TDI first gen 4Runner

Discussion in 'Build Threads' started by John Smith, Mar 4, 2018.

  1. John Smith

    John Smith Well-Known Member

    Joined:
    Jan 30, 2010
    Location:
    mt. pilot nc
    The Goal/s:

    1) Replace a blown 3.0 with a
    VW TDI (ALH)

    2) Make everything

    3) possibly offer a kit for sale (if anyone expresses interest)


    Starting with:

    1988 4Runner

    3.0, 5speed

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    Last edited: Mar 4, 2018
  2. skyhighZJ

    skyhighZJ Thanks for your taxes

    Joined:
    May 31, 2012
    Location:
    Fort Polk, La.
    Interested!!
     
  3. John Smith

    John Smith Well-Known Member

    Joined:
    Jan 30, 2010
    Location:
    mt. pilot nc
    @skyhighZJ i finished machining the adapter last week. It was done correctly, using the dowel pins from both manufacturers! Some other adapters rely on the fasteners to locate adapter placement. I’ve read blogs stating concentricity was off by as much as .060!
     
  4. skyhighZJ

    skyhighZJ Thanks for your taxes

    Joined:
    May 31, 2012
    Location:
    Fort Polk, La.
    Does it mate the tdi to the stock toy bell housing? What is the power output and do you think it will be within the power handling range of the trans? I assume it’s a w56 of some sort ?
     
  5. John Smith

    John Smith Well-Known Member

    Joined:
    Jan 30, 2010
    Location:
    mt. pilot nc
    Yes, my adapter bolts to the back of the TDI and the factory toy transmission bolts directly to it.

    I’m thinking the ALH is 90ish HP and 150lb/ft (very comparable to the 22r) While those numbers aren’t too impressive, the people that have completed the swap are saying the TDI still out-performs the 22r and 3.0.

    Both my vehicles have the 3.0 so the transmissions are the r150. I’d feel ok saying nearly all the Toyota transmissions would handle the TDI, even with upgrades and tuning.

    When I’m done, i plan on making around 100hp and 200lb/ft to the wheels.
     
    BigSouth and skyhighZJ like this.
  6. RatLabGuy

    RatLabGuy You look like a monkey and smell like one too

    Joined:
    May 18, 2005
    Location:
    Churchville, MD
    Subbed.
    Curious about mating for the auto from a 22re.
    Bolt patterns are different from the W56. Also isn't the flexplate portion specific to the 6 cyl? I believe the starter is on the opposite side from the 22r.
     
  7. John Smith

    John Smith Well-Known Member

    Joined:
    Jan 30, 2010
    Location:
    mt. pilot nc
    Right now, all I have available is an adapter for mating the TDI to the 3.0/3.4 6 cylinder engine. The pattern is different than the 22r.

    If there’s interest in a 22r to TDI swap, I’ll machine an adapter.

    The adapter would work for automatics as well. However, the 6 cylinder 4x4 transmission is electronically controlled. I’m not certain if you could make it talk with a VW ECU. I think the 2wd trans is not controlled by the ECU. I have no desire to pursue an automatic swap so I’ll never really know.
     
  8. John Smith

    John Smith Well-Known Member

    Joined:
    Jan 30, 2010
    Location:
    mt. pilot nc
    D24A7CAF-078D-4263-BAC0-C575B6D671A0.jpeg

    This was my first version. It’s an SLA part! From here, I trimmed the fat and optimized the design!
     
    1stgenxxx likes this.
  9. John Smith

    John Smith Well-Known Member

    Joined:
    Jan 30, 2010
    Location:
    mt. pilot nc
    The starter for the 22r, 3.0 and, the TDI are all on the passenger side
     
  10. Metto

    Metto Well-Known Member

    Joined:
    Mar 20, 2005
    Location:
    Huntersville, NC
    Neat! my brother has been telling me about this for the past couple of weeks, he said you were getting the adapter plate anodized. Bling!
     
    John Smith likes this.
  11. John Smith

    John Smith Well-Known Member

    Joined:
    Jan 30, 2010
    Location:
    mt. pilot nc
    Thanks!

    Yeah, he's been a huge help! I enjoy working with him. He's definitely one of the best we have!
     
  12. John Smith

    John Smith Well-Known Member

    Joined:
    Jan 30, 2010
    Location:
    mt. pilot nc
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    Ideally, I wouldn’t waste this much material but this was a piece of scrap with a miscellaneous bolt hole pattern. It’s positioned to not include those misc holes!
     
    ORV design and fab and yager like this.
  13. strange1

    strange1 Well-Known Member

    Joined:
    Mar 31, 2005
    Location:
    Elkin
    How far into the wiring have you dug? My 3.4 won’t last forever and a small diesel does sound interesting.
     
  14. Ibayne

    Ibayne Well-Known Member

    Joined:
    Jan 5, 2016
    Location:
    Fletcher
    Awesome!!!!! I’ve been in touch with a guy in Canada that does these all the time. But he uses the Aaz non computer motor that USA doesn’t have. He hasn’t done the ALH with a 3.0 he’s done plenty with the 22s....
     
  15. John Smith

    John Smith Well-Known Member

    Joined:
    Jan 30, 2010
    Location:
    mt. pilot nc
    @strange1

    Im not too deep into the wiring/harness. Should be like most other ECU “hookup”. I do know the ALH doesn’t need to see signal from the cluster. I’ve also noticed no one is using the factory Toyota tach after the swap. I’m not sure what signal it needs to see. Right now, I’m focused on getting it mounted in the vehicle with some respectable parts!
     
    strange1 likes this.
  16. John Smith

    John Smith Well-Known Member

    Joined:
    Jan 30, 2010
    Location:
    mt. pilot nc
    I’ve seen some of his stuff. You’d be much happier with my components...

    I have two reasons for starting with a 3.0.

    1) I have a good running 3.0 in my xcab. I needed a Truck/4Runner with a blown engine to accept my good engine.

    2) for whatever reason, the 22r’s have a cult following. Very few people want to give up the 22r in favor of many better engines. There’s a lot of 3.0’s out there that need work but they’re just not easy to repair. With that said, a lot of people with 3.0’s love their trucks and need/want a better solution, in comes the TDI swap!!!
     
    02gmc5.3 likes this.
  17. John Smith

    John Smith Well-Known Member

    Joined:
    Jan 30, 2010
    Location:
    mt. pilot nc
    I plan to use the VW alternator and P/S pump. I really haven’t looked into a solution for A/C. I’ll need to get the engine mounted and running first...
     
  18. RatLabGuy

    RatLabGuy You look like a monkey and smell like one too

    Joined:
    May 18, 2005
    Location:
    Churchville, MD
    Maybe I'm wrong but I think you'll be netting a loss on power (assuming stock). Efficiency though...
     
    Last edited: Mar 6, 2018
  19. John Smith

    John Smith Well-Known Member

    Joined:
    Jan 30, 2010
    Location:
    mt. pilot nc
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    Bling, Bling!
     
  20. RatLabGuy

    RatLabGuy You look like a monkey and smell like one too

    Joined:
    May 18, 2005
    Location:
    Churchville, MD
    What is that made of?
     
  21. drkelly

    drkelly Samurai wheeler

    Joined:
    Mar 21, 2005
    Location:
    Oak Ridge/Stokesdale, NC
    He is not planning on leaving the motor stock. Apparently it can easily be tuned up for more power like most other diesel engines.
     
    Caver Dave likes this.
  22. John Smith

    John Smith Well-Known Member

    Joined:
    Jan 30, 2010
    Location:
    mt. pilot nc
    Blood Sweat and Tears!


    6061 Aluminum, anodized
     
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  23. paradisePWoffrd

    paradisePWoffrd Recovering Project Junkie

    Joined:
    Nov 5, 2005
    Location:
    Newton, NC
    are you going to need to space the flywheel off the same amount, or does the adapter account for crank stick-out?
     
  24. John Smith

    John Smith Well-Known Member

    Joined:
    Jan 30, 2010
    Location:
    mt. pilot nc
    Yes, there will be a flywheel spacer and it will accommodate for the correct crank protrusion.
     
  25. Caver Dave

    Caver Dave Just holdin' it down here in BFV Moderator

    Joined:
    Mar 10, 2005
    Location:
    Hooterville (24171)
    They can be built (to near double factory levels) to the point that the OE VW halfshafts shred faster than tires!
     
    Jake_S, drkelly, John Smith and 2 others like this.

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