VW Diesel Build Up - Page 3

Flash319 · 01-26-2008, 10:52 AM

Well I got my passenger side mount welded up today. It was the easier side to do. You can see in the pictures how much shorter the engine is from the 22re. The engine mount is at the front of the diesel block and on the 22re it is in the middle. I am still going to gusset that mount a bit but I am happy with softness of the mount. The trans and engine move very well with the rubber mounts.

I might start on the other side tomorrow. Once I get the mounts done I am going to yank the diesel from the car and put it in and see how I did.

nate V · 01-26-2008, 11:03 AM

awsome work
im sure it will fit right in there!!

I will be cuerous to know what kind of millage you get out of this thing when you are all done.

82yota · 01-26-2008, 01:32 PM

Oh you have no idea how much I wish I could have had a junk motor like that to play with when doing my mounts. As well as the cab off. I had to weld the mounts in with the motor in place. Stick rods came in handy there as you can bend them. Its looking very nice. I'm curious to see what mileage you get as well. And what other little tweaks you do to it as well.

**aviator** · 01-27-2008, 08:15 AM

Very clean looking welds Flash...

Does anybody know if there are "hop-up" kits for the 1.9/2.0 vw diesels like they make for the big 3 diesels? I suspect there are in europe...

Flash319 · 01-28-2008, 05:05 AM

Well I got my drivers side mount almost done. What a pain that one is. It lines up right over the upper A-arm so I have to build up around the arm. It does not look good but I think it will work. I could have dropped it down a bit but then I would have had a hard time getting the diff dropped if I needed too. I will take some pics tonight. Now I have to wire brush the frame down a bit and throw some POR15 on it. Also start pulling the diesel.

Flash319 · 01-28-2008, 05:16 PM

Okay here is the drivers side. Not a good spot for the mount to end up. I could have moved it forward but then I would have to get rid of the serpintine belt on the diesel as the alternator sits right there. The plate is 3/8 and was bent on a brake.

I am going to gusset this side right down the inside of the frame to the top of the dif mount.

Here are both mounts. The are offest because of the alternator.

The suspention is unload but I think it will be okay with weight and won't hit the mount. I may have to trim the stamped tab on the upper arm.

Here is the mount attached. This looks very ugly but will work. Lots of angles and crap. But I managed to pick up 3 holes on the block.

This weekend the diesel comes out if I have time and the weather permits. I have to pull it outside. I ordered my Por15 today so everything will look all nice and black soon, don't worry

**aviator** · 01-28-2008, 07:22 PM

If the wx is too ugly you can always just work on the POR15 part of the project... the mounts look pretty strong...

nate V · 01-29-2008, 02:10 PM

Flash
did you get the engine out yet?
Looks like thoes are rugged mounts awesome wielding job too!

Flash319 · 01-31-2008, 07:09 AM

Well I almost got it out last night. It reminded me of why I hate frontwheel drive again. What a bastard. I ended up cutting the CV's and I still can't get the damn thing out. I am going to have to take the whole front of the car off to get it out. That is what the Hays manuals says but I thought I would try without. If you want to do any work on a FWD you have to pull the damn engine out, thus the whole front end. Stupid!!! If the car wasn't in such good shape I would just cut it up.

I wire brushed some of the truck frame as well. It is not to bad but I need to take a presure washer to it to really clean it before paint. I should have the engine out this weekend. I have to wash it up and replace the oil pan gasket. I can't wait to set it in the truck!!!

ken.vs.ryu · 02-01-2008, 08:52 AM

I can't wait untill we can have conversion kits.
Good luck!

nate V · 02-01-2008, 09:38 AM

Conversion kits for what? this swap?

Belize Off Road Team · 02-01-2008, 09:43 AM

Looks like a fun build! shouldn't be that hard considering in Mexico VW used a Toyota Hilux as their older truck and again in a few years, VW is re-releasing their Diesel truck in Canada/America with a Toyota Hilux Body.

82yota · 02-01-2008, 11:09 AM

Where did you hear they will be offering a Toyota Hilux truck with a diesel in it here in Canada? I am extremely interested in that. Have never heard about that. If you could post a link about it I would really appreciate that.

98sr5tacoma · 02-01-2008, 11:15 AM

http://www.pickuptruck.com/html/news/vw/germanspy.html

98sr5tacoma · 02-01-2008, 11:19 AM

yeah they used a hilux body but it didnt have a jetta engine so it aint that easy

Flash319 · 02-01-2008, 12:00 PM

I would not say it is easy. I have access to machining equipment and it still takes a bit of work and some hacking. I can't wait to see what happends when I put the body on...........

I got that damn engine out last night, what a pain. I have to pull the trans off and clean it up.
I got my POR15 in the mail yesterday so I will paint around where the engine is going first then put the engine in the frame to see how it looks. I am going to have to put a remote oil filter system on it as the oil filter/oil to water cooler is in the way of the mount on the drivers side.

**aviator** · 02-01-2008, 03:49 PM

as long as you do it right a remote oil system is a better idea in my book anyway you get a little more of the good stuff in the system and these engineers put the darn thing in the worst places sometimes... like the 3.0 location... did you get the marine clean and metal ready in the mail too?
I've been studying the POR15 system and talking to one of their tech/sales people and getting the lowdown on the product. You definitely need to use those products as part of the prep process for the best results it would seem...

Flash319 · 02-01-2008, 04:44 PM

I didn't get the metal ready this time. I used it before on the back part of the frame and it worked well. The frames more rusty at the front and has a lot more hard places to get at. No matter what I put on it it will rust again. This is not going to be a show truck. They want WAY to much for that stuff. $30 for a little bottle. I will take my chances without it, the rust "etches" it enough

**aviator** · 02-01-2008, 06:03 PM

yeah it did say that rusty surfaces are best... if I understand correctly the metal ready is more for smooth non-rusted metal...
how did you find the coverage with the POR? I mean how did it go on, how much did you end up using?
right now I'm primarily concerned with the floor inside the cab there are a few rusty spots I want to deal with before they become structural issues...
and I want to be sure I have enough but not too much since that stuff is expensive and if I read it right doeas not last long once opened...

kellhammer · 02-02-2008, 05:00 AM

Flash
I've been interested in converting my 89 xtra cab v6 into a diesel as a fun project. I drove it for close to 10 years without hardly a problem. Now the engine is leaking oil at the valve covers. And it get horrible gas mileage.
it's just sitting anyway. Really not worth much to anyone.
I recenlty replaced my 93 4runner's engine with a new v6. So a 1.9 tdi would physically go in ALOT easier in these trucks.
I've been lurking at toyotadiesel.com and I am turned off about having to import an engine. Plus, I saw that episode of extreme 4x4 with the greaser samari. Awesome!
Acme adapters makes a the piece to mate the VW engine to a 22r Auto trans I believe. How do you plan to deal with the electronic injection?
Could you explain you plan to accomplish this build?

Flash319 · 02-02-2008, 08:03 AM

kellhammer,
My 1.9 is not a TDI (direct injection) it is an IDI (indirect injection). This means that the explosion takes place in a pre combustion chamber inside the head, not on top of the piston. The force gets pushed through a cup to the cylinder area. This is how most diesels work until recently.
TDI's, the injectors are right on top of the cylinder and the combustion takes place there like a gas engine. This requires higher fuel pressure and electronic control of the pump.

My injection pump is a standard mechanical style pump with no electrics to make it work, all mechanical. All VW engines (that I know of) up until the TDI was introduced in 95? where like this.

If you go with a TDI you will have to get the computer, wire harness, ignition switch (imobalizer<sp> in the key, no run without the key). Big pain in the ass. You will get more power and better milage though.

This install is NOT easier then a V6 Toyota swap. There is a lot of clearance issues. If you read Zookies thread he mentions that the diesel vibrates a lot with the auto when you put it in gear. Also the torque converter will not take advantage of the diesel torque at low RPM. You will have to make very good mounts for the auto. I am using the stock 22re's.

The 1.9 that I am using was not sold in the US only in Canada. The US was TDI in 95 (from the 1.6 TD idi engine) but Canada still had TD (IDI) 1.9 until 98, engine code AAZ.

Here is the engine on the stand.

01-26-2008, 11:03 AM	#52 (permalink)
nate V Registered User Join Date: Oct 2007 Posts: 391	awsome work im sure it will fit right in there!! I will be cuerous to know what kind of millage you get out of this thing when you are all done. __________________ 1988 Pick-Up / 3.0 / 4:56 / 5 speed / 278k miles "Drive it to hell and back"

01-27-2008, 08:15 AM	#54 (permalink)
aviator Super Moderator Staff Join Date: Mar 2003 Location: COTKU,Ontario,Canada Posts: 5,339	Very clean looking welds Flash... Does anybody know if there are "hop-up" kits for the 1.9/2.0 vw diesels like they make for the big 3 diesels? I suspect there are in europe... __________________ Silver 1994 Hilux Xtra cab 4x4 3.0 K&N cone filter, ported MAF, advanced timing, oversize exhaust, free flow cat, "rumble" muffler custom covered SR5 seats, map lights, factory AC tv4184 style black interior conversion started mods to come... header, custom centre console, stereo upgrade tinted windows Founding member 1972TLC fan club Toyota Hilux... Get in or Get out of the way.

01-28-2008, 07:22 PM	#57 (permalink)
aviator Super Moderator Staff Join Date: Mar 2003 Location: COTKU,Ontario,Canada Posts: 5,339	If the wx is too ugly you can always just work on the POR15 part of the project... the mounts look pretty strong... __________________ Silver 1994 Hilux Xtra cab 4x4 3.0 K&N cone filter, ported MAF, advanced timing, oversize exhaust, free flow cat, "rumble" muffler custom covered SR5 seats, map lights, factory AC tv4184 style black interior conversion started mods to come... header, custom centre console, stereo upgrade tinted windows Founding member 1972TLC fan club Toyota Hilux... Get in or Get out of the way.

01-29-2008, 02:10 PM	#58 (permalink)
nate V Registered User Join Date: Oct 2007 Posts: 391	Flash did you get the engine out yet? Looks like thoes are rugged mounts awesome wielding job too! __________________ 1988 Pick-Up / 3.0 / 4:56 / 5 speed / 278k miles "Drive it to hell and back"

02-01-2008, 08:52 AM	#60 (permalink)
ken.vs.ryu Registered User Join Date: Aug 2004 Posts: 640	I can't wait untill we can have conversion kits. Good luck! __________________ http://ps3mods.blogspot.com - http://kenvsryu.blogspot.com 1992 X-Cab V6 5sp Manual 215k SR5 :D runnin 31x10.5 17.8mpg :)

01-26-2008, 10:52 AM	#51 (permalink)
Flash319 Registered User Join Date: Feb 2006 Location: Barrie, Ontario CANADA Posts: 885	Well I got my passenger side mount welded up today. It was the easier side to do. You can see in the pictures how much shorter the engine is from the 22re. The engine mount is at the front of the diesel block and on the 22re it is in the middle. I am still going to gusset that mount a bit but I am happy with softness of the mount. The trans and engine move very well with the rubber mounts. I might start on the other side tomorrow. Once I get the mounts done I am going to yank the diesel from the car and put it in and see how I did.

01-26-2008, 01:32 PM	#53 (permalink)
82yota Registered User Join Date: Jan 2007 Posts: 273	Oh you have no idea how much I wish I could have had a junk motor like that to play with when doing my mounts. As well as the cab off. I had to weld the mounts in with the motor in place. Stick rods came in handy there as you can bend them. Its looking very nice. I'm curious to see what mileage you get as well. And what other little tweaks you do to it as well.

01-28-2008, 05:05 AM	#55 (permalink)
Flash319 Registered User Join Date: Feb 2006 Location: Barrie, Ontario CANADA Posts: 885	Well I got my drivers side mount almost done. What a pain that one is. It lines up right over the upper A-arm so I have to build up around the arm. It does not look good but I think it will work. I could have dropped it down a bit but then I would have had a hard time getting the diff dropped if I needed too. I will take some pics tonight. Now I have to wire brush the frame down a bit and throw some POR15 on it. Also start pulling the diesel.

01-28-2008, 05:16 PM	#56 (permalink)
Flash319 Registered User Join Date: Feb 2006 Location: Barrie, Ontario CANADA Posts: 885	Okay here is the drivers side. Not a good spot for the mount to end up. I could have moved it forward but then I would have to get rid of the serpintine belt on the diesel as the alternator sits right there. The plate is 3/8 and was bent on a brake. I am going to gusset this side right down the inside of the frame to the top of the dif mount. Here are both mounts. The are offest because of the alternator. The suspention is unload but I think it will be okay with weight and won't hit the mount. I may have to trim the stamped tab on the upper arm. Here is the mount attached. This looks very ugly but will work. Lots of angles and crap. But I managed to pick up 3 holes on the block. This weekend the diesel comes out if I have time and the weather permits. I have to pull it outside. I ordered my Por15 today so everything will look all nice and black soon, don't worry

01-31-2008, 07:09 AM	#59 (permalink)
Flash319 Registered User Join Date: Feb 2006 Location: Barrie, Ontario CANADA Posts: 885	Well I almost got it out last night. It reminded me of why I hate frontwheel drive again. What a bastard. I ended up cutting the CV's and I still can't get the damn thing out. I am going to have to take the whole front of the car off to get it out. That is what the Hays manuals says but I thought I would try without. If you want to do any work on a FWD you have to pull the damn engine out, thus the whole front end. Stupid!!! If the car wasn't in such good shape I would just cut it up. I wire brushed some of the truck frame as well. It is not to bad but I need to take a presure washer to it to really clean it before paint. I should have the engine out this weekend. I have to wash it up and replace the oil pan gasket. I can't wait to set it in the truck!!!

02-01-2008, 09:38 AM	#61 (permalink)
nate V Registered User Join Date: Oct 2007 Posts: 391	Conversion kits for what? this swap? __________________ 1988 Pick-Up / 3.0 / 4:56 / 5 speed / 278k miles "Drive it to hell and back"

02-01-2008, 09:43 AM	#62 (permalink)
Belize Off Road Team Contributing Member Join Date: Apr 2007 Location: Corozal Town, Belize Posts: 2,391	Looks like a fun build! shouldn't be that hard considering in Mexico VW used a Toyota Hilux as their older truck and again in a few years, VW is re-releasing their Diesel truck in Canada/America with a Toyota Hilux Body. __________________ -Phyl 1991 Hilux Surf SSR-G Petrol 3.0L V6 193,000kms l 3.4L V6 264,000kms to be rebuilt then installed! l Rancho RS5000 l 31"x10.50"xR15 Pro Comp Xterrain l K&N Drop in filter l PP 1" Lift Coil Springs l TRD shift knob l Lv. 3 First Aid Kit l White Gauges & Temp Controls l LED conversion l 80/100W Hella H4 l Hella Black Magic l 1st Gen Roll Bar Mod l FT/RR Diff. Breathers l Smittybilt XRC8 Winch l TOYOTA TOUR 2008 トヨタ\|NEVER QUIT

02-01-2008, 11:09 AM	#63 (permalink)
82yota Registered User Join Date: Jan 2007 Posts: 273	Where did you hear they will be offering a Toyota Hilux truck with a diesel in it here in Canada? I am extremely interested in that. Have never heard about that. If you could post a link about it I would really appreciate that.

02-01-2008, 11:15 AM	#64 (permalink)
98sr5tacoma Registered User Join Date: Jan 2007 Posts: 168	http://www.pickuptruck.com/html/news/vw/germanspy.html __________________ 1998 tacoma

02-01-2008, 11:19 AM	#65 (permalink)
98sr5tacoma Registered User Join Date: Jan 2007 Posts: 168	yeah they used a hilux body but it didnt have a jetta engine so it aint that easy __________________ 1998 tacoma

02-01-2008, 12:00 PM	#66 (permalink)
Flash319 Registered User Join Date: Feb 2006 Location: Barrie, Ontario CANADA Posts: 885	I would not say it is easy. I have access to machining equipment and it still takes a bit of work and some hacking. I can't wait to see what happends when I put the body on........... I got that damn engine out last night, what a pain. I have to pull the trans off and clean it up. I got my POR15 in the mail yesterday so I will paint around where the engine is going first then put the engine in the frame to see how it looks. I am going to have to put a remote oil filter system on it as the oil filter/oil to water cooler is in the way of the mount on the drivers side.

02-01-2008, 03:49 PM	#67 (permalink)
aviator Super Moderator Staff Join Date: Mar 2003 Location: COTKU,Ontario,Canada Posts: 5,339	as long as you do it right a remote oil system is a better idea in my book anyway you get a little more of the good stuff in the system and these engineers put the darn thing in the worst places sometimes... like the 3.0 location... did you get the marine clean and metal ready in the mail too? I've been studying the POR15 system and talking to one of their tech/sales people and getting the lowdown on the product. You definitely need to use those products as part of the prep process for the best results it would seem... __________________ Silver 1994 Hilux Xtra cab 4x4 3.0 K&N cone filter, ported MAF, advanced timing, oversize exhaust, free flow cat, "rumble" muffler custom covered SR5 seats, map lights, factory AC tv4184 style black interior conversion started mods to come... header, custom centre console, stereo upgrade tinted windows Founding member 1972TLC fan club Toyota Hilux... Get in or Get out of the way.

02-01-2008, 04:44 PM	#68 (permalink)
Flash319 Registered User Join Date: Feb 2006 Location: Barrie, Ontario CANADA Posts: 885	I didn't get the metal ready this time. I used it before on the back part of the frame and it worked well. The frames more rusty at the front and has a lot more hard places to get at. No matter what I put on it it will rust again. This is not going to be a show truck. They want WAY to much for that stuff. $30 for a little bottle. I will take my chances without it, the rust "etches" it enough

02-01-2008, 06:03 PM	#69 (permalink)
aviator Super Moderator Staff Join Date: Mar 2003 Location: COTKU,Ontario,Canada Posts: 5,339	yeah it did say that rusty surfaces are best... if I understand correctly the metal ready is more for smooth non-rusted metal... how did you find the coverage with the POR? I mean how did it go on, how much did you end up using? right now I'm primarily concerned with the floor inside the cab there are a few rusty spots I want to deal with before they become structural issues... and I want to be sure I have enough but not too much since that stuff is expensive and if I read it right doeas not last long once opened... __________________ Silver 1994 Hilux Xtra cab 4x4 3.0 K&N cone filter, ported MAF, advanced timing, oversize exhaust, free flow cat, "rumble" muffler custom covered SR5 seats, map lights, factory AC tv4184 style black interior conversion started mods to come... header, custom centre console, stereo upgrade tinted windows Founding member 1972TLC fan club Toyota Hilux... Get in or Get out of the way.

02-02-2008, 05:00 AM	#70 (permalink)
kellhammer Registered User Join Date: Feb 2008 Posts: 12	Flash I've been interested in converting my 89 xtra cab v6 into a diesel as a fun project. I drove it for close to 10 years without hardly a problem. Now the engine is leaking oil at the valve covers. And it get horrible gas mileage. it's just sitting anyway. Really not worth much to anyone. I recenlty replaced my 93 4runner's engine with a new v6. So a 1.9 tdi would physically go in ALOT easier in these trucks. I've been lurking at toyotadiesel.com and I am turned off about having to import an engine. Plus, I saw that episode of extreme 4x4 with the greaser samari. Awesome! Acme adapters makes a the piece to mate the VW engine to a 22r Auto trans I believe. How do you plan to deal with the electronic injection? Could you explain you plan to accomplish this build?