Well folks, Guess it's about time to start my thread; theoretical parts are done, most of the 'junk' needed is sitting in the garage... Time for the thread to begin...

Starting point - 87 4runner, 22RE/A340:

Previous build thread here:
https://www.yotatech.com/forums/f116...r-back-126003/
Blew #3 (spit out the rings), did a half ass rebuild to get through this wheeling season, didn't work so good - got about a hundred km on the 'patch' - the donor jetta magically appeared... And thus the decent into madness has begun...

Donor - 91 vw 1.6td jetta


Keeping the A340 transmission (this will be the big difference with the other swaps), by use of a Jeep AW4 TCU (same as a340) and will retrofit the Jeep TPS to the VW IP (somehow).

Currently talking to Gilles of VW diesel fame - sorting out some of the last details, was going to go with a Toyota filter (with heater) but the Statadyne is more easily found in North America - so...

Still thinking my way through the fuel pressure issue, want to keep the toyota pump - just need to find an appropriate regulator to drop to the 5psi needed for the vw IP.

Stay tuned for the continuing decent into madness...

 

Getting ready for a few engine pulls this weekend Pulling the 1.6TD (after it gets re-timed and started), pulling the 22re and just for fun, going to squeeze some time for a engine/transmission re&re on the 90 jetta (came with the 91) to get that beast running (then I can start looking at it's electrical nightmares) as a backup vehicle...

Still stuck on some of the swap details; looking for a regulator to bring the in tank toyota pump down to 5psi for the VW - looks like I'm after a "bypass fuel regulator" but I'm sure as heck not spending 400$ on the holley that the local shops are trying to sell me... And fleabay isn't providing me a solution that fits the budget (~50$ sounds good to me). Could always just pull the fuse on the Toyota pump and run the stock VW mechanical pump, but - the toyota one is there, would be very nice to use it (and not have to add a manual hand pump for priming). The cheap little manual fuel regulators that fit the budget will probably burn out the toyota pump - even worse it makes the pump howl like a cat in heat (as I confirmed last night).

Eyeballing options on the oil filters; seriously considering going with the amsoil bypass (BK309) remote filter setup - full flow + a 2 micron oil filter... 75$usd for the bypass filter plate, bit spendier than I'd like, and not a big fan of the amsoil brand (know a few too many of their sales people who come across like used car/snake oil salesmen). But the 2 micron filtration would be nice...

 

Subscribed !!

 

Well... 12 hours of fudging around, repaired a few damaged diesel lines, a couple gallons of diesel & a can of seafoam to deal with the varnish from sitting (think the solenoid was stuck for the first few hours of trying... ).



It's Alive! Sounds a little more diesely than it should be - will have to give it a going through/over once removed; test reveal bad glow plugs, IP has been fudged around with; dont even want to know why there's black chunks coming out the exhaust... Tons of black/grey smoke at idle isn't a good sign - seems like the smoke screw's been cranked... Good excuse to talk more to giles about a rebuild I guess

Also found my step down regulator from another yota nut - used to swap a 22R into where a 22RE existed. Meanwhile the VW had an electric pump plumbed in line - at first I was thinking fuel filter w/ water warning - but no... Might come in handy.

Will have to run to PYP this weekend see if I can't find the cherokee TCU,TPS and harness...

Onto step two - remove 22RE The descent into madness continues...

 

I will admit that I am rather new to the yota seen
but ive been playing with VW's for near 10 years and 20+ cars

This is going to be GREAT!
as I have been thinking out a 1.9TDI (ALH) swap for my 22re
just dont know about bellhousing/clutch fitment
Ill give you as much info as I can as far as the VW parts go...
and I have more then any one person should have................


HOW are you adapting the VW bolt pattern to the yota tranz?
and
What clutch parts are you using (if u dont mind!!)
thanks

 

http://www.bahnbrenner.com/vw_audi/c...ler_Misc_Parts

Oil filter flange/cooler parts

 

Thanks for the link, got the remote adapter - just trying to decide if I want run a dual bypass - a regular full flow + a 2 micron bypass filter; seems like a smrt idea...

Never wrench when angry, was on the creeper sunday fighting with the engine-transmission bolts on the 22RE, grabbed the frame and yanked myself back under... Knee right into the cross member - dislocated the patella (not the first time by any means) spent today dealing with those medical types... That pretty much screwed my weekend plans at that point...

Andy

 

See the other VW swap thread - believe it's page 7 for the adapter drawings... I'm not using a clutch - automatic in mine, but still using the toyota flywheel redrilled to fit the VW funky bolt pattern...

 

Finishing up pulling an engine while in a zimmer splint - sucks... but...



Should have known I'd run into a few more differences... Toyota uses a funky torque converter - note the nice alignment tab into the crank... Hope this wont cause a problem - worst case I suppose I could just lop it off; chev/ford don't use these; though it makes sense, saves wear on that input bearing...

 

I have a 2wd pickup that I put a 1.6 TD in with an automatic. The power was not bad but it was a fresh rebuild with a performance injector pump and injectors. My truck is light and has stock 25" tires. I am a little concerned how your toyota will perform with the added weight and larger tires. How are you going to control the shifting? I used the 2wd auto so there was no wiring involved. I am currently swapping in a 5-speed.

 

cool man, good to see some VW diesel power on the boards....please take lots of pictures.
cheers

 

Yeah, i'm not too worried about power; we figure we can squeeze more HP out of this engine than the 22RE put out - and I was happy with that...

Shifting the auto - easy peasy, TCU & TPS from an XJ same controls as the a340 - just need to retrofit the tps to the IP - not that difficult.

Lots of pictures to come; just need the knee to recover and co-operate so I can get some work done in the garage...

 

VW diesel is finally hanging on the hoist in the garage... And greyhound called today... Engine adapter plates magically appeared

Yes I said plates (plural) not cheap like last time - but cut correctly this time; albeit some finishing required (all holes were drilled at .25", so I can bore out/countersink to correct size)

 

a 1.6L TDI
with the right VNT turbo
bigger pump
injectors
and some spring tension games
that "little" diesel is good for 180-200 ish HP
and round out to near 320 lb ft

few more links for ya
http://www.tdiclub.com/
http://www.dieselgeek.com/servlet/StoreFront
http://www.zdmak.com/http://www.partsplaceinc.com/

 

resurrecting this from the dead...any updates?

 

I would like to know more also

 

Been a busy year unfortunately... Just haven't had that much time to plug away at it...

Got a bit done on the engine mounts (might have a mulligan and rework the drivers side again), got the TPS mount mostly done - but slightly worried about needing to change it or add some gearing - throw on the VW is less than the XJ's; need to sit down and look at whether I can swap in a different make/model TPS with a similar throw/values or what I need to do...

 

G'day all,

Plugging away at the swap still...

Here's what I'm wondering about today - VW spacer laid on toyota flywheel:



Tempted to have someone CNC a 5mm plate with the proper bolt pattern and weld it on to the flywheel then drill/ream as needed

I know others have just rotated the bolt holes and redrilled leaving the old toyota holes in between - but I'd think that weakens the flywheel a bit too much; and there's some overlap when I play around with that layout...

Thoughts/suggestions?

Andy

 

So... Then I get the 1.6TD pulled out of the corner, and decide to have a look at how bad the head is...



I have one friend - who insists I've photoshopped that... because all VW 1.6 heads have massive cracks between the valves... Finally! We have 1 good piece from the donor engine!

 

Sorry to bring this old thread back up, but I'm looking at doing a nearly identical swap (1.9 VW engine and AW4 tranny) and was hoping you could share some more details about fitting the engine up with the transmission. I see you were working on getting the flywheel to match the pattern of the VW engine...how did you finally accomplish that?