85 4runner VW 1.9 AFN M-TDI swap

[Hardstripe]

Sent that nicked cam back, should get it in the mail today or tomarrow along with a brand new aluminum dbl pass aluminum radiator. Once i get the cam, this build will take off.. slap the cam in install new balanced injectors with upgrade nozzles, hybrid turbo upgrade, 11mm pump upgrade, then just need to come up with money for my ecu tune and hook up the harness.

[Hardstripe]

My cam came in the mail! Heres a pic of me opening the box with a steak knife and consequently visiting the doc... Its bigger than it looks, about 3/4" deep hehe

[Hardstripe]

My top speed is about 70 mph- thats really workin it, im guestamating around 5000 rpm. I need to cruise at 70 mph with 2000-2500 rpm, I think thats where my torque tops out if I researched correctly. I am digging around for some 3.54 gears in an 8" axle but having a tough time finding any- there are some adds on google shopping popping up but when I call, they are all discontinued.

http://www.precisiongear.com/toy8.htm
These are the only ones I can find, but they are discontinued when I called- I wonder if they can still make them though... like a custom order. Ill have to call them back and dig around some more. Its either that or get some HUUUUGE tires hehe.

Wierd thing is, when I enter in my specs and calculate the RPM's, it says I should be running about 2500 RPM's.... so unless im slipping like crazy, which doesnt seem likely, something is off here.

calculated at this site:
http://www.csgnetwork.com/multirpmcalc.html
specs: 4.11 gears, .850 5th gear, 33" tires, 70mph.
Use the portion at the bottom where you can manually enter the transmission 5th gear ratio.

[RBX]

What about bigger meats? Something doesn't seem right.

[TDIJ]

What happened? In post 61 you said it seemed like you nailed the gear ratio.

I am running 4.88 on 35's and am running about 3k at 75. With 4.11's and 33's you should be lower than that... especially with the 85 trans having a higher fifth gear than my 84 transmission. Are you positive you have 4.11's? Are you in low range?

Something seems off here... you shouldn't be running anywhere near 5000 rpm's. If you are on 33's, and assuming a g54 transmission it would take a rear axle ratio of about 6.6 to put you at 4k rpm and 75mph, and 8.3 at 5k rpm and 75 mph.

What are you using for your rpm reference? I know when I first put mine in, I was using my ear for reference and thought I was revving a lot higher than I was. Once I got my vcds hooked up I realized how off I was. The TDI through the turbo with no muffler sounds much different than the jeep 4.0 i pulled out, and I was running without a muffler with the gasser near the end. After nearly 10k miles I still can't stand the sound of the tdi without a muffler much over 3000 rpms. I feel like I'm raping it, and I'm no stranger to bouncing engines off of rev limiters in other cars.

If you are really revving that high... something is not right. I would quit shopping for those gears and figure out what's up. Your gear ratio should be similar to your 22re... I would say one step higher... maybe two at the most but still not that far off the best ratio for the gasser.

I'd start by verifying your transfer case range... and your rpms. if it's in high and you are revving that high it could only be serious clutch slippage(or maybe some type of trans failure)... but I would think you would see other signs if the clutch was slipping, and it would be inconsistent based off of throttle response.

Other than that... how is the build going? Do you have the alh pump and ecu hooked up yet?

I like the bob. Love when people bob 4runners and maintain the original top like that!

[Hardstripe]

well in post 61 I had not gotten it on the freeway yet, just got it up to 55 on the road out back- freeway speeds is totally different I guess, seems like shes about to pop. Thanks for the compliments on the bob, it really seems to add character to it. As to the transmission- its a brand new marlin crawler HD tranny, and without using 4-lo, the transfer case shouldnt have any gear reduction. I am going by ear- I have a rpm setup for my alternator but I still need to rig it, some soldering in the alternator case. To hit 70 I had to be going downhill and pedal to the floor- couldnt possibly get it to go any faster. I dont have the pump and ecu hooked up yet, but I have basically all the parts I need, and when summer quarter gets out I will be hittin it hard, trying to finish. I even got the ecu tuned at kerma tdi, so I am pumped- should show significant gains in HP and torque with all these upgrades. As soon as school gets out on Thursday, I will be slapping that cam in, bolting on the turbo, putting in the pump, installing the balanced injectors, making some custom mounts for my fmic and new double pass rad, then fixing up the plumbing a bit. This stuff should only take a couple of days to do it right, then I will grab that wiring harness and put it on some pressboard, and start labeling.... and labeling.... have to make sure I have all the sensors, find out where they go, figure out how this 3 bar map goes on, the maf, and try to get this silly electrical gas pedal to work somehow. hehe. I hate wiring crap.

[TDIJ]

okay... I would bet it is just the sound, and it's not really revving that fast. Don't spend money on gears until you get the computer hooked up and can plug vcds into it to read rpms... or your alternator tach set up. I'm sure you will find that you aren't wrapping it out near as much as you think once you find a way to verify your rpms.

Do you have a turbo on it right now? if not... you will have no power to get to highway speed whatsoever. I've blown my turbo hoses a couple times (really need to get them flared so they quit slipping off) and limping it to the next place to stop is painful, even at full throttle, the power just disappears once you get to a certain rpm.

As far as the wiring goes... it's not nearly as bad as I thought it was going to be. My best suggestion is to get a good wiring diagram (bentley manual) and study it. Then get a large poster board and draw your own diagram with all the wires you actually need. This will allow you to visualize everything, and see how it all connects. It is hard to really envision it all when you are flipping around between a dozen pages in the book.

I'd share mine with you except I used the ahu. Yours shouldn't be much harder as long as you had kerma delete the immobilizer with the tune.

[Hardstripe]

thanks for the idea. I did have a turbo on it, the stock borg warner.. had it up to 16 psi tops, but usually ran around 14 psi. not a really huge turbo.

[TDIJ]

Okay... that's likely the one or similar to the one I have. I'm still running stock turbo/nozzles/tune. I have no problem running highway speeds... I have roughly the same usable power as I used to in my 6 cylinder. I know you are on a manual pump... and not a quality one at that... but I would think highway speed should be doable without a descent. You will have no issue with power once you get your kerma tuned computer in it... promise!

What turbo are you planning on running?

[alexandrlehmann]

i dont know where you are located but there is a company called Gears & Rears up here in canada that im pretty sure has toyota 8" stuff. google them if you cant find anything

Originally Posted by Hardstripe

My top speed is about 70 mph- thats really workin it, im guestamating around 5000 rpm. I need to cruise at 70 mph with 2000-2500 rpm, I think thats where my torque tops out if I researched correctly. I am digging around for some 3.54 gears in an 8" axle but having a tough time finding any- there are some adds on google shopping popping up but when I call, they are all discontinued.

http://www.precisiongear.com/toy8.htm
These are the only ones I can find, but they are discontinued when I called- I wonder if they can still make them though... like a custom order. Ill have to call them back and dig around some more. Its either that or get some HUUUUGE tires hehe.

Wierd thing is, when I enter in my specs and calculate the RPM's, it says I should be running about 2500 RPM's.... so unless im slipping like crazy, which doesnt seem likely, something is off here.

calculated at this site:
http://www.csgnetwork.com/multirpmcalc.html
specs: 4.11 gears, .850 5th gear, 33" tires, 70mph.
Use the portion at the bottom where you can manually enter the transmission 5th gear ratio.

[Hardstripe]

I am pretty sure I posted it in here... but man- I am upgrading everything right now. 11mm alh pump, stage 2 pp762 injectors, stage 2 regrind cam, vnt 15/20 hybrid turbo (will run ~24 psi), 3 bar map, along with that chip. everything combined should double my hp and torque.

[locost7]

I was thinking about ur gearing. Have u thought about just using an overdrive box if you cant get the right diff ratio and want to stay with a certain size tire?

[TDIJ]

Maybe... I didn't go back and reread it in detail... just remembered you were going with an alh computer.

That should be a nice engine when all is said and done. I am looking forward to the day I tune/nozzle mine... that is if I don't decide to go with a manual pump. But as it is now... stock power is sufficient.

I have confidence your gearing will work itself out. Something seems a little off... but there is no reason your gearing shouldn't be working for you as is. Maybe your sense of rpms are off... maybe you just have a complete lack of power with that pump of yours... maybe both.

Like I said... my wiring is different as it's an ahu... but if you have any questions don't hesitate to hit me up.

Either way... welcome to the club... you are going to love it!

[Hardstripe]

Originally Posted by locost7

I was thinking about ur gearing. Have u thought about just using an overdrive box if you cant get the right diff ratio and want to stay with a certain size tire?

Overdrive box? Is this some kind of attachment to the w56 transmission? Ive never heard of such a thing.

[BCzuk]

Im eager to see how the wiring goes. I have a 02 ALH sitting in my garage eagerly waiting to be swapped. With your new add ons it should have some great hp/tq. Sorry if I missed it but what clutch are you running? I am planning on adding a PD150 intake with tune/nozzles and am a bit worried about killing my Marlin 1600# clutch

[Hardstripe]

I am also using the marlin 1600lb hd comp, I think it will work fine- these things are about as beefy as it gets, and designed for people who hammer on their trucks with low gears and doublers with huge tires... lots of torque.

[BCzuk]

Originally Posted by Hardstripe

I am also using the marlin 1600lb hd comp, I think it will work fine- these things are about as beefy as it gets, and designed for people who hammer on their trucks with low gears and doublers with huge tires... lots of torque.

Ya true enough. I had a little fear after reading some experiences on tdi club but cant hurt to try

[filipefalco]

Originally Posted by Hardstripe

My top speed is about 70 mph- thats really workin it, im guestamating around 5000 rpm. I need to cruise at 70 mph with 2000-2500 rpm, I think thats where my torque tops out if I researched correctly. I am digging around for some 3.54 gears in an 8" axle but having a tough time finding any- there are some adds on google shopping popping up but when I call, they are all discontinued.

http://www.precisiongear.com/toy8.htm
These are the only ones I can find, but they are discontinued when I called- I wonder if they can still make them though... like a custom order. Ill have to call them back and dig around some more. Its either that or get some HUUUUGE tires hehe.

Wierd thing is, when I enter in my specs and calculate the RPM's, it says I should be running about 2500 RPM's.... so unless im slipping like crazy, which doesnt seem likely, something is off here.

calculated at this site:
http://www.csgnetwork.com/multirpmcalc.html
specs: 4.11 gears, .850 5th gear, 33" tires, 70mph.
Use the portion at the bottom where you can manually enter the transmission 5th gear ratio.

That calculations are right. It maches exactly what my 73 cruiser does: 75mph at 3000rpm on 33".
When you talk about the torque of that engine you shouldn't forget that you have a mechanical pump and that changes torque curve completely.
Nice rig

[toygasm]

awesome build!!!my buddy and i have discussed the veedub desiel swap.i guess is popular in jeeps?(he has a cherokee).that got me thinking about doing it to a toyota but he was throwin out some very expensive build cost numbers that turned me off.after seeing your build i want to do this again.but i know i never will.lol.you will have to post some more vids once she is done.

[locost7]

i have not seen one for the w series specifically, i have seen them for the domestic crowd. try a google search, it might give you an idea if you could make it work for your application

[Hardstripe]

soooo........... been slacking off a little. Took so long between working on it Im sure Ive lost bolts, and I cant remember where some of these things go haha. I just started the diesel & heavy equipment mechanic 2 yr course at the local college, and my instructor gave me permission to bring this engine in as a project- I am going to tear it down and put it back together starting this monday! sooooo should be some cool updates, we get to see what this thing looks like on the inside.

[TDIJ]

Subscribed all over again! Can't wait to see this... please keep it current on the engine tear down and build up... I'm sure I'll be doing that to mine one day.

I would spend some time on TDIclub and research how to build it up a little while you are in there!

[coilysammy88]

Cool project. I had a good experience with the guys at acme when I did the swap in my samurai too. I ended up going with an 8 valve gas motor only because the cost of the diesel motors was so high. I did a mequasquirt computer with wideband o2 and digi injectors. After all said and done with big heavy 35-15.50-15 swamper sx's it put down 71.5hp at the wheels which is considerably better than a samurai motor but I still wish I would have gone with the diesel. Anyways, good luck and hope to see some pics of it on the trail!

[Hardstripe]

Anyone have an idea about how I can get my RPM guage to work?

[TDIJ]

I believe for the AHU it is a pretty easy deal... just plugging the right wire into your tach and possibly using an adapter to change pulses... depending on the compatibility of TDI/toyota pulses. Being a 4 cyl truck I would hope it matched.

I can't say for sure though... I haven't messed with my tach yet... I've just been using my scan gauge.

I would imagine ALH has a wire for it too.

Here's the only thread I know of directly discussing it... but it's been a long time since I've read through it

Tachometers for conversions - TDIClub Forums