pavelvoivoda
Member
Hey guys,
Few days ago, I installed the intercooler on my 1KZ-T 4Runner.
For the those of you who haven't followed, here is a link to the previous thread - 1KZ-T TD 4Runner soon to be TDI
I managed to gather all the parts for the intercooler install from a rig a friend and I bought last winter. It was a 2000 Hilux Surf TDI that had the 1KZ-TE. There are three versions of the KZ engine. 1KZ-T with mechanical pump, 1KZ-TE(electronically controlled), and 1KZ-TE TDI, which is intercooled and also electronically controlled.
I have a former UN Runner with the 1KZ-T engine. These were produced only for the UN, under that name and LHD (i think). Otherwise it's known as Hilux SW4 for SA, and the more sophisticated Hilux Surf for the RHD markets.
The 1KZ-T has a turbo and lots of empty space around it.It has an air filter that you pretty much never change and it can tell if you try to feed it water instead of diesel by the water sensor in the fuel filter. That's just about it.
There are no complex sensors of any kind, except the turbo sensor that should signal if the turbo pressure goes too high. The engine's throttle body stays open all the way when driving and is used solely for shutting the engine off, so I got rid of it, to make room for the new adapter that I built. It's just a piece of pipe and a metal plate, that I had to resurface, because it warped during welding.
The head cover is also different when the engine has an intercooler. The positive crank ventilation gases, or blow-by, is separated from the oil in the hump on the head cover. Since the intercooler stays at an angle when installed in the Hilux Surf, the PCV hump is at the rear of the cover. Because of this hump, the cover needs more space at the back. I had to reorganize the HVAC water hoses and re-tighten the main glow plugs' wire at a different angle, to make room for the oil separator, PCV hose, and mounting brackets.
The original PCV vent hose is made up of a pipe and two shorter hoses, unlike mine where it is just a longer piece of hose that connects from the turbo to the cover. I couldn't source the pipe from anywhere, so I just used my original hose and a very short copper pipe to connect the top 90 degree elbow hose that connects to the pcv hump. It turned out fine. Sorry no pic...
When trying to install the intercooler, I had a little trouble with the accelerator and cruise control links (link to a mod of installing a cruise control unit in the ECUless 1KZ-T engine - Cruise Control swap from 4runner to Hilux Surf). The brackets holding them in place, had to be removed, and I just let them hang under the intercooler. So far I haven't noticed any interference. There is enough space for them under it without damaging the fins.
The main problem I encountered during the install, was the pipe between the turbo and intercooler, was rubbing on the air filter box's intake resonator. I removed the original bolts that hold the box, and padded the two mounts closer to the engine, to raise it up enough on that side, so it doesn't rub anymore.
The hose elbow is at 30 degrees and seems as it's under strain from the pictures, but it isn't. I will carry a spare hose, in case it ruptures tho, as this engine without the turbo help, is like a dead man.
One thing to do later is to install a piece of window screen on top of the intercooler, to guard it against bugs, seeds, rocks and anything small enough to fit thru the scoop. Some intercooler fins are already partially damaged from big bugs and grass seeds, so not sure why Toyota does not ship them with a screen from the factory.
Overall the install was a success without any irreversible modifications.
One thing I noticed and read on another forum, is when you shut the car off, it jitters and shakes, when the engine comes to a halt. I realized it's because of the missing throttle body. Apparently it helps by making the shut off calmer. I kinda like it tho!
I do expect a little bit of fuel economy...hopefully.
I may add some gauges in the future for exhaust gas temp monitoring, but it's not necessary, as this engine does come stock with an intercooler and I don't expect it to cause damage in any way. There is a sensor for the air temp in the back of the cooler, and there is the half inch pipe where the turbo sensor attaches, which can be used for attaching turbo gauge and what not...
I drove it on the high here in Sofia, and I noticed that it starts to accelerate much faster at speeds above 20MPH. But no difference during acceleration from a stop. In the future, I will post if I notice any fuel economy, but that would be after the 10th full gas tank.
Few days ago, I installed the intercooler on my 1KZ-T 4Runner.
For the those of you who haven't followed, here is a link to the previous thread - 1KZ-T TD 4Runner soon to be TDI
I managed to gather all the parts for the intercooler install from a rig a friend and I bought last winter. It was a 2000 Hilux Surf TDI that had the 1KZ-TE. There are three versions of the KZ engine. 1KZ-T with mechanical pump, 1KZ-TE(electronically controlled), and 1KZ-TE TDI, which is intercooled and also electronically controlled.
I have a former UN Runner with the 1KZ-T engine. These were produced only for the UN, under that name and LHD (i think). Otherwise it's known as Hilux SW4 for SA, and the more sophisticated Hilux Surf for the RHD markets.
The 1KZ-T has a turbo and lots of empty space around it.It has an air filter that you pretty much never change and it can tell if you try to feed it water instead of diesel by the water sensor in the fuel filter. That's just about it.
There are no complex sensors of any kind, except the turbo sensor that should signal if the turbo pressure goes too high. The engine's throttle body stays open all the way when driving and is used solely for shutting the engine off, so I got rid of it, to make room for the new adapter that I built. It's just a piece of pipe and a metal plate, that I had to resurface, because it warped during welding.
The head cover is also different when the engine has an intercooler. The positive crank ventilation gases, or blow-by, is separated from the oil in the hump on the head cover. Since the intercooler stays at an angle when installed in the Hilux Surf, the PCV hump is at the rear of the cover. Because of this hump, the cover needs more space at the back. I had to reorganize the HVAC water hoses and re-tighten the main glow plugs' wire at a different angle, to make room for the oil separator, PCV hose, and mounting brackets.
The original PCV vent hose is made up of a pipe and two shorter hoses, unlike mine where it is just a longer piece of hose that connects from the turbo to the cover. I couldn't source the pipe from anywhere, so I just used my original hose and a very short copper pipe to connect the top 90 degree elbow hose that connects to the pcv hump. It turned out fine. Sorry no pic...
When trying to install the intercooler, I had a little trouble with the accelerator and cruise control links (link to a mod of installing a cruise control unit in the ECUless 1KZ-T engine - Cruise Control swap from 4runner to Hilux Surf). The brackets holding them in place, had to be removed, and I just let them hang under the intercooler. So far I haven't noticed any interference. There is enough space for them under it without damaging the fins.
The main problem I encountered during the install, was the pipe between the turbo and intercooler, was rubbing on the air filter box's intake resonator. I removed the original bolts that hold the box, and padded the two mounts closer to the engine, to raise it up enough on that side, so it doesn't rub anymore.
The hose elbow is at 30 degrees and seems as it's under strain from the pictures, but it isn't. I will carry a spare hose, in case it ruptures tho, as this engine without the turbo help, is like a dead man.
One thing to do later is to install a piece of window screen on top of the intercooler, to guard it against bugs, seeds, rocks and anything small enough to fit thru the scoop. Some intercooler fins are already partially damaged from big bugs and grass seeds, so not sure why Toyota does not ship them with a screen from the factory.
Overall the install was a success without any irreversible modifications.
One thing I noticed and read on another forum, is when you shut the car off, it jitters and shakes, when the engine comes to a halt. I realized it's because of the missing throttle body. Apparently it helps by making the shut off calmer. I kinda like it tho!
I do expect a little bit of fuel economy...hopefully.
I may add some gauges in the future for exhaust gas temp monitoring, but it's not necessary, as this engine does come stock with an intercooler and I don't expect it to cause damage in any way. There is a sensor for the air temp in the back of the cooler, and there is the half inch pipe where the turbo sensor attaches, which can be used for attaching turbo gauge and what not...
I drove it on the high here in Sofia, and I noticed that it starts to accelerate much faster at speeds above 20MPH. But no difference during acceleration from a stop. In the future, I will post if I notice any fuel economy, but that would be after the 10th full gas tank.
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