VW Diesel Build Up

Flash319 · 01-19-2008, 10:32 AM

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...........

Albert.G · 01-19-2008, 10:47 AM

wow, good job man.. did the car come with a 3vze?, alll be watchin this one forsure

SEAIRESCUE · 01-19-2008, 10:56 AM

You go man....we are watching. Bet you will get 30+ mpg on the freeway with sensible driving. May want to turn up that turbo after the boogers are worked out of the transplant.

idayota · 01-19-2008, 11:09 AM

wow...all i gotta say is wow! looks like a good time. hey, do us a favor and be as liberal as you can taking pictures, especially of all your fab work like the pilot bushing and adapter plate and stuff.

do you have the link to the zuki site?

how well will the gearing of your petrol tranny match up to the diesel motor? any thoughts on that?

looks good man, definitely keeping an eye on this one!

Flash319 · 01-19-2008, 11:40 AM

Here are the links to the other guys:

http://bbs.zuwharrie.com/content/topic,48503.0.html

http://www.pirate4x4.com/forum/showt...a+conversio n

The pictures are screwed on both of them now though because they are old. I only buy 22re trucks so that is what came out of the truck. The gearing in the truck is the standard 4:10,s. I cruse at 65 right now at 3000rpm. The diesel runs much the same in the jetta, a bit lower about 2800 at 65 so it will be a perfect fit. I am going to put a Garret T3 turbo on (current is a KKK K03 turbo). The K03 is small but good for lots of boost(20psi) at 2000rpm or so but the T3 is bigger and has a big hit at about 3000rpm so it will be perfect for on the highway and stuff.

Here are some more pics.

The 95 Cab, (looks good eh.............)

Fully rebuilt 22RE that has no KM, pulled it out after changing my mind and going to the diesel.

Custom (that means home made) single drive shaft, not sure if it is going to work as I never drove with it. It has little to no runout but was made with 1/8th wall tube so very heavy.

Spare K03 turbo, a T3 is twice the size.

Doner car, anyone wants the body let me know, in very good shape.

Engine that is going in the truck

Temp bushing made of Alum to setup my adapter. You can see the funny bolt pattern on the VW crank. One bolt is not evenly spaced. I have to intex the TOyota flywheel to make this pattern inbetween the current toyota pattern.

Here is the Oilite bushings I made. I made 3 because if this works out I am going to put one in the wifes 4runner.

So there is some more pics of the startup. I will take as many as I can. I am going to try and use the stock toyota engine mounts and locations if possible.

Victor · 01-19-2008, 12:02 PM

Nice work. I love my 2001 TDi Jetta. The truck seems heavy for that engine tho. I know others have done it but how did it affect acceleration? Especially on hills I don't think my TDi could pull my 4Runner well.

yotasavg · 01-19-2008, 12:17 PM

my friend has a built 97tdi and it is a beast i think it'll be fine in that truck. awesome project!

Flash319 · 01-19-2008, 12:23 PM

Well the truck is lighter then a runner. The stock 1.9 is 75HP and 110ft torque I think. Stock 22re is 114HP and 140ft/lb torque. I know I can get over 100HP out of the 1.9 easy so the torque will go with it and I think will surpass the 140ft/lb the 22re has. Remember the car is geared taller because it is a car.

Don't get me wrong this is not going to be a rocket ship. I will be happy with matched performance with the 22RE. I think this is achievable that is why I started this project. I will try my best to describe how the truck feels when it is running for others to judge for themselves. I am happy with the power and torque of the 22re and some think it is a huge dog. To each their own.

I am worried though because the engine is about 4 inches shorter and the pistons are tiny compaired to a 22re but we are talking DIESEL POWER MAN!!! I will just boost it through the moon and see what happends, if it is lacking that much power.

yotasavg · 01-19-2008, 12:30 PM

get a fat waste gate.

idayota · 01-19-2008, 12:52 PM

thanks for the update! when do you get to pull the motor out of the vw? did you get the body off the truck today?

Flash319 · 01-19-2008, 01:15 PM

The body comes off tomorrow. The jetta engine comes out once I get the frame and stuff ready for it. I want to paint up the frame a bit. Then when I pull the diesel I have to fix some oil leaks and clean it up. I also have to check on the crank pully because these engine are known for throwing crank pullies and destroying heads when this happends because the timing belt jumps. I have a small garage so I have to do this in stages incase I need to fix a daily driver.

tnactsuj · 01-19-2008, 06:19 PM

dubs have awesome 4 bangers.I don't think u will be disappointed if u get the turbo and a software upgrade,like the APR stage 2 kit or a similar tune from ABD tuning.I've been told 200pounds of torque isn't that much to ask with mild mods to that setup.my brother has an 02 gas power 1.8T and it makes 250 with an APR stage 1 kit and 007 forge diverter valve on the stock turbo,130mph before you even know it.I look forward to future installments.

just a 22re · 01-19-2008, 06:55 PM

man o man sounds like its going to be a very fun truck but man lol wanna do mine? i want to do one too but no money for the parts needed to do i will be watching this though!!!

Flash319 · 01-20-2008, 05:49 AM

TnactsuJ the 1.9 TD is not a TDI. It is an indirect injection diesel (IDI) with no computer, all mechanical. One wire and you are running. These engines were mostly sold in Canada from 94-98. The US had the TDI as soon as it came out (95 or 96 I think). The TDI's are direct injection (no pre combustion chamber, explosion right on the piston). That may be an upgrade in the future but you can get high numbers with an IDI just the same.

Here is a shout out to the guys on VW diesel site. http://www.vwdiesel.net/ Learned a ton from them.

idayota · 01-20-2008, 02:13 PM

one wire and you're running? that sounds amazing! how easy are they to tune with the mechanical set up? what kind of changes can you make? i assume a/f ratio, maybe airflow...what else? very interesting.

Flash319 · 01-20-2008, 03:33 PM

Diesels don't care to much about air/fuel ratio. There is no butterfly/vacuum, all the air that it can suck or get forced in. So the more fuel you give it the more power you get (to a point then you start getting a lot of black smoke and very high EGT). Fuel delivery determines the RPM not air like in a gas. Most adjustments made to a diesel are amount of fuel per injection and duration and amount of boost from turbo. Then all the usual stuff that gassers have like porting and exhaust mods.

Adjustments are made to the pump buy turning adjustment screws and have some internals in the injection pump changed for more fuel at different times. Once you learn how a diesel injection pump works you can really do a lot of tuning.

just a 22re · 01-20-2008, 10:13 PM

wow i didnt know that about them cool cool

idayota · 01-21-2008, 06:46 AM

thanks for the info flash...i don't know a whole lot about diesels and how they work. i'm excited to see it progress and am especially interested in the tuning. can't wait till you get there!

toy283 · 01-21-2008, 07:25 AM

Quote:

Originally Posted by Flash319

Temp bushing made of Alum to setup my adapter. You can see the funny bolt pattern on the VW crank. One bolt is not evenly spaced. I have to intex the TOyota flywheel to make this pattern inbetween the current toyota pattern.

Instead of grafting the Toyota flywheel to the VW engine, wouldn't be simpler to use the VW flywheel and pressure plate and then sandwich a Toyota disc in between? I'm totally unfamiliar with the particulars of VW engines, but this is the most common way of connecting unmatched engine/tranny combos in swaps.

Flash319 · 01-21-2008, 07:54 AM

The clutch on a VW is quite wierd. They engage through a push rod in the center of the input shaft. The shaft runs through the trans to a leaver that connects through a cable to the clutch pedel. I also have to use the starter from the Toyota because they bolt to the toyota transmission so I need the flywheel anyway. The VW starter bolts to the trans as well and is a different mounting.
Not a big job anyway to put some new holes in the toy flywheel. I want this to be as much Toyota as possible too.

ovrrdrive · 01-21-2008, 07:57 AM

They just did this same engine into their project Samurai on Extreme 4x4 last weekend. Sounds like a solid swap, but they rated the horsepower numbers a little lower than you did. Might possibly be a different year.

They had nothing bad to say about that engine what so ever...

They did a veggie conversion on it. With all of the restaurants around here talk of that swap always gets the wheels turning. Free gas is such a turn on...

Keep us posted on the swap.

01-19-2008, 10:32 AM	#1 (permalink)
Flash319 Registered User Join Date: Feb 2006 Location: Barrie, Ontario CANADA Posts: 825	VW Diesel Build Up 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........... Last edited by Flash319 : 03-23-2008 at 07:52 AM.

01-19-2008, 10:47 AM	#2 (permalink)
Albert.G Registered User Join Date: Jul 2007 Location: Thunder bay Ontairooo Posts: 377	wow, good job man.. did the car come with a 3vze?, alll be watchin this one forsure __________________ Snoyota...thirtee tree's lifted and locked

01-19-2008, 11:09 AM	#4 (permalink)
idayota Registered User Join Date: Dec 2006 Posts: 450	wow...all i gotta say is wow! looks like a good time. hey, do us a favor and be as liberal as you can taking pictures, especially of all your fab work like the pilot bushing and adapter plate and stuff. do you have the link to the zuki site? how well will the gearing of your petrol tranny match up to the diesel motor? any thoughts on that? looks good man, definitely keeping an eye on this one! __________________ *Wherever, Whenever, However...Tread Lightly!*

01-19-2008, 12:02 PM	#6 (permalink)
Victor Registered User Join Date: Jan 2003 Location: El Paso, TX Posts: 1,704	Nice work. I love my 2001 TDi Jetta. The truck seems heavy for that engine tho. I know others have done it but how did it affect acceleration? Especially on hills I don't think my TDi could pull my 4Runner well. __________________ "Turtle" - Green 94 4Runner Looks like one and about as fast JDM altimeter/clinometer, 2002 Sport wheels, 265/75r16 MT/R, , OME stabilizer, BJ Spacers, Cruiser Coils, removed sway bars, rattle can paint for all that peeling clearcoat! Lockright front and rear.

01-19-2008, 12:17 PM	#7 (permalink)
yotasavg Registered User Join Date: Jan 2007 Location: Chico Republic, NOR*CAL Posts: 1,421	my friend has a built 97tdi and it is a beast i think it'll be fine in that truck. awesome project! __________________ -Andrew 94 4Runner 3.0 Auto. I got mods

01-19-2008, 10:56 AM	#3 (permalink)
SEAIRESCUE Registered User Join Date: Apr 2007 Posts: 440	You go man....we are watching. Bet you will get 30+ mpg on the freeway with sensible driving. May want to turn up that turbo after the boogers are worked out of the transplant.

01-19-2008, 11:40 AM	#5 (permalink)
Flash319 Registered User Join Date: Feb 2006 Location: Barrie, Ontario CANADA Posts: 825	Here are the links to the other guys: http://bbs.zuwharrie.com/content/topic,48503.0.html http://www.pirate4x4.com/forum/showt...a+conversio n The pictures are screwed on both of them now though because they are old. I only buy 22re trucks so that is what came out of the truck. The gearing in the truck is the standard 4:10,s. I cruse at 65 right now at 3000rpm. The diesel runs much the same in the jetta, a bit lower about 2800 at 65 so it will be a perfect fit. I am going to put a Garret T3 turbo on (current is a KKK K03 turbo). The K03 is small but good for lots of boost(20psi) at 2000rpm or so but the T3 is bigger and has a big hit at about 3000rpm so it will be perfect for on the highway and stuff. Here are some more pics. The 95 Cab, (looks good eh.............) Fully rebuilt 22RE that has no KM, pulled it out after changing my mind and going to the diesel. Custom (that means home made) single drive shaft, not sure if it is going to work as I never drove with it. It has little to no runout but was made with 1/8th wall tube so very heavy. Spare K03 turbo, a T3 is twice the size. Doner car, anyone wants the body let me know, in very good shape. Engine that is going in the truck Temp bushing made of Alum to setup my adapter. You can see the funny bolt pattern on the VW crank. One bolt is not evenly spaced. I have to intex the TOyota flywheel to make this pattern inbetween the current toyota pattern. Here is the Oilite bushings I made. I made 3 because if this works out I am going to put one in the wifes 4runner. So there is some more pics of the startup. I will take as many as I can. I am going to try and use the stock toyota engine mounts and locations if possible.

01-19-2008, 12:23 PM	#8 (permalink)
Flash319 Registered User Join Date: Feb 2006 Location: Barrie, Ontario CANADA Posts: 825	Well the truck is lighter then a runner. The stock 1.9 is 75HP and 110ft torque I think. Stock 22re is 114HP and 140ft/lb torque. I know I can get over 100HP out of the 1.9 easy so the torque will go with it and I think will surpass the 140ft/lb the 22re has. Remember the car is geared taller because it is a car. Don't get me wrong this is not going to be a rocket ship. I will be happy with matched performance with the 22RE. I think this is achievable that is why I started this project. I will try my best to describe how the truck feels when it is running for others to judge for themselves. I am happy with the power and torque of the 22re and some think it is a huge dog. To each their own. I am worried though because the engine is about 4 inches shorter and the pistons are tiny compaired to a 22re but we are talking DIESEL POWER MAN!!! I will just boost it through the moon and see what happends, if it is lacking that much power. Last edited by Flash319 : 01-19-2008 at 12:25 PM.

01-19-2008, 12:30 PM	#9 (permalink)
yotasavg Registered User Join Date: Jan 2007 Location: Chico Republic, NOR*CAL Posts: 1,421	get a fat waste gate. __________________ -Andrew 94 4Runner 3.0 Auto. I got mods

01-19-2008, 12:52 PM	#10 (permalink)
idayota Registered User Join Date: Dec 2006 Posts: 450	thanks for the update! when do you get to pull the motor out of the vw? did you get the body off the truck today? __________________ *Wherever, Whenever, However...Tread Lightly!*

01-19-2008, 01:15 PM	#11 (permalink)
Flash319 Registered User Join Date: Feb 2006 Location: Barrie, Ontario CANADA Posts: 825	The body comes off tomorrow. The jetta engine comes out once I get the frame and stuff ready for it. I want to paint up the frame a bit. Then when I pull the diesel I have to fix some oil leaks and clean it up. I also have to check on the crank pully because these engine are known for throwing crank pullies and destroying heads when this happends because the timing belt jumps. I have a small garage so I have to do this in stages incase I need to fix a daily driver.

01-19-2008, 06:19 PM	#12 (permalink)
tnactsuj Registered User Join Date: Oct 2007 Posts: 53	dubs have awesome 4 bangers.I don't think u will be disappointed if u get the turbo and a software upgrade,like the APR stage 2 kit or a similar tune from ABD tuning.I've been told 200pounds of torque isn't that much to ask with mild mods to that setup.my brother has an 02 gas power 1.8T and it makes 250 with an APR stage 1 kit and 007 forge diverter valve on the stock turbo,130mph before you even know it.I look forward to future installments.

01-20-2008, 05:49 AM	#14 (permalink)
Flash319 Registered User Join Date: Feb 2006 Location: Barrie, Ontario CANADA Posts: 825	TnactsuJ the 1.9 TD is not a TDI. It is an indirect injection diesel (IDI) with no computer, all mechanical. One wire and you are running. These engines were mostly sold in Canada from 94-98. The US had the TDI as soon as it came out (95 or 96 I think). The TDI's are direct injection (no pre combustion chamber, explosion right on the piston). That may be an upgrade in the future but you can get high numbers with an IDI just the same. Here is a shout out to the guys on VW diesel site. http://www.vwdiesel.net/ Learned a ton from them. Last edited by Flash319 : 01-20-2008 at 05:52 AM.

01-20-2008, 02:13 PM	#15 (permalink)
idayota Registered User Join Date: Dec 2006 Posts: 450	one wire and you're running? that sounds amazing! how easy are they to tune with the mechanical set up? what kind of changes can you make? i assume a/f ratio, maybe airflow...what else? very interesting. __________________ *Wherever, Whenever, However...Tread Lightly!*

01-20-2008, 03:33 PM	#16 (permalink)
Flash319 Registered User Join Date: Feb 2006 Location: Barrie, Ontario CANADA Posts: 825	Diesels don't care to much about air/fuel ratio. There is no butterfly/vacuum, all the air that it can suck or get forced in. So the more fuel you give it the more power you get (to a point then you start getting a lot of black smoke and very high EGT). Fuel delivery determines the RPM not air like in a gas. Most adjustments made to a diesel are amount of fuel per injection and duration and amount of boost from turbo. Then all the usual stuff that gassers have like porting and exhaust mods. Adjustments are made to the pump buy turning adjustment screws and have some internals in the injection pump changed for more fuel at different times. Once you learn how a diesel injection pump works you can really do a lot of tuning.

01-21-2008, 06:46 AM	#18 (permalink)
idayota Registered User Join Date: Dec 2006 Posts: 450	thanks for the info flash...i don't know a whole lot about diesels and how they work. i'm excited to see it progress and am especially interested in the tuning. can't wait till you get there! __________________ *Wherever, Whenever, However...Tread Lightly!*

01-21-2008, 07:54 AM	#20 (permalink)
Flash319 Registered User Join Date: Feb 2006 Location: Barrie, Ontario CANADA Posts: 825	The clutch on a VW is quite wierd. They engage through a push rod in the center of the input shaft. The shaft runs through the trans to a leaver that connects through a cable to the clutch pedel. I also have to use the starter from the Toyota because they bolt to the toyota transmission so I need the flywheel anyway. The VW starter bolts to the trans as well and is a different mounting. Not a big job anyway to put some new holes in the toy flywheel. I want this to be as much Toyota as possible too.

01-21-2008, 07:57 AM	#21 (permalink)
ovrrdrive Registered User Join Date: May 2006 Location: Central Florida Posts: 1,448	They just did this same engine into their project Samurai on Extreme 4x4 last weekend. Sounds like a solid swap, but they rated the horsepower numbers a little lower than you did. Might possibly be a different year. They had nothing bad to say about that engine what so ever... They did a veggie conversion on it. With all of the restaurants around here talk of that swap always gets the wheels turning. Free gas is such a turn on... Keep us posted on the swap. __________________ '95 xcab 4x4 22re,3" BL, 4" Superlift, 1.5" BJ Spacers, 36x13.5 Iroks, M/T Classic Locks, 5.29's, Rear Lockright, J and C head with engnbldr O/S SS valves, RV springs, and Crane Stage 2 cam, Magnaflow 14" with 2.25" in and 2.5" out, NGK V-Power BPR6EY's, OBA with Viair 380C and a 3 gallon tank @ 180psi, Siege Engineering Train horns - Truck bought new in Dec. '94... My buildup thread: link '03 4runner V8 SR5 completely stock

01-21-2008, 08:14 AM	#22 (permalink)
Flash319 Registered User