Thought I’d share the current chapter of my stupid 5vz engine swap saga. I had been using the original radiator mated to the 3.4L engine, but the lower inlet did not line up well at all with the thermostat housing. The original radiator did an admirable job considering it was designed for a much smaller motor, but the fan really had to work to take up the slack on hot days in traffic. Unfortunately, the 50 year old radiator finally sprung a leak so I’ve taken the opportunity to finally upgrade the radiator. Options were extremely limited short of custom building, but luckily the FJ40 radiator is the same width, and slightly larger capacity, but with the mounting flanges on the wrong corners, so I got an aftermarket aluminum version. After a bit of fiddling, I managed to make some standoff spacers to bolt it through, and drilled the flanges to the necessary bolt pattern. There’s no room for a pull fan, so I previously had to just fasten a pusher fan to the front with those horrible ties that fasten through the fins. This time I went to the bother of making a custom fan bracket to hold the fan in front independent of the radiator, without obstructing any more passive airflow than necessary. (I now feel justified in picking up the various aluminum scrap I’ve found on the side of the road .) The added bonus is that now I can put the temp sensor switch inline on the lower hose instead of supplanting the draincock. I also managed to find hose sections that work really perfectly. I’m pretty satisfied, and now the electric fan has to do a lot less work.

 

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