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85 4runner VW 1.9 AFN M-TDI swap

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Old 03-22-2011, 07:18 PM   #1
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85 4runner VW 1.9 AFN M-TDI swap

This is an 85 4runner, got sick of the underpowered 22re in it that had like 90hp and got 14mpg- I could get better with a v8. This build will be my daily driver and commuter.. I will not drive a car but I want something that gets around 30 mpg with decent power. With an intercooler, and some larger injectors I will be running around 120-130 HP and upwards of 200 ftlbs of torque, and double my MPG.

This swap will be made easy with the:
-1900 mk3 afn tdi @ 110hp
-m-tdi turbo pump conversion from emiata.com,
-acme adapters toyota swap kit and sidekick motor mounts
-I will also be replacing and relocating the stock fuel tank for a larger one that will go above the rear axle
-rebuilding my front axle
-replacing my narrow rear axle with a wide track
-bobbing the rear about 13.75 inches

Funds will dictate these additions at a later date:
-hi-steer conversion
-installing longfield superaxles/ hub gears.
-marlin doubler and an attempt at a flatbelly
-bumpers and exo

And so it begins...
Been looing at this swap for a few years and its finally under way- made some small progress tonight but need some more bolts so will need to continue tomarrow.

Pulling the 22re
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Picked up my new 1.9 from quality german autoparts
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Bolting up the acme adapter
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fitting the motor mounts and changing out the oil filter mount
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The motor mount holes I need are a little rusted, might need to rethread them.. going to pbb them and see what happens.
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cant remember what the heck this is for? bearing of some sort... anyone have a clue?
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Had to stop for the night because I need bolts.. tomarrow morning I will be at the local fasteners to get what I need, then I will finish bolting on the oil filter adapter, motor mounts, clutch, and transmission/ transfer case. I will be changing out the water pump just for good measure. Then the engine will go in for its first test fit so I can design the frame side motor mounts. Once fabricated I will work on the exhaust plumbing, wiring, fuel tank, and intercooler / radiator plumbing.

At this point I am pretty much stuck waiting for my m-tdi pump, its almost a month late.

Enjoy the build!
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Old 03-22-2011, 07:28 PM   #2
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Super cool, , i'm looking forward to seeing your progress. Good Luck
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Old 03-22-2011, 07:40 PM   #3
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thanks haha this time Ill try not to burn it down when Im finished.
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Old 03-22-2011, 08:15 PM   #4
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Subscribed, for sure! This looks like it has the potential to rock. Get to work!
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Old 03-24-2011, 09:11 AM   #5
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posted this up for some questions the pirate4x4 guys were asking, thought Id share it here too because it is good info.

Jeff at acme adapters send you an oilite bushing, his kit is pretty damn good, makes it all easy and Ive got to say, his customer service thus far is hands down the best Ive ever had. I feel like hes helping me with the build like my mentor and hes been great help keeping me going in the right direction- he knows these swaps so well from doing it in samurais, that he can talk you through anything over the phone pretty efficiently.

So the engine cost about 2600 bucks plus shipping. I also bought a few parts from him, like the water pump and idler arm bearing, and a tensioner. The guy charges more for ac and per engine and turbo type. Obviously more power = more money. He also charges more for the lower mileage engines. You can make this cost a whole lot less by going with a pre-96 engine with 90hp.

The stuff I got from acme is priced on his website. I got the fuel filter and bracket, adapter plate, flywheel, oillite bushing, angled oil filter bracket, oil filter, diesel cap, and motor mounts.

I bought the m-tdi conversion from emiata for 300 bucks give or take.. this guy said he had some issues at his shop that made him put off my pump, then messed up the shipping and my parts are late. He didnt offer to refund the shipping and the customer service was mediocre. I also purchased injectors and a tool set from him to setup my timing on my engine. He charges a large core charge. I will say that this conversion will give you less possible power from your engine, but t is easily made up with a nice intercooler and nice injectors. The other option is to actually deal with the VW wiring harness and computer which I didnt really look forward to doing, or buy the pump from Germany for about 1200 bucks. This emiata guy from what I can tell has the market cornered in the US so if you plan on using him, plan waaaay ahead because time and customer service is not really his concern.

I am running 4:10 gears and 33 inch tires.. from what Ive heard it seems to do ok, but I dont want to pay for gears until I see how it drives. Ill definately be posting more on this once I get this truck on the road.

Yesterday I made some progress, I wont bother posting pics just yet but I am ready to put on the clutch and transmission and test fit the engine. I had to cut my time short because a friend I know with a rabbit blew a headgasket and was offering to teach me how to setup the timing on a vw diesel. I highly recommend anyone who gets one of these engines (vw diesel) to get the manual for it, there is a few steps and unless you are very familiar with the process you can really screw up your engine. I also learned what "interferance motor" means... if you lose your timing belt you will screw up your motor bad. The timing belt can break pretty easily.. the mechanics I have been talking to have told me that any water, oil, rocks, bark or wood, ect will break it so I have to come up with some sort of plan to protect it, and I will not be doing any water crossings haha. I got out there with a tape yesterday and did a little more measuring, the engine hight is going to be close to fit under the hood, making an attemt at a flat belley difficult at best. When I get out there today Ill be sure to put p pics of the test fit and any clearance issues I forsee. I am going to route the intercooler hoses (they are both passenger side top of motor, running toward the firewall) back to the front and down the side of the engine up near the battery. The intercooler is going to be about 24x8x3, both hoses on the passenger side. I may be trimming some metal from the grill to fit hoses on the passenger side. I will route the exhaust under the transmission over to the drivers side of the truck- all the heat shield is on that side and it is a small exhaust pipe so there wont be any clearance issues with my mild lift. I am going to try very hard not to use a body lift, I hate them, but a small one might be necessary- well see how it goes. I measured out an area for a new gas tank, it will be around 30x28x8, but I am actually hoping for something a tiny bit shorter than 8 inches.. maybe 6 inces- I want plenty of clearance at the rear diff. I bought the motor with an ac pump thinking I was going to turn it into a air compressor but after doing a little research, the pump will not work because it is coolant lubricated and doesnt really put out enough volume. I will be doing a little research to find out how difficult it will be to put a york out of an old dodge into it instead. Ill try to put up pics tonight.
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Old 03-24-2011, 09:47 AM   #6
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Old 03-24-2011, 09:27 PM   #7
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Allright made some decent progress today, I installed my clutch, finished hooking up my oil filter bracket, bolted on the transmission, and put the engine into the engine bay. Taking a day off tomarrow but hitting it hard all weekend long, starting by fabbing motor mounts on saturday, putting in the new tensioner and water pump, and finally timing the beast. I went to attach my transfer case and found that the upper bearing had stress cracks spidering out through it so I am going to pick one up tomarrow, along with a starter. Hopefully I will recieve my injection pump tomarrow, and I am crossing my fingers on a gas tank and intercooler on monday. The new wheels will be here on monday as well, going to get them mounted and on the 4runner that day. Will try to get all the plumbing and wiring done next week and set up the timing.
Clutch installed, mounts and oil filter bracket on
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fractured transfer case
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Mounted the transmission
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Gap will be filled in with inspection plate (fabricated)
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Motor in the bay
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Needs to come back a little more...
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Old 03-25-2011, 08:40 PM   #8
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I went and picked up another transfer case today and peeled off the gasket to find nearly identicle cracks in it, only less pronounced. I guess this is common for these transfer cases?

EDIT** I guess they are just casting marks haha.

Last edited by Hardstripe; 03-25-2011 at 09:34 PM.
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Old 03-26-2011, 10:40 PM   #9
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Today I made very good progress, allthough I didnt work on what I was planning. One of the more difficult challenges of doing this swap was figuring out a way to time it since I am not using a volkswagon transmission or even own one. The volkswagon flywheel is marked with a timing mark and the transmission has a sight wondow that allows you to align the mark with a mark on the sight window on top of the bellhousing to find "top dead center" or tdc. This is when both the first and last piston is at maximum hight. With no transmission, timing this engine is basically impossible, so I needed to figure out a way to be able to time it without the stock tranny. I figured that if I were to transfer the mark from the volkswagon flywheel to my toyota flywheel, then put the transmission into tdc I could make a reference point for timing it in the future. I didnt make a sight window, and I will have to pull the transmission to time it, but overall I am very pleased with the design I came up with. I used an old jack handle that was just a piece of flexible metal bent into a cylindar, widened it, then tacked on an old alan wrench to se as a pointer, pointing to the timing mark on th eflywheel from a bolt on the adapter.
Next I swapped out the water pump, installed the new injector pump, put on the new tensioner and idler arm, then set the timing and inector timing. I have no idea what to set the injector timing to.. most VW turbo diesels run from 100-110 but for this engine it is set by computer, and since I have eliminated the computer, I cant really set the injector timind, so I just set it to 105 and will see how it goes in the future.. hopefully I can find more info to verify before I try to turn the motor over. Worst case scenario, it will run like ass and Ill need to adjust it.
Here I found 5 long bolts to line up the vw flywheel and the toyota flywheel
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I marked out the position with a sharpe
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I made a new mark on the yota flywheel with an old chisel I didnt care about ruining
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Worked like a champ
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Here is my ghetto fab timing tool
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Setting timing
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all my new goodies on and timing set
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Some close ups of the M-TDI pump
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A pic of underneath my valve cover
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Old 03-28-2011, 09:31 PM   #10
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OK so after booty fabbing this beautiful timing tool, I started thinking about slinging this beast into my truck once again to get some measurements and to find out what fits.
Here it is all bolted together again, this time with the transfer case on it.
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Took out some extra crap I didnt need
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Here is a shot of the transmission offset, after some measurements with my digi angle finder it looks like its clocked 5 degrees left.
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Fiddled with the engine a bit, couldnt get it to fit far enough back into the tranny tunnel, my shifters wouldnt line up. After poking around I saw the culprit... This is a coolant line coming out of the rear of the block with some glowplugs.. I believe are related to the EGR.. I wont need these anymore, so I will be blocking this off with a plate and running my heater off the main radiator line out of the side of the block.
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Rear of block with no wiring and plumbing
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After taking off the extra parts, it fits perfect
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Then I threw on the alternater and AC, the AC doesnt fit.. I will be ordering a few parts to eliminate the AC and may consider running something off the other side of the engine for a air compressor at a later date. I ripped these part numbers from the tdiclub website.
The non-AC water pump pulley for a 1Z/AHU is PN 028 121 031K
(this is also a VR6 water pump pulley).
The shorter serpentine belt is PN 028 803 137BB
The power steering v-belt is 12 x 685 - I believe the PN is 028903137BB.
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Here is a pic from TDIClub website of what my setup will look like
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Ill be hitting it hard again on wed thurs and friday, am going to fab the design I came up with for motor mounts and get this thing in there solid. I am using the stock cross member for now until I can afford a clocked doubler adapter. My pulleys and intercooler, along with associated plumbing will be here next monday. Once I get it in, while I wait for intercooler stuff I will attempt to hook up the throttle cable, a cold start cable, the fuel lines, and vacuums. I decided for now I am going to run the stock fuel tank until I can afford an aftermarket application, so I will drain this tank and pull out the fuel pump, then run custom lines. I also need to take my PS hoses down to the house of hose and get them to make me a custom one. One thing I am worried about is the VW PS runs with a mineral oil, where as the toyota setup runs on dexron powersteering fluid. A couple people have assured me that it will be fine but hey I can still worry cant I? I also need to find a hard elbow for the lower water pump outlet that is about a half inch shorter, the one this engine came with is too long and hits my motor mount.
I called emiata today and asked about the throttle cable brackets, they forgot to include them and sent me one right out. They also included sent some instructions they forgot to put in my package too. I picked their brain a little because I couldnt find anything online for setting the M-TDI injection timing, and they told me to set it at 150. This seems a little high to me, so I am a little worried.. anyone have any experience here, maybe some insight?
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Old 03-29-2011, 12:55 PM   #11
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run iso 32 hyd oil in it, i would
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Old 03-31-2011, 07:29 PM   #12
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Bitchin' job, hardstripe. I salute your ingenuity.
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Old 04-01-2011, 07:49 AM   #13
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Good work and good research....

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Old 04-01-2011, 08:22 AM   #14
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love your toy she will love u too
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Old 04-04-2011, 07:56 PM   #15
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Thanks guys.. was supposed to pickup the rest of my parts today and alot of stuff didnt show up... I may go pickup what did show up tomarrow, but I am disgusted right now. Seems like alot of distributors within the automotive field are having a tuff time filling orders correctly and keeping their shelves stocked.
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Old 04-13-2011, 02:03 PM   #16
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Nice work.
What angle are you running the engine at?

Does the A/C not fit because of the Diff? If so do you think a body lift or solid axle swap would help?
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Old 05-01-2011, 07:25 PM   #17
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Any updates???
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Old 06-11-2011, 08:28 AM   #18
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ya, fill us in - wheres this thing stand? Great work so far!
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Old 06-12-2011, 03:50 PM   #19
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Hey guys sorry for the long wait.. school has been keeping me busy, but I hope to be finishing this project this month. I have had time to do a little fiddling here and there but havent posted anything just yet, look for more pics soon. I found the actual part number for the correct water pump belt pulley and made covers for my egr and rear water outlet. I also installed a new starter and put on the oil filter... details of all the issues I ran into and how I worked around them will be forthcoming.

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Old 07-09-2011, 06:47 PM   #20
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well guys i have a couple of months of progress saved on my evo 4g phone but cant seem to get them off of it... grrr
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