dbywaters
Active member
I started this project a year ago, the truck had a blown v6 engine but the clutch was new (5 Speed manual seems to be ok). It had sit for over 3 years under a tree with the rear window slide open enough for a bird to nest in the heater... I had a wrecked 98 New Beetle TDI for parts and had previously converted a 99 Passat to TDI using a imported engine from the Cech Republic so this was not my first TDI Conversion, I also converted a 03 Saturn Vue from a 4 cyl with VTI to the 3.5 Honda engine that Saturn offered in 04. I am pretty apt at sorting and soldering wires..... lots of wires.
My goal is to have a pickup that offers 30mpg, I am not after a bunch of power or crawling but I did want 4x4 and the 8 foot bed. I used the ACME adapter kit, a started off of a newer Toyota V6, retained the Toyota A/C compressor, everything else is VW. I deleted the EGR and shutter valve, fabricated the motor mount brackets and re-used the Toyota mounts. I deleted the block heater to allow firewall clearance and routed hoses as best I could to retain somewhat of a stock appearance. I used a Passat coolant tank, retained the Toyota air filter box and modified it to accept the MAF sensor. Some of my tubing (Intake and charge air) is still PCV pipe, but I plan to convert to silicone hose and pipe as time goes on. The charge air cooler is sandwiched between the grill and A/C condenser, the cooler is from a Audi and only required minimal trimming of grill to make it work. The A/C condenser was raised about an inch to allow for tubing to pass between it and the opening below the condenser. The oil pan is original VW and the clearance be tween it and the front IFS is good. The mount for the steering damper had to be modified by welding an extension to the existing bracket. I re-used as many of the original Toyota circuits as possible, I do not have cruise enabled or intend too. The ECM is in the same location as stock and all wring interfaced to the two stock (grey and white) Toyota connectors. I modified the drive by wire throttle pot and mounted it under the hood to use the Toyota throttle cable. I made a custom bracket for the turbo actuator as the original position was not possible for the motor mount, my bracket uses a lever to allow the actuator head to point up, the turbo is stock. I retained the VW fuel filter, mounting it on the firewall. The exhaust is all 2" with the exception of the pipe leaving the turbo which is much smaller elbow to clear the starter, then it expands quickly to 2". I do not have a spring tensioner on the serp belt, I made a manual adjuster to make it work out. The Toyota battery is the same location as stock, I did modify and reuse the VW fuse box located on the battery to power the VW Fan(s). I still need to work out the A/C cooling but it not going to be warm enough for A/C for about 5 months anyway. I have about 20 miles on the truck now, I still have some bugs to work out but I am impressed how well it pulls. I feel like it needs another gear... maybe a 5th gear change in the future for more over drive. Of course the truck needs a bunch of cosmetic upgrades.. but that will come in time. I have the following videos on YouTube which show the progress. I believe the T100 is as easy of a conversion to work as any, although it did take a while to troubleshoot and engineer some of the installation. After some more shake down I plan to learn how to reduce some of the noise in the cab, I believe the OEM Toyota mounts are a bit harsh..but it is a truck.
https://www.youtube.com/watch?v=8u-qKh3MUf4
https://youtu.be/wQJpFErihSM
I hope this inspires somebody to give it a try!
My goal is to have a pickup that offers 30mpg, I am not after a bunch of power or crawling but I did want 4x4 and the 8 foot bed. I used the ACME adapter kit, a started off of a newer Toyota V6, retained the Toyota A/C compressor, everything else is VW. I deleted the EGR and shutter valve, fabricated the motor mount brackets and re-used the Toyota mounts. I deleted the block heater to allow firewall clearance and routed hoses as best I could to retain somewhat of a stock appearance. I used a Passat coolant tank, retained the Toyota air filter box and modified it to accept the MAF sensor. Some of my tubing (Intake and charge air) is still PCV pipe, but I plan to convert to silicone hose and pipe as time goes on. The charge air cooler is sandwiched between the grill and A/C condenser, the cooler is from a Audi and only required minimal trimming of grill to make it work. The A/C condenser was raised about an inch to allow for tubing to pass between it and the opening below the condenser. The oil pan is original VW and the clearance be tween it and the front IFS is good. The mount for the steering damper had to be modified by welding an extension to the existing bracket. I re-used as many of the original Toyota circuits as possible, I do not have cruise enabled or intend too. The ECM is in the same location as stock and all wring interfaced to the two stock (grey and white) Toyota connectors. I modified the drive by wire throttle pot and mounted it under the hood to use the Toyota throttle cable. I made a custom bracket for the turbo actuator as the original position was not possible for the motor mount, my bracket uses a lever to allow the actuator head to point up, the turbo is stock. I retained the VW fuel filter, mounting it on the firewall. The exhaust is all 2" with the exception of the pipe leaving the turbo which is much smaller elbow to clear the starter, then it expands quickly to 2". I do not have a spring tensioner on the serp belt, I made a manual adjuster to make it work out. The Toyota battery is the same location as stock, I did modify and reuse the VW fuse box located on the battery to power the VW Fan(s). I still need to work out the A/C cooling but it not going to be warm enough for A/C for about 5 months anyway. I have about 20 miles on the truck now, I still have some bugs to work out but I am impressed how well it pulls. I feel like it needs another gear... maybe a 5th gear change in the future for more over drive. Of course the truck needs a bunch of cosmetic upgrades.. but that will come in time. I have the following videos on YouTube which show the progress. I believe the T100 is as easy of a conversion to work as any, although it did take a while to troubleshoot and engineer some of the installation. After some more shake down I plan to learn how to reduce some of the noise in the cab, I believe the OEM Toyota mounts are a bit harsh..but it is a truck.
https://www.youtube.com/watch?v=8u-qKh3MUf4
https://youtu.be/wQJpFErihSM
I hope this inspires somebody to give it a try!