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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 September 13th, 2010, 06:40   #1
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Default Toyota Tacoma ALH Swaparoo!!

This is my first attempted TDI conversion although I've been cerebralizing on it for several years...I've had several toyota trucks that I was "going to convert" but none felt right for the swap...so here it is, a 96' tacoma X-Cab 4x4 I found on craig's list greensboro...it was "dinged" in the front so I went ahead and had it converted to the 01' to 04' front end while it was in repair ....truck is a 3rz 4 banger with a W59 5 speed...I've already gone through one adapter idea using a rear facing VW tdi starter...but that proved to be too much interference with the transmission case.. (anyone know of a larger diameter 4 cylinder VW flywheel?) my current adapter scheme uses an ACME "clone" adapter plate and a redrilled toy flywheel ....(thanks Luke for pointing out my omission) ...more pics to come in a few days!!





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Last edited by jimbote; September 13th, 2010 at 12:44.
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Old September 13th, 2010, 06:46   #2
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on my adaptation I'm using a 3RZ starter with the "cold climate" option...this starter has a 2.0kw output same as the late tdi starters....bendix is the same tooth count as the 22re, fits in the 22re separator plate hole perfectly and it has a mount configuration that allows the starter motor to rotate out of the way of the turbo with one tab lining up perfectly with the lower 22r starter bolt hole...My friend Daniel added a tab to the bell housing for the other starter mount to bolt to...here's a video of the starter in action ... http://www.youtube.com/watch?v=hjSKiykdHrI


tab added to r series trans for the 3rz starter


pic of the tab on the w series trans


pic of original 22r starter on w series bell


3RZ starter mounted to R series trans...notice "clocking" that keeps the starter away from the turbo
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Old September 13th, 2010, 06:47   #3
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here's the harness before and after....still need to do some trimming and tying in...building basically a standalone harness that will tie into the tacoma harness at critical points


before image...harness is from an 02' manual trans jetta .... EDIT:..."most" of the harness is from an 02', some is from a Y2K jetta...I believe the glow plug and DLC harnesses are from the Y2K...


took me about 45min to get it to this point...still need the pedal with harness OBDII connector and some other bits
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Old September 13th, 2010, 06:47   #4
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more photos
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Old September 13th, 2010, 07:03   #5
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Old September 13th, 2010, 07:59   #6
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saved for future comments
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Old September 13th, 2010, 08:01   #7
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you got me!
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Old September 13th, 2010, 08:12   #8
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haha! Gonna keep an eye on this. Did a 1.6TD into a pre-Tacoma, would love to try a TDI into a Tacoma. I would imagine the Toyota flywheel is a larger diameter. That front end just bolted on?
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Old September 13th, 2010, 08:18   #9
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for the most part...yes...the core support needed welding in...but yes plug and play on the front sheet metal ...check this out ... http://www.customtacos.com/forum/sho...end+conversion and this...
http://www.tacomaterritory.com/forum...end+conversion ...keep in mind you do need fenders to make everything fit right....the aftermarket fenders also come with the required 01'-04' headlight brackets
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Old September 13th, 2010, 12:36   #10
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This is just an idea, i'm not sure if it will work. What if you were to use a W56 bellhousing and mate that to the W59 or just use the entire W56. Once you have the W56 bolt pattern Acme makes an adapter to mate the two together. Or you could also use the beefier R151 found in the 22re turbo trucks in the late 80's. This would let you use the Toyota starter, flywheel and clutch. You get your flywheel redrilled to the VW crank pattern and use a bronze bushing to replace the pilot bearing.
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Old September 13th, 2010, 12:41   #11
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This is just an idea, i'm not sure if it will work. What if you were to use a W56 bellhousing and mate that to the W59 or just use the entire W56. Once you have the W56 bolt pattern Acme makes an adapter to mate the two together. Or you could also use the beefier R151 found in the 22re turbo trucks in the late 80's. This would let you use the Toyota starter, flywheel and clutch. You get your flywheel redrilled to the VW crank pattern and use a bronze bushing to replace the pilot bearing.
thanks Luke....already there though...I should have made it clear I'm already using an ACME "clone" adapter plate and redrilled toy flywheel...just don't like the expensive ($349) starter option...I did design my own adapter plate a few years ago that used a flywheel spacer and two separate plates welded together...the flywheel spacer had me worried so it's still on the shelf...currently have two bell housing modified to fit the 3RZ starter...one W Series 22r and one R series 22r (the turbo truck version) ...thanks for the suggestion...I'll amend my earlier posting


pic of my original mock up with rear facing starter...this will work but requires some grinding/modification to the w series transmission case


and the release collar lengthened to accommodate the greater release travel required for the original design
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Old September 14th, 2010, 06:10   #12
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Default Pilot bearings...

EDIT!!!!....use a bronze bushing that extends beyond the crank snout!!!...I only had 4mm of engagement into the pilot bearing and this damaged my input!!....see post #385!!!

on this swap instead of using a bronze bushing I'm using two "inline skate" bearings stacked together and driven into the back of the crank...they are 22mm x 8mm x 7mm ???....and I think they are 608 2rs bearings?...it's been a couple a years since I found em' so don't quote me on this....you can get em just about any sporting goods store that sells inline equipment ....i think this is where I got mine..EDIT!! these are not inline skate bearing but RC car trans bearings?....anyway they have worked great for over 20K miles and I'm using three stacked together instead of two.... http://www.amazon.com/I-D-Bearing-Designation-Shield-Metric/dp/B002HAR8DS
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Old September 14th, 2010, 06:28   #13
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Default starter mounting....

just a couple of notes on mounting a 3rz starter to the W or R series transmissions...it's a good idea to use the 22r separator plate when using these starters as it's used to precisely locate the starter to the ring gear on the flywheel....ford uses this strategy as well as many other manufacturers....also on the toy bellhousing the lower threaded starter hole needs to be drilled for a bolt pass through as the 3rz starter boss is threaded
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Old September 15th, 2010, 16:09   #14
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Default test fire!!

got everything wired in and test fired it on the floor...engine runs great!!!...I'll try and post a vid to youtube when I get back from WI
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Old September 15th, 2010, 19:04   #15
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Do you know what the diameter of the transmission input shaft is off hand? I wanted to use a bearing instead of a bushing but couldn't find anything that would work without sleeving the outside of the bearing or the input shaft.

Thanks,

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