nate V

Conversion kits for what? this swap?

Belize Off Road Team

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

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

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

98sr5tacoma

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

Flash319

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

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

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

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

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

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.







Aviator,
The POR15 goes on good. It is very thin and runny so it covers very good. When it dries it gets thick. Cool stuff. It goes a long way. You are sopose to do 2 coats. I did one and I can see some rust dots in it as it comes through. I am going to do 2 coats this time. This stuff would be perfect for the floor of the cab. Put on thick and it would last a long time.

yotasavg

great progress!

Spulen81

Nice build!
Just to clarify TDIs had immobilizers after 99.5. Earlier ones do not require the ign. switch, cluster, etc. Also the immobilizer can be defeated with a chip. You can run TDIs mechanical also if you want with a special pump.

Flash319

SPulen81, I see you have a TDI in a 4runner. How is it for power and milage? Do you have any pictures?

Spulen81

These are old pics but all I have really. I "finished" the swap in November of '06. I have over 15k on it now. Right now I get about 29mpg, in the summer I was getting 32mpg mixed. This is with 4.10s and 32s. I have a nozzle upgrade but its stock otherwise. Its got around 200lb/ft of torque so it moves the truck along much better than the 22re or 3.0 IMO.

nate V

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

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

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

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

anywhere in the 50's is goood with mee
colored fuel....what ever makes smoke right