Well I am about to begin on my diesel install. I am installing a 1.9TD IDI diesel from a 97 Jetta. It is going into a 92 Extra cab 4X4 frame with a 95 body going on it. I have read a bunch of stuff from others who have done this swap and would like to thank all the others who have posted their storys (Rockclod on Pirate and Zooky on Zuwharrie) as they were a great help. I figures I would do the same for others. Zooky did a 2wd regular cab truck with a 1.9TDI and Rockclod did a regular cab 4x4 with a 1.6TD. So I may be the first for a Extra cab.
I plan on using this truck as a DD with 31" tires. I love diesels and the ability to easily tune them. They are also more economical and last a long time. Although I have 3 Toy trucks with over 400k km on them with 22re's, I love those motors too. Oh ya and there is a TURBO on them!!
Anyway here is the start and I don't know how long this is going to take but I thought I would start now because I completed the adapter for it. The other guys used ACME ADAPTERS but I found the price way to high ($350) just for a hunck of steal with some holes in it. So I made my own.
I still have to mill the edges a bit to clean it up but it works perfect.
The engine that you see is a junk 1.6 that I had laying around and used for trying out the adapter. The 1.9 is still in the car with a blown reverse gear.
I made up a bushing out of oilite for the pilot bearing. My next thing is to pull the crap body off the truck and to index drill the Toyota flywheel to bolt to the diesel.
Here is the body ready to take off tomorrow.
I am using the stock G58 trans with chain driven case. Zooky used a Volvo rad and intercooler from a 740 and it looks factory in there so I have to find one of each.
Anyway gotta get to work...........