sold new in the US.

I went with a  Chevy 6.2. I feel comfortable with that.I did a short stint as a mechanic at a GM truck dealership, so I'm familiar with them. No glamour, cool or wow factor, but it does the job. They fall short in expectations for some people that think just because it's a diesel, it should pull 10,000 lb trailers with ease up mountains. They are a lighter duty diesel and aren't designed for that. Their reputation lags behind Cummins and powerstroke because they aren't as powerful or heavy duty. They don't stand up to abuse, competition and extreme extended demands as well as some other diesels. But they can be reliable and just fine in a 1/2 ton or 3/4 ton truck and usually give years of reliable service used within their limitations. There are heavier duty and more durable diesels out there, but I think a 6.2 or 6.5 is well suited for a Land Cruiser. I feel confident  of a 250K miles sevice life without major repairs. After three years since the installation, the only repairs needed have been three glow plugs and three new injection pumps. The injection pump problems I attribute to the problems of running veggie oil.
 All Diesels have different characteristics. I wanted smooth and quiet because mine is a daily driver. Other engines will have better economy, or better power, but will rattle your teeth.
No diesel engine exceeds in all three of the following characteristics: (1)Power,(2) Economy, (3)Quietness/smoothness. You can find them that excel or stand out in two out of the three, but not all three at the same time. The 6.2 exceed at any of the three, but is decent with all three and is a well rounded engine.
 I think a 6.2 is slightly louder than the Toyota 6 cyl or Nissan diesels, but not as loud as Cummins, Powerstroke or Isuzu truck diesels.The Toyota diesel is probably a better engineered more reliable engine than the 6.2, but the 6.2 is more powerful with about the same fuel mileage. I've observed similar fuel consumption between a 6.2 powered GMC truck and a Toyota HJ45 pickup. The Toyota diesel is my first choice, but they aren't perfect or without faults either.
The 6.2 gets a bad rap because many people associate them with the bad reliability of the Oldsmobile diesels of the late 70’s early 80’s, and the electronic injection pump problems on the GM 6.5's  94 up models. They also got a reputation for being gutless and slow. They are slow by US standards, but seem powerful to those accustomed to driving stock non turbo Toyota Diesels. 

Any reliability issues that I see are problems with a 6.2 are minor and perifreal and can be overcome.
Potential problems I have observed are automatic glow plug controllers, starters and the lack of a hand fuel primer pump. 
Glow plug controllers seem to last about 2 years. They cost $85 a pop. Marginally bad ones may burn out glow plugs by activating them too long. Owners don't replace the controllers and get tired of replacing glow plugs. They now think diesels are troublesome. US auto makers use 6 volt style glow plugs. They do this for driver convenience because they heat up allot faster with 12V applied. But I think they burn out sooner and don't last as long. The Delco part# 60G (made in Germany by another company) are "self limiting" that have protection from being activated too long. Less likely to swell. They aren't listed as a replacement unit in the parts stores computers or books. Have to ask for them. Put in a  manual momentary switch to replace the automatic controller and use 12V glow plugs, you'll never have to buy a controller again, and possibly less glow plugs. Only drawback is you have to push a button to heat the glow plugs. No big deal!

Make sure the harmonic balancer is in good shape. The rubber between the inner and outer portion isn't cracked or warped. The cranks have been known to break if the balancer is bad. Otherwise the cranks are ok. I wish GM would have used forged cranks instead of cast ones though. Mid 90's 6.5 blocks have been known to crack in the web area in the lower area of the block. I would definitely use an after market stud girdle that bolts on the main caps one one of these engines to reduce the lower end flex.
GM didn't put a hand primer pump in their vehicles. If they run out of fuel, you have to crank the hell out of the engine before they prime up and start. People have burned starters up doing this.  A marine outboard primer or hand pump from another vehicle being installed  fixes this. The early starters don't seem to be resistant to heat from lots of cranking. The starters also don't like the water. They also don't fare well to multiple submerged river crossings. GM changed them in the early 90’s with a better designed starter.

What year??:
There are no years dramatically worse than others. The heads slightly weaker on earlier engines, the blocks slightly weaker on later engines, but no problems of epidemic proportions. Picking the year isn't that great of deal, run what you got. But the late eighties/early nineties engines are reputed to be slightly better. Late eighties/early 90's came the serpentine belt and assy setup which is nice. 91 or 92 came the 6.5. Then in  93 came the factory turbo. In 1994 they went computer, and have inj pumps with the the famous electronic PMD control mounted on it. The ckt board that controls the inj pumps were subject to failure. They failed because of heat. Especially the early years 94 to 96. There is a cure, you can move the PMD unit off the inj pump and mount it remotely. Still using anything with electronic controls is extra wiring work on an engine swap. The most sought after engine is the 1993 turbo charged 6.5 non electronic inj pump engine.The year for factory turbo and no electronics. 
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3 1/2 year review: Engine has performed very well. I haven't experienced any bad issues except for the Stanadne injection pumps. I have yet to get a year or 10,000 miles out of one. Maybe that can be attributedt to the fact that veggie oil gets run through it??? Shouldn't be totaly to blame. I guess they are mediocre.



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Land Cruisers Run In The Family
My dad and and three brothers all have owned or currently own Land Cruisers. My two youngest brothers now have five of them. A BJ40, two HJ45's, an HJ60, an BJ71
Four of them sit around my dads house in various stages of repair. The BJ40 is decent, The HJ60 still will get down the road, but it's on it's last leg. The 45 pickups need help, but one is getting repaired slowly.
Engine from this 75 pickup
will go in this BJ73 


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