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TDI Conversions Discussions on converting non TDIs into TDIS. More general items can be answered better in other sections. This is ideal for issues that don't have an overlap and are very special to swaping engines.

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Old August 3rd, 2018, 12:39   #31
vtpsd
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Hi Jason! No progress to speak of. I've been driving the taco quite a bit. I'm building my house now, so its been awesome to have a truck for home depot runs. I plan to start the swap this winter, and hopefully be able to use it by next summer.

It did recently start making some noises that I think are the pilot bearing, so I may be forced to start taking it apart sooner than later.
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current: 03 jetta wagon (pp520, malone stg3, straight pipe), ford tractor with saab turbo, Snarling Audi 90q AHU swap (holset he211w, 32psi, race 520's)
past:11 second audi 90 20vt monster, 20vt swapped audi 90 winter beater, 10vt swapped 4kq with efi and many many other 5 cylinder audis, and a few 1.8tq's
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Old October 1st, 2018, 09:01   #32
vtpsd
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I've been using this truck all summer. The pilot bearing in the flywheel is going very bad, so its definitely time to get serious about the ALH swap.

I got my donor ALH mk4 jetta running well. It would start fine, but stumble a fair amount and make smoke that smelled like fuel. I suspected bad injectors or a failing pump. I bottle fed it some diesel purge, and it immediately improved. I think the fuel filter or fuel pickup is restricted in the car.

Tested the group 13 numbers, they were decent. It still looks like the injectors are somewhat worn, but the car runs smooth and no smoke.

I tested compression, I got 500 470 505 480. Not the closest numbers I have ever seen, but good enough to consider things healthy in my book. I suspect this engine is highly sooted up. I will be pulling the head and cleaning all the ports and valves before putting it in my truck.

I also got the adapter from Randy at TD Conversions and test fitted it. I also got his new heavy 22re flywheel that is machined to fit the larger 10" tacoma clutch. I have a centerforce 10" clutch in there. The clutch has centrifugal weights that apply more clamping force as RPMs rise. Interesting setup. I am a little concerned about those weights rattling around at idle. We shall see.
Below is the adapter setup fitted to an AHU block I happened to have in the shop. Everything looks good!



Scrapping a MK3 that I parted to use the cylinder head on my TDI audi. Towing weight with the 4 cylinder tacoma is pretty funny. Pinned all the time.

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current: 03 jetta wagon (pp520, malone stg3, straight pipe), ford tractor with saab turbo, Snarling Audi 90q AHU swap (holset he211w, 32psi, race 520's)
past:11 second audi 90 20vt monster, 20vt swapped audi 90 winter beater, 10vt swapped 4kq with efi and many many other 5 cylinder audis, and a few 1.8tq's

Last edited by vtpsd; October 1st, 2018 at 09:18.
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Old October 2nd, 2018, 13:53   #33
Sugarkryptonite
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Cool swap buddy. I was just curious how the stock gearing is going to be with the TDI motor, have you done any calculations? I was planning on doing something similar with a GMC Canyon w/ an automatic trans (not really interested in a manual), but I'm worried about the 4x4 gearing, and how hard it would be to change to accomodate the TDI motor gearing.
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Old October 3rd, 2018, 06:21   #34
vtpsd
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I haven't done much gearing calculation. Honestly, my trucks gearing is way too high currently for the gasser, and feels like it could even be a little high for the TDI. I havent bothered to check, but I think it has 3.88's, plus 31" tires.

5th gear is basically useless below 70MPH.

I know others have used stock toyota gearing without issues.

In a perfect world, i might even want to lower my final drive on both axles, but I hope I dont need to.
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current: 03 jetta wagon (pp520, malone stg3, straight pipe), ford tractor with saab turbo, Snarling Audi 90q AHU swap (holset he211w, 32psi, race 520's)
past:11 second audi 90 20vt monster, 20vt swapped audi 90 winter beater, 10vt swapped 4kq with efi and many many other 5 cylinder audis, and a few 1.8tq's

Last edited by vtpsd; October 3rd, 2018 at 06:37.
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Old October 5th, 2018, 11:07   #35
Runninwild
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You more then likely have 4.10 diff gears. I'm planning on 4.56 or 4.88 in my taco with 35's.
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Old October 7th, 2018, 04:24   #36
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Quote:
Originally Posted by vtpsd View Post
I haven't done much gearing calculation. Honestly, my trucks gearing is way too high currently for the gasser, and feels like it could even be a little high for the TDI. I havent bothered to check, but I think it has 3.88's, plus 31" tires.

5th gear is basically useless below 70MPH.

I know others have used stock toyota gearing without issues.

In a perfect world, i might even want to lower my final drive on both axles, but I hope I dont need to.
your stock gearing is 3:59, which is why i swapped to 4:10 in my rig... used gears are cheap, all first gen sequoias have 4:10 and the drop out will bolt right in your 8.4 as will 1st gen tundra, though not many tundras were 4:10 ... you can use any third gen 4runner or first gen tacoma front diff (4:10 of course) and sequoia/tundra front diffs may also work
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Old October 7th, 2018, 04:26   #37
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Originally Posted by Runninwild View Post
You more then likely have 4.10 diff gears. I'm planning on 4.56 or 4.88 in my taco with 35's.
nope, all the 3rz 4x4 manual tacomas with stock 235's had 3:59's
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Old October 9th, 2018, 07:33   #38
vtpsd
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Thanks for the input Jim. I verified the truck does have the 3.59 gears. I will try it with those, but I'm guessing I will want to regear.

I have the Non-ADD front diff, which I like. I have regeared a toyota rear end before, but never an IFS front diff. Do parts like gears swap between ADD and non ADD diff housings?
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current: 03 jetta wagon (pp520, malone stg3, straight pipe), ford tractor with saab turbo, Snarling Audi 90q AHU swap (holset he211w, 32psi, race 520's)
past:11 second audi 90 20vt monster, 20vt swapped audi 90 winter beater, 10vt swapped 4kq with efi and many many other 5 cylinder audis, and a few 1.8tq's
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Old October 9th, 2018, 12:03   #39
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Originally Posted by vtpsd View Post
Thanks for the input Jim. I verified the truck does have the 3.59 gears. I will try it with those, but I'm guessing I will want to regear.

I have the Non-ADD front diff, which I like. I have regeared a toyota rear end before, but never an IFS front diff. Do parts like gears swap between ADD and non ADD diff housings?
you can use the diff from an ADD truck by unbolting all the ADD parts and bolting on your non-ADD axle and tube, it's what i'm running on my truck ....my diff came from a third gen runner with ADD
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Old October 9th, 2018, 12:28   #40
vtpsd
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Perfect! Good info.

A friend down the road has a v6 parts truck, dont remember if its a 5-speed, but if it is, it sounds like it would be a 4.10 truck.

I should be able to use front diff and rear 3rd member from that right?
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current: 03 jetta wagon (pp520, malone stg3, straight pipe), ford tractor with saab turbo, Snarling Audi 90q AHU swap (holset he211w, 32psi, race 520's)
past:11 second audi 90 20vt monster, 20vt swapped audi 90 winter beater, 10vt swapped 4kq with efi and many many other 5 cylinder audis, and a few 1.8tq's
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Old October 9th, 2018, 12:59   #41
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Originally Posted by vtpsd View Post
Perfect! Good info.

A friend down the road has a v6 parts truck, dont remember if its a 5-speed, but if it is, it sounds like it would be a 4.10 truck.

I should be able to use front diff and rear 3rd member from that right?
If it's a Tacoma without e-locker, yes, if it's a 4Runner only the front diff will work... all 3rd gen 4Runners had 8in rear axles... Tacomas have 8.4 rear axles except the ones that have e Locker
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Old October 11th, 2018, 07:53   #42
vtpsd
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Quote:
Originally Posted by jimbote View Post
If it's a Tacoma without e-locker, yes, if it's a 4Runner only the front diff will work... all 3rd gen 4Runners had 8in rear axles... Tacomas have 8.4 rear axles except the ones that have e Locker
It is a v6, 5-speed 4x4 tundra. I dont know the year. I dont think it can be an elocker?

According to this, it basically has to be a 4.10 truck, I think.
https://www.tundrasolutions.com/foru...f-gear-ratios/
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current: 03 jetta wagon (pp520, malone stg3, straight pipe), ford tractor with saab turbo, Snarling Audi 90q AHU swap (holset he211w, 32psi, race 520's)
past:11 second audi 90 20vt monster, 20vt swapped audi 90 winter beater, 10vt swapped 4kq with efi and many many other 5 cylinder audis, and a few 1.8tq's
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