I have a 2.5" exhaust with a single muffler (Magnaflow IIRC--the one with the better warranty
). It is quieter than the 22R-E was. In fact, right after I got it done I drove it about 500 miles without any muffler (just the OEM dump from the turbo and exiting right where the muffler should be). The turbo whine was SOOOO cool there. The only reason I put on a muffler was that at a certain speed, going up hill, I got a wierd resonance that was pretty loud. It is smooth too (I was worried about that because I used the solid mass flywheel). It's at least as smooth as it was with the gas engine, maybe smoother.
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How much did you spend on this swap? My 22re is dead! and I was thinking about doing the 3.4 5vz-fe swap, but if this swap is as easy as you say besides the wiring I might do it instead. Do you have any #'s on the new motor as in hp and torque? My rig will be strictly off road so fuel milage will not be an issue. It just means I will be able to go farther on the trail. Let me know what you think.
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I spent around 9 grand doing mine, but that includes a bunch of other stuff. I didn't leave a bearing unchanged, I put in new seats, etc... I think the actual cost to get the diesel in and running was around $5,500.
I *think* the 2LT-E is rated around 105HP, but I can't find that number anywhere. Either way, it's FAR peppier and torque-ier than the gas engine. In fact, it feels better than my Dad's 2001 Taco. The torque actually worries me a bit, I feel like I could snap a driveshaft pretty easily if I wasn't careful. In low range, my Toyota is comparable to the old Dodge's we've got (flat fender power wagons).
The downside of a turbo diesel for off roading is that there are some flat spots in the torque band that the engine may not be able to accelerate out of. There are hills that I can climb at 35mph, or 28mph, but 31 just doesn't work. You can downshift, or you can carry more speed, but it's more complicated than a normally aspirated engine. Of course, once the turbo spools up, I'm usually taking my foot off the gas because it just winds up really fast.
If I were looking to build a rock crawler, I'd look at either a 3L engine (same mechanical issues as this, but no hard electricals), or a 1KZ-TE. Both are pretty much immune to the head cracking issues associated with the 2LT-E (and I'd worry about hammering it too hard), and the 3L, being normally aspirated, would have a more conventional torque curve. I understand that they are very similar in driveability to the 2LT-E (aside from the turbo's ability to handle high altitudes better). But that said, I have been nothing but amazed at mine off the roads. In fact, if I did a lot of that, I'd either install a hand throttle or much stronger throttle return springs. When you hit any bump of consequence, your foot bouces off and the drop in power makes you virtually stop, which bounces your foot onto the throttle, which makes you leap forward like a jackrabbit... I'm sure you know the drill, but the diesel has been the most noticeable vehicle I've ever driven like that.
Dan
PS-last I checked, a 3L engine was around 3 grand, and it's a one wire hookup to make it run....