djtc

Hello everybody, my is Dimitrios and since I have a swapped Toyota pickup I thought I would create a thread about my project among others.

Deatails about the truck
1990 toyota pickup (originally v6)
xtra cab (originally red)
4.56 gears
stock suspension
now has a w56 5speed
1.9 vw TD AAZ mechanically injected (being swapped for newer tdi with mechanical Landrover 300tdi pump+mods)

So I bought this truck from a "Toyota expert" in southern Ontario Canada already swapped with an aaz for a ridiculously high price (my fault).Anyhow after going over the truck at home I had found out that the guy that did the swap should probably not ever do another one of these conversions. As an example, my starter almost fell off, the exhaust all 2.5" stainless piping with nails used as exhaust hangers, clutch slave bolts finger tight, coolant leaking, motor mounts were barely welded and many other little nick knacks.

When I picked it up (6hrs away from home)





Before buying the truck I had bought an ahu(tdi) complete but without tranny locally to have in case I found a nice pickup that was not swapped. After driving the aaz powered truck for about 1 month I found that it was relatively under powered even with the 4.56 gears and 31" tires. Fast forward to last week, the clutch on the truck was acting really weird and I thought best bet would be to pull the motor out and swap in the ahu with a new clutch set-up.

Although she was able to pull a chopped up Porsche 944 turbo chassis (not so heavy)


I then ordered a land rover 300tdi IP , intercooler ,piping, various gaskets and seals, timing belt kit, .216 veg nozzles and the necessary vdo boost and egt gauges.

I then started to do my research on clutches that would suit my needs. Roughly 200ft/lb of torque running 4.56 gear and 33" + off-roading every 2nd week. I needed something tough. I then found out through a tdiclub member that the late 22re flywheels can be machined to accept the 5vz clutch which is around 9 3/4" diameter v.s the 9 1/4" for the late 22re style. So I then ordered a new flywheel and an aisin ckt-040 clutch kit.

djtc

this past week I received all the parts and I also had the flywheel machined to accommodate the larger disk and also had the flywheel re drilled.

Land rover 300tdi pump
With Ahu sprocket

Could not find a pilot bearing from 12 Id to 21od so I had to order 2 of each ( 12id-15od /15id-21od)


New Flywheel before

After

With new clutch disc


Motor removal


Messy wiring job


This is why the clutch did not feel right..

Comparison between new and old flywheel with the botch "redrill"

djtc

Remember those mounts I mentioned earlier..

Full beads ?don't need that! ( not to mention that the plate that bolts on to the motor is only 1/8" thick and relies on 2x 12mm bolts..)

Because of these awesome mounts I get to keep the Toyota PS pump and Alternator(even though it is weaker than the vw )

Also got her some new meats


That's about where I am at right now.For some reason the modified pan that he made hits the modified oil pickup when installed on the ahu...makes no sense to me.You'll have to see this oil pan, another amazing creation!

I also have to pickup a bigger k14 turbo+manifold, install new timing belt,pump and nozzles.Hopefully she'll be back on the road next week.

wamabama88

Do you have the specs for the flywheel type and spacing between the redrill and where did you get the pilot bearings

Jimmyjohn

You have any pics of the oil pan? This looks like a daunting project.

space-junk

iTrader: (1)

Djtc hasn't been active on the forum in over a year.