06 hilux engine swap

Turbo, Manifolds, Exhaust, Intercooler, Internals etc

06 hilux engine swap

Postby muddyhilux2020 on Sat, 23 May 2020 2:37 +0000

Further to my other post regarding engine faults, I'm posting this separately as it's a different subject

What engines have people successfully swapped into a hilux of this age?

Mine is a 4wd truck but dont mind losing the 4wd if needed, decent tyres and the rear diff lock would be enough for most of what I do

Have been considering whether I could shoehorn a BMW M57 3.0 6 pot in, or indeed a OM605/606 (2.5 5 pot or 3.0 6 pot merc turbo diesel)

In an ideal world I would like to drop a Cummins 6BT or ISB into the engine bay, I know the front diff would need removing to make some room, and uprated springs, but would be more than happy to remove the 2kd and gearbox/transfer box to make room for a 6bt and ZF 5 speed or 6 speed box

I'm a diesel mechanic by trade and would like some fuel economy so a petrol lump is out!
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Re: 06 hilux engine swap

Postby HK1837 on Sat, 23 May 2020 5:49 +0000

Marks 4WD are soon to release an LS conversion but that is all I know of.
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Re: 06 hilux engine swap

Postby Gipsy on Sat, 23 May 2020 6:57 +0000

Englander mate, LS might be a bit illegal in the old dart, but certainly worth considering. He did say he preferred a diesel. Maybe worth looking at the V6 range of diesels from Europe like BMW etc. Jeep diesels make plenty of hp and the early ones were made by Mercedes in Austria. If the Toyota 4.0 V6 fits as HK has, worth looking at one like yours HK?
Cheers Gipsy :D
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Re: 06 hilux engine swap

Postby HK1837 on Sat, 23 May 2020 1:07 +0000

I got he said diesel but I’ve never heard of any swaps for anything other than the upcoming LS one. Normally people want more go and petrol is the answer to that. If people still want diesels then normally they buy something with a bigger diesel like a Patrol or Landcruiser, which end up using similar fuel to a 4.0L V6 anyway.

From what I understand the big challenge with conversions into 2005 onwards Hilux is the Toyota dash and body, it needs the engine ECU to operate it and getting it to talk to a foreign engine ECU is very difficult.
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Re: 06 hilux engine swap

Postby Gipsy on Sat, 23 May 2020 1:46 +0000

Yep that's what I thought, too much trouble to go to a different engine, with electronic problems just the beginning. That's why I suggested a swap to Toyota petrol V6 because the gen7 is built to have one in it and the bits are readily available even in Europe. I don't see the value in going for a swap to another diesel because of inherent fragility of modern diesels. Why swap your engine to one which probably has more problems than your old one? The V6 Toyota fills the bill for simplicity and ease of swap.
Cheers Gipsy :D
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Re: 06 hilux engine swap

Postby muddyhilux2020 on Sat, 23 May 2020 4:14 +0000

It needs to be diesel, uk fuel costs are high, and sub 20 miles per gallon is excruciating on the pay packet each week!

I'm not talking modern diesels as much, M57 BMW is easy to run in a conversion, OM605/606 with mechanical pump means no ECU etc

And the cummins 6bt is well known across the world for simplicity, reliability, power and torque

I'm not too fussed about the dash working to be honest!
Fuel gauge and temperature gauge are easily done after market for very little, the rev counter isnt needed but easily added from alternator w terminal, and the speedo is easily solved either gps speedo, or indeed an after market setup utilising a wheel sensor or even prop sensor

So that side of it I'm not worried about

The toyota v6 fetches silly money in the uk, so while it would be an easier conversion, it would be prohibitively expensive

That's why I just wondered if anyone had fitted a merc, bmw or a cummins lump

I've personally helped and advised on a few Cummins into Land Rover conversions and know of an L200 with a 6bt as well
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Re: 06 hilux engine swap

Postby HK1837 on Sat, 23 May 2020 6:11 +0000

I get it, was in NZ in February and it was like 60c per litre dearer for basic 91 ULP than it was for diesel. In Australia E10 is normally roughly the same price as diesel so if you want more go than the 3.0L diesel has the V6 makes more sense than a diesel upgrade.
Without the Toyota ECU nothing much will work on the car, it controls everything. You have to keep it. This is what has been holding up the LS V8 conversion for years. I bought my original 2010 V6 auto in 2010 with the intention of converting it to an LS engine. I got sick of waiting and supercharged the 2011 (that replaced the 2010 when written off). Still waiting! Marks 4WD say it is not too far away. Mine is getting a bit old now to convert though. I’d talk to Marks though, if they can do an LS and 6L80E they may be able to do a 6.6 Duranax and 4L80E.
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Re: 06 hilux engine swap

Postby muddyhilux2020 on Sat, 23 May 2020 6:59 +0000

Duramax v8 would be perfect but cant get them in the uk easily!

If I fit a 6bt, I would ditch the 4wd system anyway, engine would be easy wiring

Rear diff lock would just be hard wired switch, wipers, lights, etc dont need ecu do they?

Can always rewire if needed, done electric window modifications before etc so no issue

Edit:
Meant to add, fuel prices in uk are around £1.10 for petrol and around £1.20 for diesel, per litre
So 10mpg (15mpg petrol vs 25mpg diesel) makes a huge difference per week!
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Re: 06 hilux engine swap

Postby muddyhilux2020 on Sun, 12 Jul 2020 5:33 +0000

Time for an update!

Cab has been lifted off, and tub is unbolted
2kd has been pulled along with gearbox and front diff

A 150hp Cummins 6BT has been shoehorned into the chassis with the ZF 5 speed gearbox.
Reversed the sump to allow engine to sit forwards as far as possible, and the donor DAF 45 radiator and Intercooler fit JUST behind the front crashbar

Still got a lot of work to do but it's in!
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Re: 06 hilux engine swap

Postby Gipsy on Mon, 13 Jul 2020 6:30 +0000

Send some pictures :)
Cheers Gipsy :D
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Re: 06 hilux engine swap

Postby hiluxxury on Mon, 13 Jul 2020 7:11 +0000

I'd love to drop a M57 in my lux.. my old X5 had 200kw and 600nm stock.

The 6bt is a great engine but it is so heavy. Keen to see how this goes.
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Re: 06 hilux engine swap

Postby Gipsy on Mon, 13 Jul 2020 9:23 +0000

That's what I would go for, a M57 or similar 3.0 litre V6 diesel. Having bought a jeep V6 diesel, when it did work it was a rocket ship, but unfortunately it didn't make it home from the dealer so I got my money back and bought a Hilux :D
Cheers Gipsy :D
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Re: 06 hilux engine swap

Postby muddyhilux2020 on Mon, 17 Aug 2020 6:45 +0000

Gipsy wrote:That's what I would go for, a M57 or similar 3.0 litre V6 diesel. Having bought a jeep V6 diesel, when it did work it was a rocket ship, but unfortunately it didn't make it home from the dealer so I got my money back and bought a Hilux :D
The 6BT is 250kg heavier than the 2KD it replace, but with removing the front diff and shafts, that's 50~100kg weight saving, so with body off it's only sitting about 1/2" lower than when 2kd was in with body off, plus the body will be stripped of some weight, not a lot I admit but no ecus, heater box is removed and the zf s5-42 is a little lighter than the stock toyota box with transfer box

So all in all I reckon about 150~200kg heavier, but thats mostly behind the front axle line as well which is good
Probably not a huge difference to having a big ARB type winch bumper hanging off the nose!

I have a 40L air tank fitted opposite side to the diesel tank as well

Body lift is 7~8 inches, but not on tube spacers, I have built custom box section lift blocks for the rear 4 cab mounts which will be braced to the chassis rails, and then the front body mounts are a custom built crossmember that fits across top of chassis, to stiffen the front end and give the required lift as well

Its quite agricultural build wise, but its done for strength and simplicity rather than winning style awards!

Its still not finished, but is getting there slowly between other jobs and typical stuff!

Once its done, I will make a thread and upload a load of pictures to show the build and will run through everything done!

The engine is now setup as required though with a 3200rpm spring and a +40hp boost pin, so with a tweak of max fuel screw as well it should be pushing 200~220hp at approx 2800rpm, and peak torque of 600~650lbft (~810 to ~880nm) at 1600~1800rpm
But with masses of torque from idle (300lbft at just above idle)

Gearing on the toyota diff which I believe is 3.583 puts 60mph at ~1850rpm, right in the sweet spot, and 70mph is ~2150rpm if needed, thats on 30" measured 245/75R16

In time I plan on changing the rims for either modular or something else with a wider offset but still 16"
ideally 30~50mm more to kick the wheels out nicely, and fit 235/85 or 265/75 or possibly 255/85 (33 inch) as that will drop rpm approx 100~120rpm or 150~170rpm respectively
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