Victor

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

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

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

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

just a 22re

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

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

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

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

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

It certainly looks like it "could"...

Rather Diesel

Cool swap.

Roy

82yota

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

Flash319

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

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

double. delete

yotasavg

looks good flash!

Tdubbs05

this is just awesome.

aviator

Depends on the model/year in some cases it was the same harness and some stuff was just capped off (84-88) for the newer trucks (89-95) it seems that they used several different harnesses. In your case everything should be there for the cluster except for the lead for the tach but this was just a wire off the coil/cap I think... mine is going bad when it is cold and damp I get an intermittant signal and the tach starts jumping lol... you might also be missing the oil pressure lead I'm not sure if it was a different sensor with just the idiot light.

Flash319

Thanks Aviator. I will have to rig something for the tach anyway because it will get the signal from the alternator or I will have to add something to the crank. I have the whole harness from the 92 anyway so if I have to I will just cut and paste what I need, which is not much.
I put the oil sender unit on the engine today. I just had to move the oil supply for the turbo over a bit so that it would fit. The Jetta just had a dummy light. It screwed right in with no problem.


I also got my EGT probe in the mail last week so I installed it in the exhaust manifold. This required just drilling and threding a hole. This is nessesary when you do any tuning on a diesel. You must know the exhaust gas temperature or you risk melting stuff (ie head, pistons important things....)
You can see it coming out of the bottom of the manifold in the picture.

yotasavg

i can't wait to hear a sound clip or see a video.

how much tuning are you gonna do? is it for performance or millage ect...?