Tacoma TDI project

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Re: Tacoma TDI project

Postby ringbearer » Tue May 01, 2018 12:58 pm

You totally should have towed the Yota with the Jetta ;)
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Re: Tacoma TDI project

Postby dana » Fri May 11, 2018 7:48 am

nothing exciting to report, other than I had a strange issue yesterday that nearly torched this truck. Went to start it, and the starter turns half a revolution, stops and smoke starts pouring out from under the hood. Popped the hood and found both battery cables red hot and the battery posts and plastic starting to melt! I had tools with me and got the ground off somehow. It was really only about 15 seconds, but I thought that I might end up with a burned truck or an exploded battery in my face. Pretty scary. I got a nasty burn on my thumb from ripping the ground off.

I figured the starter must have shorted to ground internally. I tore all the wiring out in the parking lot and rigged up a jumper from the alternator to the battery and fuse box, pushed her down a hill, jumped in and bump started it and went about my day. Ran a bunch of errands and just left it running everywhere.

Pulled the starter, and it was dead shorted inside the solenoid. Rebuilt the main wiring and put in a NAPA reman starter.....which of course has a faulty bendix, and only works one out of every four tries.....Back to the parts store.

Glad the truck didnt burn. I did not have a fire extinguisher with me.
current:
-mk4 tdi wagon with some mods
-TDI b3 90q, holset turbo, be strong little connecting rods!
-the turbo tractor
past:
-11 second 90q junker
-20vt swapped 90q winter beater
-efi 10vt 4kq
-way too many other long gone urs's, 200's 4000's, b5's
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Re: Tacoma TDI project

Postby ringbearer » Fri May 11, 2018 11:50 am

Glad you saved it! Too soon to burn it down.
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Re: Tacoma TDI project

Postby audifreakjim » Fri May 11, 2018 11:54 am

Just because it isn't an old Audi, doesn;t mean you shouldn't have a fire extinguisher
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Re: Tacoma TDI project

Postby dana » Fri May 11, 2018 12:54 pm

audifreakjim wrote:Just because it isn't an old Audi, doesn;t mean you shouldn't have a fire extinguisher
:lol:
very true words. Added to my road survival kit in this truck.
current:
-mk4 tdi wagon with some mods
-TDI b3 90q, holset turbo, be strong little connecting rods!
-the turbo tractor
past:
-11 second 90q junker
-20vt swapped 90q winter beater
-efi 10vt 4kq
-way too many other long gone urs's, 200's 4000's, b5's
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Re: Tacoma TDI project

Postby vt10vt » Fri May 11, 2018 2:11 pm

Guess this thing isn't so boring after all.
Last edited by vt10vt on Sat May 12, 2018 11:45 pm, edited 1 time in total.
-Shawn C.
2001 S4 6spd Avant blk/blk - stock daily
2002 01E B6 A4 Built FYF, Built 1.8T, HX35 ~330whp
1989 MC-1 200 Avant- MS1 -Gone but will never forget her lessons
1987 5ktq Sedan - Best $500 beater ever
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Re: Tacoma TDI project

Postby audios » Sat May 12, 2018 9:06 am

dana wrote:The ETDI swap is so simple, once the harness is pared down. Electronic control of the TDI makes it so much better in every way in my opinion.
-full glow plug control
-working OBD plug and check engine light for VT inspection Nazis. This alone makes the ETDI swap a requirement in my opinion.
-cruise control
-viable tach output
-engine tuning variable with variable outdoor conditions

Some people love an MTDI, but it does not make sense to me, especially when swapping into an OBDII vehicle.



I agree, this is why i am searching for a pre '97 vehicle as obd2 will not be an issue here in NH. I know it is '95 now the guy i go to for inspections said they are changing it to 97.
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Re: Tacoma TDI project

Postby dana » Mon Oct 01, 2018 10:12 am

I've been using this truck all summer. The pilot bearing in the flywheel is going very bad, so its definitely time to get serious about the ALH swap.

I got my donor ALH mk4 jetta running well. It would start fine, but stumble a fair amount and make smoke that smelled like fuel. I suspected bad injectors or a failing pump. I bottle fed it some diesel purge, and it immediately improved. I think the fuel filter or fuel pickup is restricted in the car.

Tested injector balance numbers with VAG COM, they were decent. It still looks like the injectors are somewhat worn, but the car runs smooth and no smoke.

I tested compression, I got 500 470 505 480. Not the closest numbers I have ever seen, but good enough to consider things healthy in my book. I suspect this engine is highly sooted up. I will be pulling the head and cleaning all the ports and valves before putting it in my truck.

I also got the adapter from Randy at TD Conversions and test fitted it. His adapters are much better than some of the others on the market, because they use the dowel pins on the engine to align, not the threaded holes, which vary from block to block. This caused many clutch and pilot bearing failures on others who used the ACME kits that have been out for a while.

I contacted Randy several years ago because i saw he was making VW kits for other truck transmissions, and I asked about toyota. I told him I would buy one if he made them. I kept checking in over the years, and he finally got enough people interested, so he decided to make the part.

His kit was intended for a 22re flywheel with a 9 1/4" clutch. Other people have had issues with those clutches holding, and one person had machined the 22re flywheel to accept a larger 10" clutch from a v6 tacoma. This was a good setup for him, but his flywheel was too light.

Again, I contacted Randy and inquired, because I saw he offered heavy flywheels for other applications. I was able to convince him to make a heavy flywheel that fits the 22re bolt pattern and takes a 10" clutch. He sells centerforce clutches, so I got a clutch rated to 385 foot pounds.

They are strange clutches, they have weights that swing out and apply more clamping pressure as RPMs rise. I am suspicious that the weights are going to make noise at idle, but he has them on other TDI swaps with good luck. We will see.

Below is the adapter setup fitted to an AHU block I happened to have in the shop. Everything looks good!
Image
Image

Scrapping a MK3 that I parted to use the cylinder head on my TDI audi. Towing weight with the 4 cylinder tacoma is pretty funny. Pinned all the time.
Image
Image
current:
-mk4 tdi wagon with some mods
-TDI b3 90q, holset turbo, be strong little connecting rods!
-the turbo tractor
past:
-11 second 90q junker
-20vt swapped 90q winter beater
-efi 10vt 4kq
-way too many other long gone urs's, 200's 4000's, b5's
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Re: Tacoma TDI project

Postby Afterthought » Mon Oct 01, 2018 12:06 pm

This project is awesome !

I wonder how you will be able to tow with the TDI in it .
I had a new Tacoma with the v6 and I still couldn’t tow anything close to car size without just maxing it out . Makes sense then why people get the 4 cyl, to get the better mileage and still probably be able to tow about the same amount .
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Re: Tacoma TDI project

Postby jbrentd » Mon Oct 01, 2018 12:37 pm

Cool project!

Afterthought wrote:I had a new Tacoma with the v6 and I still couldn’t tow anything close to car size without just maxing it out .


I know my v6 Toyota was having a hard time bringing my coupe home.
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Re: Tacoma TDI project

Postby dana » Mon Oct 01, 2018 12:59 pm

Afterthought wrote:This project is awesome !

I wonder how you will be able to tow with the TDI in it .
I had a new Tacoma with the v6 and I still couldn’t tow anything close to car size without just maxing it out . Makes sense then why people get the 4 cyl, to get the better mileage and still probably be able to tow about the same amount .


I have helper airbags in the truck, which helps the ride a lot with heavy tounge weight.

I Know it will tow better with the TDI. I have towed some retardedly overweight things with my mk4 jetta and it had no issue power-wise. Its never going to be a heavy hauler, but I know the TDI has a better power curve than the Toyota 3rz.
current:
-mk4 tdi wagon with some mods
-TDI b3 90q, holset turbo, be strong little connecting rods!
-the turbo tractor
past:
-11 second 90q junker
-20vt swapped 90q winter beater
-efi 10vt 4kq
-way too many other long gone urs's, 200's 4000's, b5's
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