non suzuki swap

[Zuzuki]

Here is another non suzuki swap
http://sandiego.craigslist.org/car/232231417.html
I'll post this in the "Links and Deals" forum too.

[zooky]

nice Jeep, that thing must be cool with a diesel.
Is a standard battery good enough? I had to move the battery to mount the air cleaner and now I have to relocate it. I could stuff it on the other side but if I need a bigger battery I'll probally relocate to the bed. Future plans include a custom bed, so I can incorporate a batery box into it. I have some other mods planned but have to finish the engine first.
Today I started fitting the intercooler, radiator and cooling fan from a volvo. Its all going to fit well.
Do these engines viberate alot?

[wildweasel]

Looks good dude! once you get that all done you can help me stick one in the X90. 

[zooky]

the X90 would be sweet with this swap. I know you would make your own fuel too. I got a way around using a computer with a 4 speed if you do this some day...

[Spulen81]

Wow, great work.  I am in the process of swapping a TDI into my '86 4Runner right now.  Actually its going on the road this week.    I'm still working on finishing the endless little details though. 
I did my mounts pretty much to the way you did, I'm using all VW accessories including power steering so I couldn't use the Toy frame mount on the DS either.   
I had some pretty big clearance issues between the oil pan and front diff and the firewall as you did.  Your oil pan idea probably would have been a big help in that area.  I ended up lifting the whole drivetrain up a bit and doing a body lift at the same time.   I didn't move the engine forward because I didn't want to mess with the drive shafts and everything.  The BL was actually big help down the road when making the exhaust.  Trying to maneuver 2.5" exhaust around the T-case and everything was a little tight.   If this was a straight axle truck it would have been much easier to do IMO.

Do you have any pics of the Montero cannister?  That sounds exactly what I've been looking for.

[deepmud]

links to the TDI runner!! Pics? Sweet!

[Spulen81]

I'm too lame to have a web page, haha.  I will put up a post soon, I just found this page and its a great resource.   

[zooky]

TDI in a 4Runner? I told my wife I wanted to build her one of those when this is done, she just rolled her eyes (thats "wife" for 'no', for you single guys). That would be a perfect family vehicle. How far are you from completing it? I’d like to hear how it drives.
Today I happened to be mocking up my air intake plumbing and Montero air cleaner assembly. For some reason I had a metal canister style stuck in my head. In my quest for junkyard parts I found exactly what I was looking for. Its from an ’89 Montero with the V6, I’ve seen them in other Mitsubishis since.


I already decided to put it where the battery was since the turbo is over there. I drilled a big hole down through the battery tray and inner fender into the forward part of the wheelwell. In these next 2 pictures you can see the tubing I used to draw air from behind the front bumper. The tube says Saab on it, not sure what model it came off of, I found it in a Volvo I was getting parts from. It worked out perfect.




The original plan was to replace the right front blinker on the bumper with a ram air opening, its in the right spot just in front of where the Saab tube is. I am worried about sucking in too much crap so will settle for cool air for now. It would be easy to add ram air later. The fit of that canister and plumbing is perfect, looks like it was made for this application. So far the buildup has been pretty easy but there are so many “little things” to take care of and many trips to the junkyards. I think I have almost everything, just need to put it all together. Once I get it running there are other things I want to do to the truck so its going to keep me busy all winter.

[Spulen81]

That is exactly what I have been looking for.  Hopefully they have a Montero at the pick n pull. 

[zooky]

you should be able to find an air filter canister from any of these vehicles. There will be some differences, mostly inlet/outlet configurations and mounting brackets. I cut the mounts off, thats the reason for the filler in the first pic above

air filter housing:
 DODGE   
 1987 - 1992 COLT
 1990 RAM 50
 1989 RAIDER
 
  EAGLE 
 1989 - 1992 SUMMIT
 1990 - 1994 TALON
 
  HYUNDAI 
 1992 - 1995 ELANTRA
 1991 - 1995 SCOUPE
 1990 - 1994 EXCEL
 1989 - 1998 SONATA
 
  MITSUBISHI   
  1990 - 1994 ECLIPSE
  1989 - 1991 MONTERO
  1986 - 1987 GALANT
  1990 - 1994 PRECIS
  1989 - 1993 GALANT
  1988 - 1990 SIGMA
  1987 - 1992 MIRAGE
 
  PLYMOUTH 
  1987 - 1992 COLT
  1990 - 1994 LASER
 
 
 

[quietmission]

How's the project going?  Any test drive yet?  Keep us posted with the progress and pics.

[zooky]

How's the project going?  Any test drive yet?  Keep us posted with the progress and pics.

its going slowly, busy at work the last 2 weeks I hope to get out there this weekend. I want to set the timing and get the covers, pulleys and belts on so I can finish the cooling system. Then its a bunch of little things. If I get something done I'll post some more pics

[Spulen81]

Thanks for the list.  It should be pretty easy to find.

[zooky]

It was a pretty busy weekend on the toyota, I didnt get as much done as I had hoped. I had a few bugs to work out and spent some time planning how the rest of it is going to go together. No pics, nothing worthy. I worked in the cab of the truck a bit. I painted the gage pillar pod and snaked the wiring and pressure tubes (EGT and boost) to the pillar. I installed the new instrument cluster (w/tach) but forgot to rewire the LED's for the 'glow plug' and 'JET A' indications. I want to install a second tank for the jet fuel and will have an indicator to tell me what tank its running on. I tried to mickey mouse something together to time the injector pump but wasnt happy with my setup, instead of messing with it I ordered the correct tool. I got this on Ebay for $100:



VW210 - Timing Belt tension Gauge
VW382/7 - Piston Protrusion bridge
VW203b - Injection Pump Sheave Puller
2064 - Injection Pump Sheave Locking Pin
2065 - Camshaft Locking Bar
2066 - Injection Pump Timing Adapter a Dial gauge
plus a pointer to use the flywheel timing marks without the bell housing

It even includes a real rarey- a tachometer adapter that works with an old convention tach/dwell meter.

Two Bentley manuals and one VW manual

I think I made out OK. Got to go to the junkyard and look for hoses for the turbo...

[deepmud]

I'd love to hear some comparisons between a triggered tach light and the dial indicator settings.