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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 May 20th, 2011, 08:46   #16
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nice adapter also...is this for the four cylinder bell or the V6? maybe I should read...
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Old May 20th, 2011, 16:19   #17
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well maybe I should clarify...The truck had the a340h but I bought a w56 and im doing the 5spd swap at the same time.
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Old May 20th, 2011, 16:27   #18
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Quote:
Originally Posted by ToyotaTDI View Post
Wow dennis just checked out your site as well thats quite the project you got there. Great site buddy lots of good info on there, your doing the TDI world a service my friend.

Cheers!
Thanks for the complement. I wanted to share my build with every one on the internet not just TDI club (but you guys are still my favorite), that's why I made a site instead of just a build thread. If I would have known how much time it takes to make a web site, I probably would have just done a build thread
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Old May 25th, 2011, 14:00   #19
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I will be going with an aftermarket intercooler setup but am having trouble finding intercoolers short enough to fit behind the 4runner grille.

Anybody have any experience with http://www.frozenboost.com or any of the cheaper universal intercoolers?

Most reviews seem to be not bad for the price

Last edited by ToyotaTDI; May 25th, 2011 at 14:17.
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Old May 25th, 2011, 16:04   #20
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Default Cheap intercoolers

I have never ordered anything from Frozenboost (been there many times evaluating options), but I have used and have seen friends use CXracing and have had no problems with their products, especially for the price. Their universal piping kits work really well as well. I usually buy from them off ebay as you can usually beat their website prices that way.
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Old May 25th, 2011, 21:31   #21
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I think my intercooler is a CX racing unit from ebay. I cant recall the size but you can see how well it fits in my build thread. I think it was just over $100 for the intercooler and a universal piping kit. I'll see if i can dig up what size it was.
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Old May 25th, 2011, 22:00   #22
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Default Intercooler

Over All Size: 27" X 5.5" X 2.25".
Core Size: 21" X 5.5" X 2.5".


$109 + S&H on ebay through DNAMotoring. Included 8 pieces of 2.5" aluminum intercooler piping throughout, 8 silicone couplers, and 16 clamps.

http://cgi.ebay.com/ebaymotors/ws/eB...SA:MOTORS:1123
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Last edited by cumminsfromthecold; May 27th, 2011 at 19:42. Reason: useless information
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Old May 26th, 2011, 23:56   #23
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Snap...thats a good deal. Make sure to update your thread when you get that bad boy installed
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Old May 27th, 2011, 00:24   #24
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yeah that seems to be the standard issue toyota swap IC kit. I think every one i have seen so far has it.
LOOKIN GOOD!
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Old May 27th, 2011, 19:59   #25
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Default Re intercooler for Toyota TDI

Thanks, guys. The quality of that set-up is better than I expected.

Using an air filter set-up almost just like e*clipse's. Also, on my older rig, I had to add a few washers/spacers to the vertical metal strut supporting the hood latch assembly - that allowed the intercooler to slip in.

E*clipse's thread shows a nice way of routing everything into that particular corner, and eventually, that's the plan.
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Last edited by cumminsfromthecold; June 21st, 2011 at 11:09. Reason: change is the only constant
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Old August 25th, 2011, 00:26   #26
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Long time, no updates...I have been busy as excrement working on my final project for engineering. Building a kickass racing simulator for www.vrx.ca is all I can say for now. Will post the final product at the end of september. If anybody knows alex tagliani, its for him, its gonna end up costing about 60k

Back on topic. Fair amount of work has been done, I'm just horrible with updates and pictures.

3.0 V6 and automatic have been pulled and sold. MAN that thing was a sausage to get out of there....its about 6 or so inches longer then the w56 IIRC. Gave the engine bay a nice spray bomb and a quick prep. While the engine was also I also got a chance to drill the 32mm hole in the firewall to accommodate the master cylinder. Starting to wish I started with a standard truck...




The truck was also given a 3 inch body lift...now I know there are some haters out there. I have had lots of trucks, with all sorts of lifts, and I can honestly say if your not gonna wheel almost every weekend, the body lift is just fine. The clearance the body lift creates works wonders on fitment issues. Love it


I also managed to get an intercooler kit from CXracing of ebay, not bad for 180 bucks. The fins are a little mangled but as long as it works...im pleased.


The dimensions of the intercooler are 28x7x2.5 with 2.25 piping

Last edited by ToyotaTDI; August 25th, 2011 at 00:55.
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Old August 25th, 2011, 00:44   #27
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I also found a great solution to the firewall clearance problem everybody has been having. The crossmember from the A340H bolts to the W56 transmission AND moves the whole setup 3 inches forwards. As you can see in the pictures here, no problem clearing the firewall.



While im on this topic, I was looking for a few opinions on the slope of the engine, there is definetly a hefty angle on it, pretty much what the stock 3.0 v6 was at. Here is a picture taken between the body and the frame of the transmission to show the angle.

Anybody know if the TDI engine minds running at such an angle? I know the stock v6 was close to this angle, just worried that a transverse engine may not be used to this.

Unfortunately the oil pan drain plug hits the front differential, so a diff drop or oil pan smash is the only way to get he engine lower in the truck.

Here is another view, as you can see I picked up an oil stand from a 1.8T passat as a few members around here have suggested. This solution takes care of the clearance issues associated with making a drivers side engine mount, and IMO is way more reliable then a filter relocation kit.

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Old August 25th, 2011, 00:51   #28
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Here is another pic of the angle, you can see the angle of the timing cover with reference to the radiator. The radiator has just been mocked up for now, need to look into some sort of controller/relays to power it. Anybody have a solution for this? Might just end up going with a tarus fan or similar mounted on the stock rad. There is a great writeup on pirate if anybody is interested.

http://www.pirate4x4.com/forum/showthread.php?p=8171423

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Old August 25th, 2011, 12:40   #29
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Controlling the radiator fans should be pretty easy.

On my setup, I have a temp switch in the radiator. When it gets hot, the switch closes. That switch controls a relay which runs the fans.

There's more sophisticated ways to do it -- temp switches with two set points to run the fans on low or high. I think there may be a way to control it with the computer too.

I'm going with the simplest method

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Old August 27th, 2011, 23:53   #30
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Yeah I was thinking of running some sort of relay setup. Just thought I heard something about somebody using thier stock ECU for an output signal.

Anybody have experience with the angle of the TDI engines? How much can these engines handle?
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