Builds 1964 FJ40 Diesel build, 5 speed, vw TDI, 35's....Lets not call it a restoration. (2 Viewers)

[HandForged]

Need to give some Credit to DIESEL CONVERSION SPECIALISTS in Kallispell, MT. The adapter kit they sent me is a super piece of kit. I had some initial concerns and beat the tech guys up pretty hard before ordering this kit. it uses all of the factory bolt holes, has the alignment pins and still centers the engine/transmission unlike ninety percent of the other adapters out there trust me, I looked. That takes some doing. All I can say is it's very well thought out, uses all stock parts so there's no odd or off brand parts, this starter for that flywheel for this clutch...just get the 3.0 R150 5 speed starter, flywheel and clutch. Bolt them on. I love it.

OH, and before I forget to mention. The center bore runout is around 0.004, so the alighnment on the input shaft is VERY good.

 

[HandForged]

I have been asked for some pictures of the adapter I am using, so here you go. Diesel Conversion Specialists makes it really easy. It even includes the pilot bearing with the flywheel adapter! Bolts are all grade 8, labeled as to where they go. Directions are fairly sparse but there really isn't much needed either. Plates lock together with locating pins. I really like the location of the starter and the use of the transmission locating pins. The best thing I am seeing is that it is a full circle adapter for maximum strength. This adapter is one of the more expensive options out there, I agree with that but sometimes, most times. The options that cost a little more money are often times more well thought out, better designs and better development.

 

[fjdiesel]

How thick is that adapter? Just curious how far it moves that transmission back.

 

[HandForged]

How thick is that adapter? Just curious how far it moves that transmission back.

Roughly two inches

 

[HandForged]

Sun came out today and I had a little extra time so I yanked the little diesel out of the Passat. It is always surprising just how small these little monsters are. In the picture that is a typical ball peen hammer and my hand for comparison. No forced perspective. It must really be awful to know that the 350 guys install those giant motors looking for horsepower and it doesn't make as much as this little engine that is the size of a pony beer keg. HAHAHAHhahhahaaaaaa….

She'll get a good cleaning, accessories are already stripped down and I'll go ahead and hang the adapter kit on. I need to pick up a clutch but otherwise the engine transmission are ready to be mated up and set inside their new home. Not sure at this point what I will do in the short run. Might go ahead and strip down the wiring harness and run it as it is until I get all the correct parts for the manual pump swap. I have a good deal of money and effort into it. Might as well play with it a little

 

[HandForged]

Here are some considerations for those playing along. The intake manifold on these are know to clog with crap over time. Also the input is facing the wrong way for use with an intercooler without having boos plumbing that crosses over the valve cover. This one will be replaced with a later model that faces forward. The other option of course is to simply plumb the boost directly from the turbo into the intake. I have seen it done but it's not what I want to do. Power steering pumps on these are fairly low output as the VW cars all have rack and pinion steering, so they don't flow enough for use with the larger Saginaw power steering pumps. That will be rectified with a Gm style pump and a custom bracket. As this is a 1Z, the crank has a small V belt from the crank to the water pump and power steering pump, as well as ribbed belt that would have driven the AC compressor which I will not be using.

 

[HandForged]

Test fit the adapter. Seeing as how this is officially for a later model TDI, there was a small concern about fitment. Well, not anymore. This adapter is magic! Removed the tin pan from the mounting surface and bolted it on. Easy as that. Dead-nut perfect. Although it is a little bit "too pretty". It will get dirty soon enough.

 

[HandForged]

Realized that I need to get some Por 15 or chassis saver shipped in...DANG IT. Now would be a great time to wire wheel and shoot the frame after welding in the new motor mounts.

 

[mrjordann]

I'm guessing you don't know very much about land cruisers... None of the drivetrain in my truck is original or numbers matching. In fact nothing is stock or numbers matching with the exception of the frame, tub and tailgate. I have no part of the SBC crowd, never put one in a cruiser. This old truck is rough, that is the reason I chose it for this. I am not a restoration guy. I'm a diesel mechanic and gear head. I am installing a drivetrain that weighs approximately 300 pounds less than the factory drivetrain, makes double the horse power/ torque, while being MUCH more reliable and has parts availability at any parts store in the country? I wouldn't really call that a burden. If you think this one looks rough, you should have seen where I started with my last cruiser build...

Well I called a SBC a burden not your diesel... But how come I "don't know very much about land cruisers"?

 

[HandForged]

Well I called a SBC a burden not your diesel... But how come I "don't know very much about land cruisers"?

Mainly as you didn't know the f145 engine, transmission, top, windshield frame or doors were even close to correct for a 1964 landcruiser.

 

[REZARF]

Cool thread man, when is the 40 rescue mission in Lewistown? Clock is ticking with the snow on the way

 

[mrjordann]

Mainly as you didn't know the f145 engine, transmission, top, windshield frame or doors were even close to correct for a 1964 landcruiser.

Oh that's true. Obviously the top wasn't. An F145 might not be correct but it's more correct than a vw

 

[FJBen]

Here are some considerations for those playing along. The intake manifold on these are know to clog with crap over time. Also the input is facing the wrong way for use with an intercooler without having boos plumbing that crosses over the valve cover. This one will be replaced with a later model that faces forward. The other option of course is to simply plumb the boost directly from the turbo into the intake. I have seen it done but it's not what I want to do. Power steering pumps on these are fairly low output as the VW cars all have rack and pinion steering, so they don't flow enough for use with the larger Saginaw power steering pumps. That will be rectified with a Gm style pump and a custom bracket. As this is a 1Z, the crank has a small V belt from the crank to the water pump and power steering pump, as well as ribbed belt that would have driven the AC compressor which I will not be using.

Which year intake faces forward?

Yeah I've cleaned my intake twice now, the first time it was almost completely plugged up.

 

[fjdiesel]

Speaking of intakes... On the tdiforum there was a post where someone did flow tests on intakes. Of course, I saw it right after I bought a PD150. After reading the article the PD150 came in second, so I wasn't too worried about it. I don't recall which one flowed the best. It was off a newer model IIRC... Maybe save you some time searching and give you a cheaper junk yard option..

 

[fjdiesel]

Post #162 in my thread has a pretty good pic of the PD150 intake which faces forward. HTH.

 

[Godfather90]

On my first conversion i used an MKII 8V intake and port matched it:

On my second conversion I cut the AHU intake and rotated the inlet 180*:

On my third i used the ALH:

On my 4th conversion I was going to use the BHW with some work done to it, but I believe I went with the PD140. The PD150 aims towards the flywheel.

There are many ways to do this.

-Mike

 

[HandForged]

I have my eye on a builder in the UK that makes a really nice high flow intake. It beats everything on the market that I am aware of. EGR delete and a straight through flow design. That and they are only about 250.00 US. They have a lot of really nice parts for the 1.9 TDI. I've been relying on those overseas guys for a good amount of knowledge on this front. They are light years ahead of us here unfortunately.

The mechanical pump I have in the works is actually off of a Landy 300 TDI. They have been doing this swap for 20 years and we just now figured it out...LOL. There's just SOOO much more tech out there for these engines that we in the states are even aware of. Expand your horizons! HA!

 

[rkymtnflyfisher]

They are light years ahead of us here unfortunately.

Thanks to the EPA more than likely.

 

[HandForged]

Thanks to the EPA more than likely.

Possibly but I also think folks in the US never really took this engine seriously. Americans are all about BIG BIG and BIGGER! Small super efficient diesels are not out forte. The europeans took it and ran like someone was chasing them.

 

[Godfather90]

We should meet in the middle and drag race when you're ready.