New Project: Family Wagon! (part 4, conclusion)
6) Electrical systemAt this point I was at a crossroads regarding the electrical system. The Canadian trucks are all 24v operating systems, while the California and all gas trucks are 12v electrical systems. I had done inconclusive research on whether I could create a “dual” system using both 12v and 24v systems by tapping one battery in the series. As a result, I was left with the known choices of either converting the 12v California truck to 24v or converting the 24v Canadian motor to 12v. Converting the motor to 12v meant another trip to Spector Off Road to purchase a 12v starter, alternator, glow plugs and related glow plug components. I would also need to make wiring modifications, as the wiring harnesses are very different.
In the end, I decided using more time over more money. I had the entire 24v conversion “kit” sitting there, in the Canadian truck. I called Heidi and asked her to change the date of my return ticket to Costa Rica, adding another week to the project window.
My first step in the electrical swap was to pull all the wiring from the “donor” diesel truck. I first pulled the under hood wiring back in through the firewall on both sides, then pulled the main harness from the inside behind the dash, keeping as many connections together as possible. At the junction where the wiring passes to the rear, there was a big plug for the rear lights and lift gate. I followed this back and grabbed as much wiring as possible. However, the rear lamp assemblies were in an advanced state of corrosion and could not be removed, much less reused! My solution was to obtain all the rear 24v bulbs from the local NAPA store and reuse the clean non-rusty Cali lamp assemblies!
Next I stripped out the wiring from Red. This doesn’t take too long, but the slight adaptations that are necessary for the year model and fuel differences between the trucks gave me a few moments of study as I pieced together the routing and connections. For information I had access to Mitchell Manuals wiring diagrams, which proved very valuable in the process. As the system came together, I was also able to diagnose and repair broken wires to the rear window wiper and washer system. I used all the Canadian relays, switches, resistors, modules and instrument cluster.
Testing dash functions before final assembly. The dash went together slower than it came apart, 'cause there's a sequence that must be followed. Get it out of order and you have to back up and correct your mistakes. With all the ducting, it gets packed.
7) Results, remaining issues and problems
After doing the electrical conversion the truck was ready to be driven. I drove the truck around the San Diego area, running errands and enjoying the remaining days of my stay in the San Diego area. At the very end of our stay we delivered the 2 trucks to a shipper for their overseas journey to Costa Rica. I call the swap a complete success and look forward to tackling the remaining issues very soon:
A) I have a drivability issue to solve: The diesel truck has a heavy surge at light throttle, especially in the lower gears. I posted this issue on the IH8MUD.com forum and received some great potential solutions. I’ll get after the problem when I see the trucks again. I should see them in another month (Jan ’08)
B) The tachometer and fuel gauges are intermittent. I believe the fuel sender is failed and poor connections are the culprit for the tachometer.
C) The Canadian trucks don’t generally come with air conditioners for some reason. So I am going to need to source the pieces missing from the motor to mount and drive an air conditioning pump. The Red truck has a complete A/C system otherwise.
D) When I chose to convert the truck to 24v, I created further problems to solve: The Warn winch is 12v and needs to be removed, find a replacement, or refit the existing unit with a 24v motor.
E) The ARB compressor and solenoids are also 12v. So the air lockers are dead weight until I get that sorted out. I discovered a factory 12v tap off the first battery in the series. This tap powers the headlights! With this discovery, I have an opportunity to research a solution for some small accessories, like the radio (also 12v), the ARB compressor and the cigarette lighter.
8) Summation and recommendations The entire project, starting with the flight to Vancouver and ending with the delivery of the trucks to the shipper occurred within a span of 3 weeks. I like what I have accomplished. To me the truck is as close to factory as can be. With the exception of the FJ VIN#, this truck is a Toyota HJ60. For our principal “daily driver”, anything less would have me doubting myself. I have a sense of security and look forward to OEM reliability and ease of service.
Labels: 4wd, Conversion, Costa Rica, Swaps, Toyota Land Cruiser











