After reading your thread, I to plan on doing this conversion. I have a 1993 4cyl 4x4 extra cab and I just picked up a 1997 TD Jetta for this project.I had a few questions:

1- Did you use the VW accelerator pedal or cable?
2- For the power steering lines, did you get new ones made or did you modify the vw ones?
3- What kind of mods if any did you do to the injection pump?

Oh ya, Excellent work!, I found your thread to be very informative.

 

I cut the Toyota cable down and just used it. You can see in this picture a bit. I used the end off the VW that attaches to the pump then made a collar with some set screws that hold the 2 cables together.


I went to a hydraulic place and had them make me a hose for the steering. I used the bottom bango fitting that came on the VW then a compresion fitting to a new hose. If you plan right (I didn't) you may be able to use the toyota presure line and just get a compression fitting to the steel VW line.

As for mods I put on a EGT guage for starters. Make sure you do this because it is easy to get hot, also easier to put the probe in before the engine is in. I then changed the aneroid pin to a 1.6 and cranked in the max fuel screw about 1 turn. I also backed the wastegate off to allow for about 14psi peak boost.

YOu have to watch it with the max fuel screw. At first I had it where if I floored it or was climbing a hill I could fly right past 1400F EGT which is bad. You won't know this without a guage.

 

This build looks awesome and I wish you the best of luck. The only thing I would consider doing different is mating two of these engines in a mid engine configuration, but I have no idea how you would do the 4x4 with that. Of course the bed would be useless

 

https://www.yotatech.com/forums/f116...pickup-143387/

Here is an AWSOME example of mid engine truck : ) I know I've enjoyed this build! And look forward to seeing it run! : )

Enjoy!!

And again, Great Job with your conversion! I'm jealous and would like to do something similar. Keep up the great work!

 

sweetness my friend sweetness

 

So what's the coldest you've started it in and what did you do to help it (block heater, coolant heater, etc). Still looking at a VW diesel as the way to go, but not sure it can start in the -38C (before wind chill) here. Also wondering about heat in the cabin...

Thanks

 

my toyota diesel starts in-40 wind chill...
i just glow it for 30 seconds and it starts everytime..

this would be a great swap for a trail rig.. i love diesels now and i always look for vw donor cars!

 

This setup is for sale. I need a vehicle that I can drive all year round. I am putting the 22re back in. Will sell the whole setup for $1200 obo.

 

i seen your engine on kijiji...
why cant you drive this year round?

 

Doesn't start very good when it is cold. It will start but you have to crank and heat, crank and heat. I just want the love of my life back, 22re. The engine runs very good other then getting it going when cold.

 

Not for nothing Flash but is that with having the truck plugged in all night?

I thought the VW's were better then that...

 

That is pretty sad. Are you sure all the glow stuff is working fine on it? My 1kz-te will start at -40 without a plug in. Takes about 5 seconds of cranking till shes rolling over fast enough to run on its own but I've never had a problem. Plug it in and off it goes like its summer. Are all VW cars like this? If you why are there so many driving around in the winter?
Sad to see all this work to be just taken out again. One thing a fellow on the toyotadiesel forums did with his 2L was he took a grid heater from a Dodge and put in the intake. He said it makes a big difference. Also do you have winter oil in it? Full synthetic 5W40 makes a massive difference in the cold. As does having 2 875 CCA batterys.

 

2 my 2lte yota diesel will start noproblems sometimes i let it glow 20 seconds but she always fire right up... but i also have 2 battiers and running 0w40 synthetic for the winter

 

our vw tdi starts great in the winter...rougher, for sure, but still great. had a snap of -30F and didn't have a problem. once i had to glow it twice. we dont plug ours in because we live in an apartment.

sounds like something is up with your motor, like the glows arent working right. its so tough to diagnose these things in the dead of winter when its butt cold to work outside, but a multi-meter will tell you a lot on whether they are getting juice and if the resistance across all the glow-plugs is the same. i had two plugs go out this fall/winter and that made a difference even in 25F weather. you should be able to find some specs on what the ohm rating should be on your particular plugs. my 2000 tdi is .05-.15. anything out of that spec means they aren't working at full capacity and maybe not at all.

i'm bummed youre swapping back to the 22re, but the yota motor is a great motor. definitely my favorite 4cyl gas motor. in any case, props to you for getting the diesel in there and getting it to work as well as you did. very nice.

 

TDI's are a different animal. Direct injection and computer control of pump advance. My glow plugs are all brand new. All of my IDI diesels don't start worth crap without plugging in. Thats just how it is. Also this engine has 330,000 km on it so I imagine the compression is not as high as when new.

 

Might want to see if you can scare up one of the diesel powered coolant heaters... I see them at the wreckers in old chevies and dodges every now and then... Given the one in my 6.2 chevy warms up the radiator quite nicely - even 'incorrectly' plumbed into the coolant system (as there's no good 'proper' way on the IDI diesels) it'd probably more than do the job...

Wish I was closer, i'd buy your idi in a second...

 

If your glow plugs are working, then you probably have low compression. Low compression in a diesel will cause a no start in cold weather. I see it all the time at work.

Does it blow smoke on startup?

 

good to know about IDI motors. i've never owned one, but plan on it scrounging up a rabbit or golf for a daily driver. still bummed about all the work you put in the project, but the write up is priceless for anyone looking to do this in the future. thanks again.

 

I sold the motor. I kept most of the conversion stuff though. I have the adapter plate, engine mounts and flywheel. I will sell all for $$200 US.

 

how much canadian.. and this is for a 22re stock truck