92 Toyota ALH TDI

I've had my tdi Toyota running for a few years.
So here's the basics.
ALH engine
vnt17 hybrid
.280 injectors
11mm pump
Fx300 10" clutch masters clutch
V6 trans
Custom made adapter plate by local machine shop
Malone tuning

So I just upgraded to the r150 trans and got it all out together but the starter didn't engage. Did some research and figured out the v6 ring gear has 120 teeth and the 4cyl. flywheel I'm using has 115. I haven't found a flywheel with 6 bolts that has 120 teeth. Only thing I found is grinding the starter to move it closer. Which I don't really like.
http://forums.tdiclub.com/showpost.php?p=3734795&postcount=17

But I want to get it running again after being down for over a month so I just did it to get me going. What are the others doing for flywheel with the r150 trans??

Everybody like pictures!!






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Have enough fuel?? Awesome build, think you could fire off a few photos for our gallery? always happy to see these things used properly.

I'm not sure that it's used properly lol! I've got the stage 3 tuned for .205 injectors and 2.5 bar map but I've got .280 injectors and 3 bar map lol. Not exactly recommended I know! But it works quite well!! Boost comes on plenty early I think which makes me worry about turbo reliability. But I've been running it like this for over a year.


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Well, the inevitable happened and I blew my turbo. Money is kinda tight right now but my dream is to go compound turbo. But I'm not sure if the stock internals will be able to handle the boost. I'm thinking stock early tdi wastgated turbo or gt2052 for hi pressure and holset he221w or hx30 for low pressure.

joewrench said:

Boost comes on plenty early I think which makes me worry about turbo reliability. But I've been running it like this for over a year.

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joewrench said:

Well, the inevitable happened and I blew my turbo.

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Wow, I guess you kinda called that...

-Todd

Joewrench,
I'm looking at clutches for my swap.. how is your clutchmasters working out?
I'm staying with the w56 and smaller flywheel.. and was wondering if the fx300 is 'enough'.

Shuda kept my mouth shut lol

I haven't had mine long but I'm guessing I was making 300 ftlb and it slipped a bit right after I put it in but I believe it takes a while to fully break in.

Does anybody have drawings for the exhaust manifold flange for 8v? Or a good place to buy them at a good price? I'm thinking I'll build my own header manifold.

joewrench said:

Does anybody have drawings for the exhaust manifold flange for 8v? Or a good place to buy them at a good price? I'm thinking I'll build my own header manifold.

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https://blackhazeworkshop.com/en/parts/exhaust_manifold_flange_8v_tdi.html

75 bucks, CAD, seems a little high.. but it is stainless. I think going with stainless will help on the expansion rate and keeping a good seal.

Finally got my compounds together and running! I went with the k03 early tdi turbo for the hi pressure and hx30 for the low pressure hoping to not get to much boost to early for the stock bottom end. It seems to be working well. I have the hi pressure set to make about 18psi over the low pressure and the low pressure is set at 18 which puts me up at 36. That's getting plenty hi for a stock bottom end I'm thinking!! I'm trying to figure out an effective way to limit the boost closer to 30. I don't hit 36 till about 2500 rpm but that still seems like it's rod buckling boost.

https://vimeo.com/197475619
The video is with the hi pressure set at 15 psi over lo pressure which put overall boost at 30 but the response of the hx30 is much better with it set at 18


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when do you start getting boost? I see 35psi of boost at 2600 rpm with my single he211 on my AHU.

I get 25 psi by 1800 and 36 by 2500.
Do you have a stock bottom end?


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Yes I do. Interesting to see those boost numbers. i get peak boost about the same time, but you get significant boost earlier. I think I have about 5 psi by 1800. Makes total sense, and I suppose that is the whole point of a compound setup!

Didn't we set that thing to 30 PSI? haha. How's the fueling? EGTs climb pretty quick. That's some impressive low RPM boost! feel free to send some logs my way.

Owain@malonetuning said:

Didn't we set that thing to 30 PSI? haha. How's the fueling? EGTs climb pretty quick. That's some impressive low RPM boost! feel free to send some logs my way.

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Another video with it set at 36 psi. https://vimeo.com/199686391
https://vimeo.com/199685207

Just a slight haze at WOT I'm happy with that. I gotta take some time to do some logs. Which logs do u need?



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What's the optimal rpm for fuel efficiency on an ALH? I replaced the 5th gear gearset in the r150 trans with r452 gears. 4.10 rear ends 32in tires and a .69 overdrive now. My cruising rpm at 100 kph is now about 1800. I love how much quieter it is in the cab but my first tank of fuel was only 22 mpg!! Pretty bad from the 35 I got when my rpm was about 2400. But it was also my first tank with the compound turbos so I've been into the throttle a lot!! It has plenty of power for cruising at that rpm but I'm not ok with that kind of fuel mileage!


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Anywhere around peak torque typically, lower doesn't hurt I'm rarely past 2500 in my PD and it spends a lot of time in the 1800 range getting 40 mpg city. Should get back towards the 30s once your right foot calms down colder temps hurt fuel economy by at least 10% too