2005 CRD swap into fj40

THREED · **Posted:** Sun Jan 01, 2023 8:14 am

Interested in the comparison to the cummins 2.8. While I am a die hard cummins fan, I purchased 2 CRD's and an extra motor as felt the engine, transmission, and control units made for a better swap "package".
Really look forward to your updates, love the build!!!

fjdiesel · **Posted:** Mon Jan 02, 2023 12:14 pm

Thanks, I have a buddy who did the Cummins. We both think the CRD is smoother and quieter. We haven't lined up to run down the road. lol. but we will next summer. I am changing my gear ratio this winter and a few other odds and ends.

But so far they are both awesome mods.

One major deciding factor for me was the factory automatic trans. Easy to get a replacement also.

fjdiesel · **Posted:** Fri Feb 10, 2023 11:22 am

I have a couple questions for you all.

First, when removing the egr cooler. What is the best thing to do with the coolant line? I think I am over thinking it, but, I am wondering if it would be better to plug the head and keep it flowing through the head, rather than dump it???

Second, when doing a swap what are you guys doing for the coolant reservoir? Is there a cooling reason these have a pressurized reservoir??? Or are the same results achieved with a radiator with a vented cap and just an overflow bottle???

Please let me know what your guys thoughts are. I am gonna redo my cooling system in the next couple weeks and these are 2 items that are changing...
Thanks

WWDiesel · **Posted:** Fri Feb 10, 2023 3:29 pm

fjdiesel wrote:

I have a couple questions for you all.
First, when removing the egr cooler. What is the best thing to do with the coolant line? I think I am over thinking it, but, I am wondering if it would be better to plug the head and keep it flowing through the head, rather than dump it???

Quote:

IMO, You should plug the coolant outlet in the center of the head, replace the 5/8" "Y" fitting with a straight 5/8" hose coupler, and remove/delete all the EGR cooler hoses, lines, etc.
If you leave the EGR OEM coolant lines in service, all the flow will be bypassing the thermostat completely and dumping directly into the water pump suction header and without the EGR cooler in the circuit, there is no restriction to the flow in the hoses. And when the thermostat is open/bypass circuit closed, the flow in the OEM EGR cooler hoses will be bypassing the radiator 100% of the time and thus heating the coolant in the water pump suction that is going into the engine. So there is plenty of good reasons to eliminate the EGR coolant hoses and plug/cap the fitting in the center of the head. See Picture 1 below.
FYI, • EGR coolant plug in head: 18mm OD x 6mm ID, M12x1.5 threads
An Oil drain plug M12 X 1.5 for BMW and Mercedes Benz will work just fine. See picture 2 below.

Second, when doing a swap what are you guys doing for the coolant reservoir? Is there a cooling reason these have a pressurized reservoir??? Or are the same results achieved with a radiator with a vented cap and just an overflow bottle???

Quote:

If you are adding a old style radiator with a pressure/recovery type cap, then you will not have to have the OEM style plastic reservoir. But you will need an overflow/recovery type bottle. The important thing is to ensure that the engine block is full of coolant all the time, especially the aluminum head! The purpose of the OEM coolant reservoir is it's location, much higher than the top of the head, to ensure no air pockets get trapped in the aluminum head as we all know these heads can't handle hot spots as they will crack.

Please let me know what your guys thoughts are. I am gonna redo my cooling system in the next couple weeks and these are 2 items that are changing...
Thanks

Picture 1
EGR Coolant Flow (OEM)

Picture 2

Oil drain plug M12-1.5 for BMW and Mercedes Benz

fjdiesel · **Posted:** Fri Feb 10, 2023 3:37 pm

Thank you very much!!!! That is exactly what I was wondering.

I felt on a hot day at freeway speeds that the temp would creep a little higher than I thought it should. And that makes sense now seeing your pic and reading how the coolant goes. I bet too much of my coolant wasn't even getting to the radiator!!

Thanks again.

fjdiesel · **Posted:** Fri Feb 10, 2023 3:44 pm

You do bring up a very good point about the OEM coolant reservoir...

I will look at that in more detail. Because the last thing I want is to damage the head....

krb · **Posted:** Sat Feb 11, 2023 8:02 am

So, is there no room in the engine bay for the OEM pressurized reservoir? Or are you just trying to simplify and clean up under the hood? If that's the case, would you use/relocate the FJ's?

I just replaced the non-pressurized overflow in my XJ, it's rectangular shaped, about the size of a loaf of bread, if you're looking for options.

fjdiesel · **Posted:** Sat Feb 11, 2023 3:10 pm

It is a bit of both. I was looking to clean it up and space is at a premium.

Thanks. I will look at what that tank looks like and check fit.

Thanks again.

krb · **Posted:** Sun Feb 12, 2023 7:50 am

Dodge trucks have, basically, a blockish one, '72-92. Thats about all I'm really familiar with that aren't all funky to fit.

fjdiesel · **Posted:** Mon Feb 13, 2023 2:01 pm

Thanks. I will check that out.

krb · **Posted:** Tue Feb 14, 2023 6:50 am

I mis-spoke on the years. They must have started in the mid 80s. I was thinking of the washer tank in the earlier models...

fjdiesel · **Posted:** Tue Feb 14, 2023 6:34 pm

No problem. I will be working on the cooling and hooking up AC in a couple weeks.

I am trying to wrap up 4 link in the rear now. Cooling next. Summer is coming!! lol.

krb · **Posted:** Sat Apr 08, 2023 8:39 am

Gotten any work done since?

fjdiesel · **Posted:** Sat Apr 08, 2023 10:03 am

Well, I got the 4 link rear end and parts all powder coated. Installing it today!!

fjdiesel · **Posted:** Sat Apr 08, 2023 10:06 am

Here is a pic of it mocked up a couple weeks ago before I sent it in for powder coating.
I am pretty anxious to see how it drives!!

krb · **Posted:** Sun Apr 09, 2023 5:53 am

Cool, is that the original FJ axle?

fjdiesel · **Posted:** Mon Apr 10, 2023 10:00 am

Not anymore. I found a full float from an fj60 that I picked up to use. Mainly because I wanted an Eaton Electric locker. And they won't work with a semifloat.

THREED · **Posted:** Fri Apr 21, 2023 6:49 pm

This thing is gonna have crawler status!

fjdiesel · **Posted:** Mon Apr 24, 2023 5:36 pm

Not that extreme! I just want it to ride good and handle good on forest roads and trails. And 2 lane highways.

fjdiesel · **Posted:** Wed May 03, 2023 10:58 am

Ok, time for an update.

Got the 4 link rear with 2017 JK coils in. RIDES AWESOME!! Probably the second best upgrade, right after the CRD!!

I did have to put a lift leaf spring in the front to level the rig back out, but the stance and ride is awesome. I am really surprised at how well the coils and leafs seem to be balanced. I will get a pic posted soon, I need to wash the rig first. lol.

I need to give a huge thank you to WWdiesel for posting the cooling diagram and verifying that I needed to block off the hose from the egr cooler!! Thank you!! I got that done last night and my test drive this morning was perfect!! No more temp creeping up at higher speeds! So, thank you again!!

I have a little shudder at lower speeds I need to look for, it seems like it is coming from the transmission... I have a couple spares, I wondered about changing the valve body to see if that makes a difference....

2005 CRD swap into fj40

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