VW Diesel Build Up - Page 4

nate V · 02-03-2008, 07:41 AM

Sweet job man!!!!

Flash
If you had to choose what year and what model VW would you recommend for a DD application? I am going to be getting a job the requires some traveling and want the best millage i can get with a diesel. As i understand it the early 90's jettas and earlier rabbits for some where around 50-60 mpg. So with your expert opinion what do you recommend?

Flash319 · 02-03-2008, 11:04 AM

Best milage would be the 1.6L Turbo. They were pre 94 I think. That is what that block is that I am using for a template. Same engine as 1.9 but a bit smaller cylinders. The 1.6's go back into the early 80's with a turbo or not. I had a non turbo 86 Golf and that thing was great on fuel but very gutless. Make sure you get a turbo. A early 90's Golf would be the best. I have heard upwards of 50mpg. The Jetta's weigh more so you loose a bit. If you have lots of money then a new TDI golf would be better but cost more to fix and get parts.

nate V · 02-03-2008, 02:00 PM

money???? what money
thanks for the info
what kind of millage were you getting with your 86 gulf?have to check out Craig's list for a gulf with a 1.6 turbo thing ans see what they are going for. Do you know specificially what years the 1.6 turbo were available?

Flash319 · 02-03-2008, 02:11 PM

All of the Jetta/golf/rabbit diesels up to 92 are 1.6L. There are also some 1.5L but I think they are early 80's. After that they are 1.9 TD's or TDI's . I don't know what I was getting with the 86 but it was in the 50's for sure and it was WAY wore out. I was running colored fuel in it as I got it for free

.......

nate V · 02-03-2008, 02:25 PM

anywhere in the 50's is goood with mee

colored fuel....what ever makes smoke right

Victor · 02-04-2008, 07:09 AM

My 1.9 TDi Jetta gets about 48 highway with an auto tranny. This is a very interesting conversion but I think the recommendation for a TD engine (not direct injection) is a good one. Much simpler hookup and there are some good power mods for it out there. If you do figure out how to put a TDi in you can get it chipped. Another advantage not mentioned for the TDi is that it has a variable vane turbo - it can provide more boost at low RPMs to compensate for turbo lag.

Where are you guys mounting your intercoolers? A lot of guys at an Australian site I went to mount it over the stock Toy diesel engine so that they can put a scoop in the hood to directly feed air to the intercooler.

Flash319 · 02-04-2008, 09:29 AM

Spulin81 put his in the front. I think I will put mine there to depending on what size I get. Spulin81 did the TDI. He has a write up on TDIclub.

I have read a lot of problems with the VNT turbos. They stick and stop working. The other thing that I noticed was that the TDI exhaust points down. This causes the turbo to sit very close to the frame and starter. The 1.9 and 1.6 go up giving more room.

My weekend got shot. I got some of the stuff taken off the engine. I am going to clean it up this week and order a oil filter relocation kit from summit. Hope to drop it in this weekend.

Flash319 · 02-07-2008, 03:48 PM

Well I got the engine in today. I had to put the VW trans back on to find TDC. The germans build good stuff but man what a stupid setup that is. The pointer for TDC is on the trans so if you have the engine on a stand you are screwed. I put the trans back on and scribed a mark on teh front pully so I can find it if I have to.

I was worried about the clearance under the pan but it worked out good.

I checked the pan gasket and it was okay but there is still oil getting out on the one side of the engine. I think it is just blowby so I will wait and see how bad it is when it is running.

nate V · 02-07-2008, 04:48 PM

looking good flash keep up the good work !!!!!!

just a 22re · 02-07-2008, 04:53 PM

how did you figure out the clutch set up for this one i dont think i saw it in your right up but man looks real good but tiny lol going to be a gas sipper thats for sure

Flash319 · 02-07-2008, 06:51 PM

Well I mounted the Toyota fly wheel on the VW crank, then just use the regular Toyota clutch assembly. The only other thing is the pilot bushing in the VW crank.

Victor · 02-08-2008, 06:33 AM

Looks really good. When are you going to hook up that one wire and fire it up? I'd love to see a vid of that

**aviator** · 02-08-2008, 08:41 AM

Lookin really good Flash. That POR15 looks like it covered well...

It looks like such an iitty-bitty little engine in there lol... you should paint a sign on the top cover... "The little engine that can."

Flash319 · 02-08-2008, 04:23 PM

Well I will not start it up until I get the cab on so that I have somewhere to mount the rad. As for 1 wire I sort of lied, 2 wires, one for the starter solinoid and one for the fuel cutoff valve

. I guess if I pull start it 1 wire would do!!

Aviator, I will let you know if it "can" or not. I hope so.........

**aviator** · 02-09-2008, 10:14 PM

Quote:

Originally Posted by Flash319

Well I will not start it up until I get the cab on so that I have somewhere to mount the rad. As for 1 wire I sort of lied, 2 wires, one for the starter solinoid and one for the fuel cutoff valve

. I guess if I pull start it 1 wire would do!!

Aviator, I will let you know if it "can" or not. I hope so.........

It certainly looks like it "could"...

Rather Diesel · 02-10-2008, 10:54 AM

Cool swap.

Roy

82yota · 02-13-2008, 01:35 PM

Any updates at all? I'm really interested in seeing how this all plays out.

Flash319 · 02-14-2008, 12:04 PM

I am about to drop the body on. I am just waiting till the weekend for some help. It's heavy. There is a big dent on this side behind the door I have to pull out but the floor and firewall are excellent on this body.

I am also going to have to pull the dash out of the wreaked body because it has a full guage set, this one is just a speedo. Does anyone know how bad of a job that is going to be? Did Toyota use the same harness and just not plug stuff in? Any info would be great.

This body was from a V6 auto so I need to move the clutch assembly as well.

I painted the rest of the frame except for the front part by the power steering. Oil everwhere and I can't pressure wash it as it is way to cold outside. You can see the new pully on the front of the engine. This is for removal of the AC pump and keep the serpintine setup. I don't have it on yet because the alternator may be close to the fender, not sure.

I also got in my oil filter relocation kit from Summit. Looks like it is going to work good. This is the end in the engine then there is a filter assebly that you can bolt anywhere for the filter.

Sosborne · 02-14-2008, 12:55 PM

Quote:

Originally Posted by ken.vs.ryu

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

Tell me about it. I would love to do this swap to my work truck that gets driven 100 miles a day. I've been wanting a diesel in my toyota for a while now. I even have a source for cheap biodiesel.

I just can't weld. Otherwise I would be collecting parts right now.

Sosborne · 02-14-2008, 12:58 PM

double. delete

yotasavg · 02-14-2008, 01:01 PM

looks good flash!

02-03-2008, 07:41 AM	#76 (permalink)
nate V Registered User Join Date: Oct 2007 Posts: 391	Sweet job man!!!! Flash If you had to choose what year and what model VW would you recommend for a DD application? I am going to be getting a job the requires some traveling and want the best millage i can get with a diesel. As i understand it the early 90's jettas and earlier rabbits for some where around 50-60 mpg. So with your expert opinion what do you recommend? __________________ 1988 Pick-Up / 3.0 / 4:56 / 5 speed / 278k miles "Drive it to hell and back"

02-03-2008, 02:00 PM	#78 (permalink)
nate V Registered User Join Date: Oct 2007 Posts: 391	money???? what money thanks for the info what kind of millage were you getting with your 86 gulf?have to check out Craig's list for a gulf with a 1.6 turbo thing ans see what they are going for. Do you know specificially what years the 1.6 turbo were available? __________________ 1988 Pick-Up / 3.0 / 4:56 / 5 speed / 278k miles "Drive it to hell and back" Last edited by nate V : 02-03-2008 at 02:04 PM.

02-03-2008, 02:25 PM	#80 (permalink)
nate V Registered User Join Date: Oct 2007 Posts: 391	anywhere in the 50's is goood with mee colored fuel....what ever makes smoke right __________________ 1988 Pick-Up / 3.0 / 4:56 / 5 speed / 278k miles "Drive it to hell and back"

02-04-2008, 07:09 AM	#81 (permalink)
Victor Registered User Join Date: Jan 2003 Location: El Paso, TX Posts: 1,723	My 1.9 TDi Jetta gets about 48 highway with an auto tranny. This is a very interesting conversion but I think the recommendation for a TD engine (not direct injection) is a good one. Much simpler hookup and there are some good power mods for it out there. If you do figure out how to put a TDi in you can get it chipped. Another advantage not mentioned for the TDi is that it has a variable vane turbo - it can provide more boost at low RPMs to compensate for turbo lag. Where are you guys mounting your intercoolers? A lot of guys at an Australian site I went to mount it over the stock Toy diesel engine so that they can put a scoop in the hood to directly feed air to the intercooler. __________________ "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.

02-07-2008, 04:48 PM	#84 (permalink)
nate V Registered User Join Date: Oct 2007 Posts: 391	looking good flash keep up the good work !!!!!! __________________ 1988 Pick-Up / 3.0 / 4:56 / 5 speed / 278k miles "Drive it to hell and back"

02-03-2008, 11:04 AM	#77 (permalink)
Flash319 Registered User Join Date: Feb 2006 Location: Barrie, Ontario CANADA Posts: 885	Best milage would be the 1.6L Turbo. They were pre 94 I think. That is what that block is that I am using for a template. Same engine as 1.9 but a bit smaller cylinders. The 1.6's go back into the early 80's with a turbo or not. I had a non turbo 86 Golf and that thing was great on fuel but very gutless. Make sure you get a turbo. A early 90's Golf would be the best. I have heard upwards of 50mpg. The Jetta's weigh more so you loose a bit. If you have lots of money then a new TDI golf would be better but cost more to fix and get parts.

02-03-2008, 02:11 PM	#79 (permalink)
Flash319 Registered User Join Date: Feb 2006 Location: Barrie, Ontario CANADA Posts: 885	All of the Jetta/golf/rabbit diesels up to 92 are 1.6L. There are also some 1.5L but I think they are early 80's. After that they are 1.9 TD's or TDI's . I don't know what I was getting with the 86 but it was in the 50's for sure and it was WAY wore out. I was running colored fuel in it as I got it for free .......

02-04-2008, 09:29 AM	#82 (permalink)
Flash319 Registered User Join Date: Feb 2006 Location: Barrie, Ontario CANADA Posts: 885	Spulin81 put his in the front. I think I will put mine there to depending on what size I get. Spulin81 did the TDI. He has a write up on TDIclub. I have read a lot of problems with the VNT turbos. They stick and stop working. The other thing that I noticed was that the TDI exhaust points down. This causes the turbo to sit very close to the frame and starter. The 1.9 and 1.6 go up giving more room. My weekend got shot. I got some of the stuff taken off the engine. I am going to clean it up this week and order a oil filter relocation kit from summit. Hope to drop it in this weekend.

02-07-2008, 03:48 PM	#83 (permalink)
Flash319 Registered User Join Date: Feb 2006 Location: Barrie, Ontario CANADA Posts: 885	Well I got the engine in today. I had to put the VW trans back on to find TDC. The germans build good stuff but man what a stupid setup that is. The pointer for TDC is on the trans so if you have the engine on a stand you are screwed. I put the trans back on and scribed a mark on teh front pully so I can find it if I have to. I was worried about the clearance under the pan but it worked out good. I checked the pan gasket and it was okay but there is still oil getting out on the one side of the engine. I think it is just blowby so I will wait and see how bad it is when it is running.

02-07-2008, 06:51 PM	#86 (permalink)
Flash319 Registered User Join Date: Feb 2006 Location: Barrie, Ontario CANADA Posts: 885	Well I mounted the Toyota fly wheel on the VW crank, then just use the regular Toyota clutch assembly. The only other thing is the pilot bushing in the VW crank.

02-08-2008, 06:33 AM	#87 (permalink)
Victor Registered User Join Date: Jan 2003 Location: El Paso, TX Posts: 1,723	Looks really good. When are you going to hook up that one wire and fire it up? I'd love to see a vid of that __________________ "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.

02-08-2008, 08:41 AM	#88 (permalink)
aviator Super Moderator Staff Join Date: Mar 2003 Location: COTKU,Ontario,Canada Posts: 5,339	Lookin really good Flash. That POR15 looks like it covered well... It looks like such an iitty-bitty little engine in there lol... you should paint a sign on the top cover... "The little engine that can." __________________ 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.

02-08-2008, 04:23 PM	#89 (permalink)
Flash319 Registered User Join Date: Feb 2006 Location: Barrie, Ontario CANADA Posts: 885	Well I will not start it up until I get the cab on so that I have somewhere to mount the rad. As for 1 wire I sort of lied, 2 wires, one for the starter solinoid and one for the fuel cutoff valve . I guess if I pull start it 1 wire would do!! Aviator, I will let you know if it "can" or not. I hope so.........

02-10-2008, 10:54 AM	#91 (permalink)
Rather Diesel Registered User Join Date: Mar 2006 Location: Maryland Posts: 184	Cool swap. Roy

02-13-2008, 01:35 PM	#92 (permalink)
82yota Registered User Join Date: Jan 2007 Posts: 273	Any updates at all? I'm really interested in seeing how this all plays out.

02-14-2008, 12:58 PM	#95 (permalink)
Sosborne Registered User Join Date: May 2004 Location: Rochester, NY Posts: 100	double. delete __________________ A free people ought not only to be armed and disciplined but they should have sufficient arms and ammunition to maintain a status of independence from any who might attempt to abuse them G.Washington

02-14-2008, 12:04 PM	#93 (permalink)
Flash319 Registered User Join Date: Feb 2006 Location: Barrie, Ontario CANADA Posts: 885	I am about to drop the body on. I am just waiting till the weekend for some help. It's heavy. There is a big dent on this side behind the door I have to pull out but the floor and firewall are excellent on this body. I am also going to have to pull the dash out of the wreaked body because it has a full guage set, this one is just a speedo. Does anyone know how bad of a job that is going to be? Did Toyota use the same harness and just not plug stuff in? Any info would be great. This body was from a V6 auto so I need to move the clutch assembly as well. I painted the rest of the frame except for the front part by the power steering. Oil everwhere and I can't pressure wash it as it is way to cold outside. You can see the new pully on the front of the engine. This is for removal of the AC pump and keep the serpintine setup. I don't have it on yet because the alternator may be close to the fender, not sure. I also got in my oil filter relocation kit from Summit. Looks like it is going to work good. This is the end in the engine then there is a filter assebly that you can bolt anywhere for the filter. Last edited by Flash319 : 02-14-2008 at 12:08 PM.

02-14-2008, 01:01 PM	#96 (permalink)
yotasavg Registered User Join Date: Jan 2007 Location: Chico Republic, NOR*CAL Posts: 1,527	looks good flash!