VW Diesel Build Up - Page 12

82yota · 07-30-2008, 07:42 PM

I'm pretty sure a guy that used to frequent the toyotadiesel.com site put a 5 cyl merc into his runner. I can't remember his name though. I think there are some pictures of it in the photogallery on that site though.

And Flash. How is the motor running? Is it liking the warmer weather? Once I cruise on the highway for a while and really get that intake air hot and the EGTs up she loses quite a bit of power. I just picked up my intercooler two days ago though so hopefully will get started on it this weekend and will be able to tell you how it goes. Hopefully will have a pyrometer on Friday as well so I can monkey with the boost a bit.

Flash319 · 07-31-2008, 04:47 AM

The engine is running great. I have put 3 more tanks of fuel through it with a consistent 30 mpg. I am thinking of the IC as well. If I am climbing a hill I can easily push the EGT;s over 1400f. I always keep my eye on that gauge.

I have a slight vibration still in the driveline. I think I may have fixed it last night and will see today when I drive it.

When I installed the engine/trans I aimed the output flange of the T-cast at the pinion yoke as I was planning on running a single drive shaft. Now that I am not the first shaft is running on an angle to the hanger bearing. I re-drilled the hanger bearing holes to move it over as far as I could. It is still to angled about 2 degrees but I am hoping that will fix it.

I only saw the vibration over 80 km/h and it came in about ever 1-1.5 seconds and only under load.

I am worried about my injection pump because the pulley is wobbling. I can't find anything wrong with the pulley and think it is the pump bearing that is going. No leaky though????

I have been driving the truck all over and am very confident in it now. I drove 800km in the last 2 days.

BigSki · 08-02-2008, 09:19 PM

Quote:

Originally Posted by Flash319

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.

instead of using the MKII/MKIII style clutch, you can use a G60/ VR6 flywheel which mounts in a "regular" fashion, then have that redrilled for the 'yota PP.

This G60 "hybrid" clutch is what all of us TDi freeks use when we start changing nozzle tips and having the ECU's reflashed. My '99 TDi put out 120 HP/,410 tq/lbs at 2100 RPM at the last dyno day 2 years ago. This Hybrid clutch holds up fine with no increas in pedal effort. I'm seriously considering a TDi swap into my '92 xcab toyota PU. The "performance" and "economy" of the 3.0 is rediculous, but I like the truck, so some kind of engien swap is in order.

AndyL · 08-10-2008, 11:02 AM

If anyone's looking to get an adapter made - I'm about to order up 2 from a local CNC plasma cutting shop. Estimated cost is 75$cdn each (+ shipping to you) can easily add to that order...

Flash319 · 08-10-2008, 06:49 PM

Sending one my way for free right???

Gramps · 08-21-2008, 05:46 AM

After reading your thread, I to plan on doing this conversion. I have a 1993 4cyl 4x4 extra cab and I just picked up a 1997 TD Jetta for this project.I had a few questions:

1- Did you use the VW accelerator pedal or cable?
2- For the power steering lines, did you get new ones made or did you modify the vw ones?
3- What kind of mods if any did you do to the injection pump?

Oh ya, Excellent work!, I found your thread to be very informative.

Flash319 · 08-24-2008, 05:10 AM

I cut the Toyota cable down and just used it. You can see in this picture a bit. I used the end off the VW that attaches to the pump then made a collar with some set screws that hold the 2 cables together.

I went to a hydraulic place and had them make me a hose for the steering. I used the bottom bango fitting that came on the VW then a compresion fitting to a new hose. If you plan right (I didn't) you may be able to use the toyota presure line and just get a compression fitting to the steel VW line.

As for mods I put on a EGT guage for starters. Make sure you do this because it is easy to get hot, also easier to put the probe in before the engine is in. I then changed the aneroid pin to a 1.6 and cranked in the max fuel screw about 1 turn. I also backed the wastegate off to allow for about 14psi peak boost.

YOu have to watch it with the max fuel screw. At first I had it where if I floored it or was climbing a hill I could fly right past 1400F EGT which is bad. You won't know this without a guage.

Pale Rider · 09-06-2008, 08:46 PM

This build looks awesome and I wish you the best of luck. The only thing I would consider doing different is mating two of these engines in a mid engine configuration, but I have no idea how you would do the 4x4 with that. Of course the bed would be useless

grant526 · 09-07-2008, 09:45 AM

http://www.yotatech.com/f116/trick-hilux-pickup-143387/

Here is an AWSOME example of mid engine truck : ) I know I've enjoyed this build! And look forward to seeing it run! : )

Enjoy!!

And again, Great Job with your conversion! I'm jealous and would like to do something similar. Keep up the great work!

07-31-2008, 04:47 AM	#277 (permalink)
Flash319 Registered User Join Date: Feb 2006 Location: Barrie, Ontario CANADA Posts: 872	The engine is running great. I have put 3 more tanks of fuel through it with a consistent 30 mpg. I am thinking of the IC as well. If I am climbing a hill I can easily push the EGT;s over 1400f. I always keep my eye on that gauge. I have a slight vibration still in the driveline. I think I may have fixed it last night and will see today when I drive it. When I installed the engine/trans I aimed the output flange of the T-cast at the pinion yoke as I was planning on running a single drive shaft. Now that I am not the first shaft is running on an angle to the hanger bearing. I re-drilled the hanger bearing holes to move it over as far as I could. It is still to angled about 2 degrees but I am hoping that will fix it. I only saw the vibration over 80 km/h and it came in about ever 1-1.5 seconds and only under load. I am worried about my injection pump because the pulley is wobbling. I can't find anything wrong with the pulley and think it is the pump bearing that is going. No leaky though???? I have been driving the truck all over and am very confident in it now. I drove 800km in the last 2 days. __________________ 89 Extra cab, 22RE not pretty but it gets me there. 420,000 km 95 VW Diesel Extra Cab Toyota, not done yet(edit: DONE!!!)..... http://www.yotatech.com/f116/vw-diesel-build-up-135203/ 92 Runner, Bone stock 415,000km WANTED: Rust free 89-95 extra cab any condition

08-10-2008, 06:49 PM	#280 (permalink)
Flash319 Registered User Join Date: Feb 2006 Location: Barrie, Ontario CANADA Posts: 872	Sending one my way for free right??? __________________ 89 Extra cab, 22RE not pretty but it gets me there. 420,000 km 95 VW Diesel Extra Cab Toyota, not done yet(edit: DONE!!!)..... http://www.yotatech.com/f116/vw-diesel-build-up-135203/ 92 Runner, Bone stock 415,000km WANTED: Rust free 89-95 extra cab any condition

08-24-2008, 05:10 AM	#282 (permalink)
Flash319 Registered User Join Date: Feb 2006 Location: Barrie, Ontario CANADA Posts: 872	I cut the Toyota cable down and just used it. You can see in this picture a bit. I used the end off the VW that attaches to the pump then made a collar with some set screws that hold the 2 cables together. I went to a hydraulic place and had them make me a hose for the steering. I used the bottom bango fitting that came on the VW then a compresion fitting to a new hose. If you plan right (I didn't) you may be able to use the toyota presure line and just get a compression fitting to the steel VW line. As for mods I put on a EGT guage for starters. Make sure you do this because it is easy to get hot, also easier to put the probe in before the engine is in. I then changed the aneroid pin to a 1.6 and cranked in the max fuel screw about 1 turn. I also backed the wastegate off to allow for about 14psi peak boost. YOu have to watch it with the max fuel screw. At first I had it where if I floored it or was climbing a hill I could fly right past 1400F EGT which is bad. You won't know this without a guage. __________________ 89 Extra cab, 22RE not pretty but it gets me there. 420,000 km 95 VW Diesel Extra Cab Toyota, not done yet(edit: DONE!!!)..... http://www.yotatech.com/f116/vw-diesel-build-up-135203/ 92 Runner, Bone stock 415,000km WANTED: Rust free 89-95 extra cab any condition

09-07-2008, 09:45 AM	#284 (permalink)
grant526 Registered User Join Date: Jan 2008 Location: Sacramento area, Ca Posts: 201	http://www.yotatech.com/f116/trick-hilux-pickup-143387/ Here is an AWSOME example of mid engine truck : ) I know I've enjoyed this build! And look forward to seeing it run! : ) Enjoy!! And again, Great Job with your conversion! I'm jealous and would like to do something similar. Keep up the great work! __________________ '85 Standard Cab 4.5" HD SuperLift Custom Winch bumper 33x12.50 Mud Rovers Lincoln Locked in the rear DD's: '87 XJ and '91 Suzuki DR650s Wheel Responsibly, Don't screw it up for others...

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07-30-2008, 07:42 PM	#276 (permalink)
82yota Registered User Join Date: Jan 2007 Posts: 273	I'm pretty sure a guy that used to frequent the toyotadiesel.com site put a 5 cyl merc into his runner. I can't remember his name though. I think there are some pictures of it in the photogallery on that site though. And Flash. How is the motor running? Is it liking the warmer weather? Once I cruise on the highway for a while and really get that intake air hot and the EGTs up she loses quite a bit of power. I just picked up my intercooler two days ago though so hopefully will get started on it this weekend and will be able to tell you how it goes. Hopefully will have a pyrometer on Friday as well so I can monkey with the boost a bit.

08-10-2008, 11:02 AM	#279 (permalink)
AndyL Registered User Join Date: May 2007 Location: Calgary, Eh! Posts: 86	If anyone's looking to get an adapter made - I'm about to order up 2 from a local CNC plasma cutting shop. Estimated cost is 75$cdn each (+ shipping to you) can easily add to that order...

08-21-2008, 05:46 AM	#281 (permalink)
Gramps Registered User Join Date: Aug 2008 Posts: 1	After reading your thread, I to plan on doing this conversion. I have a 1993 4cyl 4x4 extra cab and I just picked up a 1997 TD Jetta for this project.I had a few questions: 1- Did you use the VW accelerator pedal or cable? 2- For the power steering lines, did you get new ones made or did you modify the vw ones? 3- What kind of mods if any did you do to the injection pump? Oh ya, Excellent work!, I found your thread to be very informative.

09-06-2008, 08:46 PM	#283 (permalink)
Pale Rider Registered User Join Date: Sep 2008 Posts: 15	This build looks awesome and I wish you the best of luck. The only thing I would consider doing different is mating two of these engines in a mid engine configuration, but I have no idea how you would do the 4x4 with that. Of course the bed would be useless

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