surf 1kz-te 1st modifications

[stealth]

Gidday guys,

Did a search but didn't seem to find anything,

I have brought my old ladies surf and it is stock as a rock, I'm wondering what are the best mods to in a rough order, so far it looks like turbo back exhaust is the number one mod to make to keep the head cool as possible, (also reading the other thread about egt sensor makes me think this is possibly essential too) but where to from here?

My goal for this truck is just a reliable daily with some occasional towing and some light off-road trips (exploring the back country)

If you were in my position where would you start?

thanks

[northland_pajero]

Unless it came with full service details I would start there, I went as far as also changing the timing belt and water pump on my 3L (2. hilux when I first got it.

[stealth]

Yeah it was my old ladies, so although i don't have the service history (recpts) i have talked to the old man and he had the garage do everything when it is due...hes a bit like that. Im thinking of stuff that falls outside the general maintenance.

[kbushnz]

Open up the exhaust, new dump pipe and 2.5 inch exhaust.
Remove EGR system and possibly remove intake manifold and clean out all the gunk.
Fit an EGT gauge. Esp if towing so you don't push it too hard.
Then drive it for a while and see if that fits your needs...

[bronx89]

Open up the exhaust, new dump pipe and 2.5 inch exhaust.
Remove EGR system and possibly remove intake manifold and clean out all the gunk.
Fit an EGT gauge. Esp if towing so you don't push it too hard.
Then drive it for a while and see if that fits your needs...

Sorry to hijack, but why would you remove the EGR? What are the pros? Doesn't the EGR system lower combustion chamber temperatures?

[Heath]

I'll rewrite this quickly and keep it short this time, sorry less detail this time (lost the first response).

EGR cycles dirty exhaust into the intake manifold and combines it with the oily air from the crankcase to make a gooey sludge that sticks and blocks air flow. Less air means an imbalanced fuel ration (more fuel than air = more heat) which is bad.

Block it off, jam the valve shut or remove it completely is best.

New freeflowing exhaust including dump pipe gets the heat away from the head, gauges to keep an eye on things (EGT, water,boost etc) because the toyota ones dont do a good job of anything except showing the past not real time temps.

Fit the EGT probe pre turbo so you get an exact indication of combustion temps as soon as you can.

Lower temp thermostat maybe to get engine temps a little lower and a radiator clean out (rodding, etc) to keep things cool.

Drive to the EGT gauge. Mine has an alarm to warn me of temps if pushing too hard (so does the water temp gauge look up auberins on the web).

An engine flush and decent coolant/antifreeze too will help. Aussie swear by the red toyota coolant (If my memory serves me right).

Heath

[tallsam66]

I'll rewrite this quickly and keep it short this time, sorry less detail this time (lost the first response).

EGR cycles dirty exhaust into the intake manifold and combines it with the oily air from the crankcase to make a gooey sludge that sticks and blocks air flow. Less air means an imbalanced fuel ration (more fuel than air = more heat) which is bad.

Block it off, jam the valve shut or remove it completely is best.

New freeflowing exhaust including dump pipe gets the heat away from the head, gauges to keep an eye on things (EGT, water,boost etc) because the toyota ones dont do a good job of anything except showing the past not real time temps.

Fit the EGT probe pre turbo so you get an exact indication of combustion temps as soon as you can.

Lower temp thermostat maybe to get engine temps a little lower and a radiator clean out (rodding, etc) to keep things cool.

Drive to the EGT gauge. Mine has an alarm to warn me of temps if pushing too hard (so does the water temp gauge look up auberins on the web).

An engine flush and decent coolant/antifreeze too will help. Aussie swear by the red toyota coolant (If my memory serves me right).

Heath

You can get a 71 degree toyota thermostat....the aussies seem to use these as do i....i can get the part number if needed.
If you have an auto install a trans cooler.
If you aircon is dead remove the cooler that is in front of radiator.
Several of us have put redline water wetter in radiator , this helps to make the water better at transfering heat , therefore cool.ing better.

[kbushnz]

Open up the exhaust, new dump pipe and 2.5 inch exhaust.
Remove EGR system and possibly remove intake manifold and clean out all the gunk.
Fit an EGT gauge. Esp if towing so you don't push it too hard.
Then drive it for a while and see if that fits your needs...

Sorry to hijack, but why would you remove the EGR? What are the pros? Doesn't the EGR system lower combustion chamber temperatures?

This from Wiki

By feeding the lower oxygen exhaust gas into the intake, diesel EGR systems lower combustion temperature, reducing emissions of NOx. This makes combustion less efficient, compromising economy and power. The normally "dry" intake system of a diesel engine is now subject to fouling from soot, unburned fuel and oil in the EGR bleed, which has little effect on airflow but can cause problems with components such as swirl flaps, where fitted. Diesel EGR also increases soot production, though this was masked in the US by the simultaneous introduction of diesel particulate filters.[6] EGR systems can also add abrasive contaminants and increase engine oil acidity, which in turn can reduce engine longevity.[7]
Though engine manufacturers have refused to release details of the effect of EGR on fuel economy, the EPA regulations of 2002 that led to the introduction of cooled EGR were associated with a 3% drop in engine efficiency, bucking a trend of a .5% a year increase.[8]

So basically as Heath said it gunks everything up for no real gain.

[Heath]

Could check the fan hub thingee is doing its job to cool the radiator as part of a check of the cooling system. If its not pulling enough air when its hot you could put a little more silicon stuff in the hub to firm it up a touch (make it roar).

[tallsam66]

Could check the fan hub thingee is doing its job to cool the radiator as part of a check of the cooling system. If its not pulling enough air when its hot you could put a little more silicon stuff in the hub to firm it up a touch (make it roar).

Viscuios fluid is available from BNT ... Stock VF-50

You need impact driver to undo the viscuios hub screws

[bronx89]

Could check the fan hub thingee is doing its job to cool the radiator as part of a check of the cooling system. If its not pulling enough air when its hot you could put a little more silicon stuff in the hub to firm it up a touch (make it roar).

Viscuios fluid is available from BNT ... Stock VF-50

You need impact driver to undo the viscuios hub screws

2nd that, did mine and a mates and they were both virtually empty. Filled them up and boy do they roar now, temps are also way down. If you don't have an impact driver can just use a decent philips, hammer, and vice grips; works a treat.

[bronx89]

Thanks for the EGR system info too. Will def look at taking mine out. Anyone have a link to a post/thread with info and photos of someone doing it? A tutorial kinda thing.

[a80crewza]

Im keen to know how to take remove EGR also

[kbushnz]

Im keen to know how to take remove EGR also

The power of google....

http://www.4wdaction.com.au/forum/viewt ... 4&t=135134

Have a read and has a few photo's of what needs blocking off...

Enjoy..

[a80crewza]

Right, thanks. I understand whats going on now. Is removing/blocking the egr system 'legal'? Like if I asked a mechanic about it would it be okay?

[Dirtydog]

its quite hard to tell if the egr systems removed most the time,

and it doesnt affect warrents either.

[a80crewza]

Can I remove the system without taking much stuff out? I don't have much expertise with this sort of stuff either, but have got the tools to do it.. would it be safe enough to do myself or should I get a mechanic to have a look? Or is there an easier way to stop the egr? Like jamming a ball bearing in the hose?

[kbushnz]

No smog checks in NZ....So they should have no issues...
There was a chap on here who made up the blanking plates...
Easy enough to do yourself..

[tweake]

fully legal to disable emissions systems in nz.
which is good as on older engines the emission systems cause more emissions than they reduce.

[a80crewza]

Thanks guys. I know this is for a 2lt, but is this a good tutorial to follow?: http://daemon4x4.org/portal/articles.php?rid=6

And do I remove everything this pic shows? (except the metal gaskets): http://img263.imageshack.us/img263/9082/egr2pn8.jpg

What should i do with the plugs and hoses that would be left over after removal?

[tweake]

i'm not 100% sure if the 1kz butterfly system is the same as the 2lte.
main thing they are doing by modding the butterfly is to disable the partial closing when egr is on but still shut when engine turns off.

plug any left over vac hoses.
i think the egr is a real pain to get to to remove. you may just have to plate it.

[a80crewza]

So just keep everything there (If i can't get it out), but put blanking plates in at both ends and bolt it all back together, will that do the trick? Do I need to unplug anything? Do I need to do anything to the butterfly valve? Or, is this all I need to do: http://www.toyotasurf.asn.au/techsite/egr.htm ? Im getting confused with all the different approaches people have to this , just need one way

Doing this will get the egts down, right?

[SamLogan]

I don't think its illegal. I have done mine. It is a very fiddly job on the vehicle so when I pulled my engine out for a freshen up I did it then. You just need to go and get 2 new gaskets (one for each side) and cut 2 plates out with the bolt holes in the right place. I think the intake manifold one needs to be roughly the same shape. Then all you need to do is undo the bolts and pull the pipe off. The intake side is the hardest. I believe you need to pull of the tps to get to it. Once that is all done block the vaccum lines off to the ufo looking thing (that's the actuator) and you are done. If you have big hands get someone with small hands to help

Sam

[Slydho]

First mods. New air and fuel filter. Block off egr system a must and not as complicated as they are making it out to be. Performance dump pipe (pm me) and egt after that mods become more involved.

[SamLogan]

you have to remember yours is a van. there is not much room between the back of the engine and the firewall in the surfs

Sam

[Slydho]

That is Van design dude Please refrain from limiting my fabrication ability with your comments. Till me there isn't much room which means there is room just not enough for you to make anything in.

[SamLogan]

I wasn't saying anything of the sort. Just talking about the comment of how hard it is to do the egt. Its not hard but fiddly.

[rob-mu]

That is Van design dude Please refrain from limiting my fabrication ability with your comments. Till me there isn't much room which means there is room just not enough for you to make anything in.

And how about you please refrain from trying to sell your fabrication ability without being a vendor ?