www.tdiclub.com

Economy - Longevity - Performance
The #1 Source of TDI Information on the Web!
Forums Articles Links Meets
Orders TDI Club Cards TDIFest 2016 Gone, but not forgotten VAG-Com List Unit Conversions TDIClub Chat Thank You




Go Back   TDIClub Forums > VW TDI Discussion Areas > TDI Conversions

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.

Reply
 
Thread Tools
Old November 16th, 2006, 07:42   #1
Spulen81
Veteran Member
 
Join Date: Mar 2004
Location: Warners, NY
Default 4Runner TDI swap

I got the 4Runner on 9/1 and I've been working hard to get it done before the nasty weather hits. I live in upstate, NY and its creaping up quickly. I never drove this truck prior to the swap so I'm really hoping it doesn't have too much wrong with it. Its not a NY native therefore super solid. The donor engine was from a '97 Jetta TDI with 110K on it, it was missing very little when I got it. This was done with a Acme kit, they have been great with tech help, btw. I got it together and running in about 2 months, with quite a bit of research done beforehand.
I have alot of other pics during the build up but they are temporarily being held hostage by my home laptop at the moment. I will post up some of the build pictures later on and current pics with it cleaned up.

Here it is in all its glory, the paint is really faded and the other side has some dents in the 1/4 but I could care less. It will most likely be painted a flat tan color once I finish up everything.


Here is the very dirty engine and compartment. Detailing this stuff is on the short list. These pics are from a few weeks ago.. the wiring is cleaned up quite a bit now.


Starter to turbo clearance... yikes. I had to swap in a different starter for clearance. The starter will be blanketed and the exhaust sheilded so hopefully its OK. I want to do a different manifold and turbo down the road. I have an older TD t3, I might rebuild and use.


Here are the accesories... all factory VW from the TDI, the crank V-belt pulley is a smaller one from an ABA code gasser and its way smaller. My stock one was bent so I had to make do with this one for now. Everything fits great WITH the AC deleted. The compressor would not have fit but there is a really cheap way to delete using a factory non AC waterpump pulley and a shorter serp and v-belt. I used a PS hose kit from PSC to make a pressure line along with a couple adapter fittings and a new return hose. So far so good.


And the intercooler, I just saw this one on ebay and took a chance hoping it would fit. It did after some minor cutting. Its a nice Spearco unit and only $100. I sold my stock TDI intercooler for $100 so it worked out great.


Here are a couple more engine shots, again these are a few weeks old.




Its alot further along now and its going on the road today. So the maiden voyage is after work tonight.
__________________
-1986 Jetta Coupe, AHU, R520s,Alligator 3 bar, D24 manifold, GT2052 - SOLD
-1986 4Runner TDI - SOLD
-1991 GTI-TDI - SOLD
-2011 Golf TDI

Last edited by Spulen81; November 16th, 2006 at 08:07.
Spulen81 is offline   Reply With Quote
Old November 16th, 2006, 08:08   #2
anb957
Newbie
 
Join Date: Mar 2006
Default very nice!

Would like to hear more about the performance of this beast once you get it running. I always like the 1st gen 4runner with the removable top. Great truck. I wonder how it will perform with the 1.9TDI on the highway and what kind of fuel economy you will see.
anb957 is offline   Reply With Quote
Old November 16th, 2006, 08:19   #3
Spulen81
Veteran Member
 
Join Date: Mar 2004
Location: Warners, NY
Default

Me too, haha.

Its got 10lb/ft over the 22RE it replaced so I'm guessing it will drive pretty much like a stock 4runner. I'm hoping to get 25-30mpg with it. The 22RE can get in the 20s pretty easily so I don't think its impossible.
__________________
-1986 Jetta Coupe, AHU, R520s,Alligator 3 bar, D24 manifold, GT2052 - SOLD
-1986 4Runner TDI - SOLD
-1991 GTI-TDI - SOLD
-2011 Golf TDI
Spulen81 is offline   Reply With Quote
Old November 16th, 2006, 08:39   #4
joshgb
Veteran Member
 
Join Date: Jun 2005
Location: Cachagua, California
Default

I love it...I've been looking for something more rugged to swap a tdi into for a long time but a 4runner never occurred to me. I can't see whether it you have a stick or an auto but how much work was involved in mate-up with the clutch/torque converter? How about engine mounts and whatnot? Was your intercooler swap-out a fit issue?
Also what comes with an acme kit...where do I find more information about them?
Keep us posted!
joshgb is offline   Reply With Quote
Old November 16th, 2006, 09:01   #5
Spulen81
Veteran Member
 
Join Date: Mar 2004
Location: Warners, NY
Default

A Toyota or Suzuki would be the easiest. Acmeadapters.com is the place that sells the kit. They have full swap kits for Suzukis with everything you need.
The Toyota kit is basically an adapter plate and a flywheel. They make a kit for autos and sticks. You can basically use any Toyota transmission that was behind a 4cyl in rear or four wheel drive Mine is stick, you use a Toyota clutch, Toyota starter.

I fabricated the mounts, hoses and stuff. The TDI intercooler is just shaped wierd, the one I'm using made IC tubing and everything short and easy to run.
__________________
-1986 Jetta Coupe, AHU, R520s,Alligator 3 bar, D24 manifold, GT2052 - SOLD
-1986 4Runner TDI - SOLD
-1991 GTI-TDI - SOLD
-2011 Golf TDI
Spulen81 is offline   Reply With Quote
Old November 16th, 2006, 10:43   #6
turkeyssr
Member
 
Join Date: Jan 2003
Location: Monterey, CA
Fuel Economy: 44 avg.
Default Emissions?

How in the world do you pass an emissions test when you swap to a diesel engine?
__________________
John
Somewhere Near Monterey
turkeyssr is offline   Reply With Quote
Old November 16th, 2006, 10:56   #7
RabbitGTI
Veteran Member
 
RabbitGTI's Avatar
 
Join Date: Jul 1997
Location: Wisconsin
Fuel Economy: Don't know. I just feed it and drive.
Default

Quote:
Originally Posted by turkeyssr
How in the world do you pass an emissions test when you swap to a diesel engine?
Move out of California
__________________
Rabbit GTI racecar RIP, 84 Rabbit GTI, 88 Golf GL, 97 Passat TDI, 07 Jetta 2.5, 02 Beetle 2.0, 08 Jetta 2.5 with Aisin Box.
RabbitGTI is offline   Reply With Quote
Old November 16th, 2006, 12:14   #8
joshgb
Veteran Member
 
Join Date: Jun 2005
Location: Cachagua, California
Default

Quote:
Originally Posted by turkeyssr
How in the world do you pass an emissions test when you swap to a diesel engine?
Someone else correct me if I am wrong... but around here (Oregon) people I know who have swapped into a body that originally had a diesel option have not had much of a problem registering their vehicles---those were people though in counties without DEQ testing, which is most of this state.

I have heard of local Portlanders who have registered diesel conversions after passing DEQ, again usually if the original model had a diesel option but I cannot confirm that. I would guess they probably put newish cleanish TDIs into older vw gassers.
California bashing aside, I see from Acme's site a fair number of California vehicles so it must be possible there (or maybe the rigs on the Acme site have some kind of imaginative extra-legal work around.)




btw turkeyssr: I am originally from "somewhere near Monterey" (Cachagua) myself and am looking for a tdi for my mom there if you know of anything.

Last edited by joshgb; November 16th, 2006 at 12:17.
joshgb is offline   Reply With Quote
Old November 16th, 2006, 17:02   #9
94x
TDIClub Enthusiast
Vendor
 
Join Date: Nov 2006
Location: Westfield, Massachusetts
Default

I'm a MA inspector, no problem for gas/diesel swaps as long as "required" emission equipment is in place. Early in the MA inspection, I must manually enter "gas, diesel, propane, NG...." don't know how NY does it.

If the swap looks professional, I would not poke around to "find stuff". So, I suggest make the wiring look nice, no leaks, no missing bolts or hardware, all brackets attached securely, and by all means (my pet peave) bracket the battery down, NOT a bungee cord.

Good luck with your swap.
94x is offline   Reply With Quote
Old November 16th, 2006, 18:05   #10
jaybeat
Member
 
Join Date: May 2006
Location: West Linn, Oregon
Default

Quote:
Originally Posted by joshgb
Someone else correct me if I am wrong... but around here (Oregon) people I know who have swapped into a body that originally had a diesel option have not had much of a problem registering their vehicles---those were people though in counties without DEQ testing, which is most of this state.

I have heard of local Portlanders who have registered diesel conversions after passing DEQ, again usually if the original model had a diesel option but I cannot confirm that. I would guess they probably put newish cleanish TDIs into older vw gassers.
California bashing aside, I see from Acme's site a fair number of California vehicles so it must be possible there (or maybe the rigs on the Acme site have some kind of imaginative extra-legal work around.)




btw turkeyssr: I am originally from "somewhere near Monterey" (Cachagua) myself and am looking for a tdi for my mom there if you know of anything.
FWIW, I exchanged emails w/the folks at ACME and they said that none of their customers have had problems with testing, including folks in Portland w/DEQ.
jaybeat is offline   Reply With Quote
Old November 16th, 2006, 19:50   #11
realslimshaver
Veteran Member
 
realslimshaver's Avatar
 
Join Date: Jun 2006
Location: cambridge ontario
Default

in ontario if u swap in a diffrent engine all u have to do is get it declaried a hot rod and u never have to do an etest again.
__________________
2002 Jetta GLS TDI 560000Km 5speed
Vag-com,euro stwich, W8consle,mudflaps, monster mats,evo skid plate, audi tt petal set
realslimshaver is offline   Reply With Quote
Old November 16th, 2006, 19:57   #12
Spulen81
Veteran Member
 
Join Date: Mar 2004
Location: Warners, NY
Default

The maiden voyage was a success! The truck drives great even with a really bent wheel. The power is pretty decent even at 9psi. It pulls fine, moves right along. I'm very happy with it.

I did have a small electrical problem causing the battery not to charge. I had to call the women for jump.
__________________
-1986 Jetta Coupe, AHU, R520s,Alligator 3 bar, D24 manifold, GT2052 - SOLD
-1986 4Runner TDI - SOLD
-1991 GTI-TDI - SOLD
-2011 Golf TDI
Spulen81 is offline   Reply With Quote
Old November 17th, 2006, 07:25   #13
JimDog
Member
 
Join Date: Nov 2003
Location: Lafayette, CA
Default

Quote:
Originally Posted by RabbitGTI
Move out of California
Actually, California is one of the easiest states to register diesel conversions. You take your vehicle to the DMV, fill out a "Statement of Facts" form, and mark the appropriate check boxes for "change of motive power." They might ask to see it, to verify that the conversion has actually taken place. However, many DMV employees couldn't spot a diesel even if Rudolph himself was driving it, so often they'll just take your word for it. They'll issue a new title and registration card, showing the new fuel type, and then it's exempt from emissions testing, just like any other diesel vehicle in California.
__________________
Jim Meehan
Lafayette, CA
'09 VW Jetta SportWagen TDI
JimDog is offline   Reply With Quote
Old November 17th, 2006, 07:39   #14
KROUT
persona non grata
 
Join Date: Aug 2005
Location: JAX FL
Default

What tranny did you use for the swap? Did you use an auto or stick?
KROUT is offline   Reply With Quote
Old November 17th, 2006, 08:30   #15
Spulen81
Veteran Member
 
Join Date: Mar 2004
Location: Warners, NY
Default

Its the stock Toyota 5 speed, W56.
__________________
-1986 Jetta Coupe, AHU, R520s,Alligator 3 bar, D24 manifold, GT2052 - SOLD
-1986 4Runner TDI - SOLD
-1991 GTI-TDI - SOLD
-2011 Golf TDI
Spulen81 is offline   Reply With Quote
Reply


Currently Active Users Viewing This Thread: 1 (0 members and 1 guests)
 
Thread Tools

Posting Rules
You may not post new threads
You may not post replies
You may not post attachments
You may not edit your posts

BB code is On
Smilies are On
[IMG] code is On
HTML code is Off

Forum Jump


All times are GMT -7. The time now is 13:23.


Powered by vBulletin® Version 3.8.5
Copyright ©2000 - 2017, Jelsoft Enterprises Ltd.
Copyright - TDIClub Online LTD - 2017
Contact Us | Privacy Statement | Forum Rules | Disclaimer
TDIClub Online Ltd (TDIClub.com) is not affiliated with the VWoA or VWAG and is supported by contributions from viewers like you.
1996 - 2017, All Rights Reserved
Page generated in 0.18772 seconds with 9 queries
[Output: 122.34 Kb. compressed to 101.25 Kb. by saving 21.09 Kb. (17.24%)]