Newby wanting to convert Toyota 4Runner

[DRAY]

First question - what engine do I use. I just want to get the most for my money. I am looking for efficiency as much as wanting power. I have been reading for days and still...
The 4runner is currently an automatic, but I think I have a 5spd donor coming.
BTW, I mechanic for a living, mainly on Generators, Manlifts, Forklifts, anything electrical and hydraulic. Not claiming to be smart, just wanted you to know so we can communicate better.

 

[PradoTDI]

I would recommend a 1Z, AHU or ALH. I personally have an ALH in my Toyota LandCruiser and am very happy with it. The ALH is probably the best of the three in terms of parts availability, tuning potential and fuel economy. What 5-speed are you going to use, the R150f? There is a 5th gear swap you can do on the 1996+ R150f to give it a better overdrive ratio for running a TDI; it dropped my cruising rpm by around 700 at 70mph.

 

[Jard]

Have you looked at the Toyota diesels? L or KD. They may be easier to swap in, less modifications needed.

I would say they ALH, they seem to be a better swap for power and efficiency in the heavier vehicles, without needing a lot of electrical work to run.

 

[PradoTDI]

Toyota diesels will be much more expensive and less efficient than an ALH, and the electronically controlled ones like the 2L-TE and 1KZ-TE will be quite difficult to wire up and get parts for. I actually swapped my LandCruiser from a 2L-TE to an ALH and have 45hp/100ft-lb more power, get 5-8mpg better and I don’t have to worry about overheating and cracking a $2000 cylinder head.

 

[jmodge]

ALH gets my vote, but my experiences are limited to them. Efficient and simple. Whatever you get, I would suggest buying the whole car so you can play with it and learn a bit about what goes into diagnostics to keeping them running correctly, how the coolant system operates, engine controls, power ranges, idiosyncrasies, etc. I think it would make your planning more successful. Otherwise you can dump a lot of time and money into something and still not quite know what you have or what you really want.

 

[Jard]

Toyota diesels will be much more expensive and less efficient than an ALH, and the electronically controlled ones like the 2L-TE and 1KZ-TE will be quite difficult to wire up and get parts for. I actually swapped my LandCruiser from a 2L-TE to an ALH and have 45hp/100ft-lb more power, get 5-8mpg better and I don’t have to worry about overheating and cracking a $2000 cylinder head.

That is crazy! I never knew, I have just been seeing a lot more diesel swaps in yotas, they are swaping in the 2L or KD. But damn, the power and efficiency differences are quite impressive.
This makes me want to swap my ALH into my Nissan now.

 

[1.9ZOOK]

Are the Toyota diesels available in the US now?
When I did my ALH swap 5 years ago I looked into them
and they were not allowed in the States.

 

[DRAY]

Wow, thanks for all the replies. I use discussiont forums for my Duramax repairs, and Ford info, and ... I really expected I would look at this post tonight and read a bunch of replies telling me to read more here before asking a question like that. Instead I got a lot of freindly info - Thanks!!

I have found a New Beetle, 2001, 280k miles on it but it runs and drives- for $1500. Should I jump on it? Isn't it an ALH?

 

[Jard]

They are still not allowed, as far as I know.
I have seen three yota's with diesel swaps, here in my hometown.

01 is an ALH. $1500 for a donor car, that seems like a good deal.
What is the history of it, do you know? Maintenance done?

 

[DRAY]

Guy bought it at an auction. I did start it and it sound fine to me. Looks like the timing belt cover is off but the AC and everything else seems to be there. That about all I know. Made the deal to buy it tomarrow for 1250.
Any links and/or advice on rebuilding the ALH to go into my 1990 4 runner, will be appreciated. I think I found a donor toy with a 5 speed in it - my 4 runner is an auto. I would not mind the auto, but from what I have read so far, a 5 spd would be the way to go. Any thoughts?

 

[Jard]

This is where the "you need to read/do research" comes in. Check the 4runner sites for alh swaps.

5 speed would make your life easier. I bet there are produced adapters too.

VW 1.9 TDI to R150 Adapter Kit | Doomsday Diesel

Garage Sale Special - Save $40 off MSRP on 9-1/4" Flywheel Option. Only 1 left! The VW TDI to R150 Adapter Kit will mate your VW TDI donor motor to your stock Toyota 5-Speed manual R150 transmission from a 1988-2004* Toyota Pickup/4Runner. All hardware is included, as well as the adapter plate...

www.doomsdaydiesel.net

Heres the first google search. You could make one yourself if you have a way to cut steel.

I would check the tbelt still. Better safe then sorry.
You might want to check compression and cylinder leak down, to make sure the head gasket, rings, valves are good.
Check the ecu, if you are able, for any potential problems.
Check the turbo, actuator.
Since the motor will be out, it will be really easy to check and replace items.

I am no expert, my experience is on gas vehicles, with my own jetta as most of my small diesel experience. So I may not be hitting the diesel specific checks.

 

[DRAY]

The beetle is complete and running. I want to do a complete rebuild and do performance mods as I go. With 280k on the engine, I figure it would be best to have a fresh engine. I have been looking everywhere and finding all kinds of info. Trying to get to the meat of the info is the hard part. But I will continue to search and read. If anyone has links or info to the mods I should look at doing... Thanks agian

 

[Jard]

Dirt lifestyle, the youtuber, may give you some ideas.

 

[03Golfer]

I'm in the middle of an ALH into toy pickup, and have previously owned a 2LTE surf. Don't swap to that toy engine - head cracking is common and it's gutless. I got about 22mpg with 31s and 4.56 gears. Couldn't pull a hill on the freeway to save its life.

I recommend the v6 trans in the Toyota, and a late alh. 121 pin ecu and a stronger block (just learned about the block today as I'm boring to 81mm. May be less of an issue for stock bore).

Don't be like me with an 80 pin ecu and the 4cyl trans

Braden

 

[DRAY]

Thanks 03Golfer. Its that specific advice that I really appreciate. Your talking about the 5 spd transmission?
I bought the Beetle today(it is an 2002 according to the title) and I brought home the doner 1992 Toyota that has a V6 and 5 spd. Might be able to get the 92 toy running, think it has a headgasket issuer but ran when parked. The Beetle runs and drives.
So here is the line up - 2002 Beetle 5Spd with 280k running, 1992 Toyato single cab 4x4 5spd 85K might run, 1990 4runner v6 autom 135K engine locked up.
This is where I am going, until someone changes my mind.
Try to start donor Toy and see if trans and XFER seem ok - then pull drivetrain and rebuild since it only has 85k on it.
Pull engine and transmission from 4runner labeling every wire
Rebuild TDI with as much performance as I can afford and adapt to 5spd from 92 toy.
Goal is to turn the 4runner into an "overlander" that gets really good mileage and can do some moderate to serious off roading. Don't want to go to Moab, just want to be able to take trails in the mountains and deserts without getting stuck.

Thanks for all the info!!! Keep it coming!

 

[PickleRick]

What year 4 runner? On my 87 I had to do a 2 inch body lift and hybrid metal/aluminum oil pan to clear my TDI over the ifs. An ifs lift drop bracket would likely eliminate the need for the body lift, used in combo it would give you so much room for activities.

I used a 2 inch thick diesel conversion specialist r150 kit to help push my motor forward enough to clear the tandem pump. I think the ALH is injection pump? I've never seen one in person but if so all you need is to clear the real coolant T. You have to find a way to keep the coolant flowing from the TDI heater core, the 4 runner cuts flow off when heat is turned off. I used some brass Tees to make this happen.

For my 87 the BHW brackets put all my accessories in perfect position like the OEM 22re. My 5 speed shifter is just a few inches further forward than the original slush box opening in the trans tunnel. I had to fab an ac compressor bracket as the BHW brackets sat too low. I did have to relocate my front steering damper mount on the frame as it hit the crank pulley. The ALH may allow it to sit a little further back and be a non issue. Looking back now I wish I had cut the fire wall and boxed it in a little further back, live an learn.

Because of my 2 to 2.5 it inch suspension lift and motor positioning my factory rear drive shaft no longer fit, too short and because of the angle I needed a double cardan.

Lucky a 3rd gen 5 speed 4x4 rear drive shaft is plenty long enough and double cardan so a 400 Buck shaft vs 700 dollar custom.

My front drive shaft was either a mt or slush box stock shaft, I think. I have several 1st gen tr4 shafts that came with two rigs, one worked. (Both 22re)

I am using the 2005 bhw ac compressor adapted to the OEM 4 runner ac system.

Faast forward automotive did my ECU tune, made the Passat gauge cluster to fab into my dash and made my wiring harness. I'm using the Passat go pedal and faast cruise control.

I'm using the 3.4 flywheel and clutch kit and 3.0 starter.

Using factory Passat alternator, PS pump. Even reused the Passat fuel filter hanging about where the original fuel filter fit. I really need to find a low psi fuel pump to mount in tank rather than the 22re pump with a return t by the fuel pump.

Most of this info will be very close to what fits in a 2nd gen 4 runner as well.

I couldn't run and fmic because I kept ac and have a winch front bumper. The 4 runner has an additional condenser that takes up more room behind the grill than pickups. I ran an mr2 intercooler mounted to a custom skid plate. I'm running a brm in intake with deleted asv to keep the charger pipes short as possible. Without a winch bumper a cheap eBay fmic wood have fit below the grill and been hidden behind the bumper.

I have a build thread on ih8mud, easier to post pics there.

Forgot to add, use a BHW or similar exhaust manifold if possible as many have issues with tight clearance with the transverse model turbos and the Yota starter. Might also have some issues with getting the downpipe around that front drive shaft

I'm running Mandel bend 2.5 from turbo back.