1993 Hilux Surf 1.9TDi swap

[Fantastika]

I was swapping a 2.4l commonrail 5 cylinder volvo diesel engine in to my 4runner, until i realised how much extra work it would be with relocating the CP3 and the vacuum pump, and figuring out the messed up wiring, so that project is cancelled, instead i will be swapping in a 1.9 TDI from a B5.5 Passat. Got the engine and the wiring for 250eur though its missing the turbo and the exhaust manifold. Engine code is AVF if anyones interested, its the 96kw version and is theoretically more tunable than the volvo engine, or at the very least the tuning is easier and much more understood. No pictures of the engine itself as somehow i didnt take any.
I looked around at what sort of adapters id need to run the stock toyota transmission and i decided i would make my own, i have access to a cnc and 3d scanning so its not asambitious as it may seem. Bought a broke 1.9TDI to scan the transmission side bolt holes

the scan came out pretty good, and from it i made a simple setup out of ply on a laser cutter to make sure my cad aligns with reality

Next i have to scan the transmission but for that i first have to take it out of the car and is its wintertime and cold currently that wont happen for a little while. In the meanwhile i will sort out the exhaust manifold and turbo, havent quite decided what turbo to use, the 2260 is commonly used but i want really nice and quick spool as its an offroader so i might go with a TB15 or a 2056v.

 

[AirheadNut]

I have a VW blueprint of one of their industrial 1.9 TDI's that shows dimensions of all the bolt holes on the block, it's what I used to design my adapter plate. I can share it if you'd like to use it to double check your scan.

For the transmission side of the adapter I had a precision 3D scan made of a spare bell housing and empty transmission case I had. I used a 5VZ-FE bell housing so it won't be the same as yours, but the scan enabled me to translate the location of the input shaft centerline to the plane of the bell housing.

 

[Fantastika]

I have a VW blueprint of one of their industrial 1.9 TDI's that shows dimensions of all the bolt holes on the block, it's what I used to design my adapter plate. I can share it if you'd like to use it to double check your scan.

For the transmission side of the adapter I had a precision 3D scan made of a spare bell housing and empty transmission case I had. I used a 5VZ-FE bell housing so it won't be the same as yours, but the scan enabled me to translate the location of the input shaft centerline to the plane of the bell housing.

Did you scan it with the input shaft in place? If not how did you locate it afterwards? And if you could send over your blueprints id be very thankful! Also what manufacturing method did you use for your adapter?

 

[AirheadNut]

I scanned the transmission without the input shaft, the guy who did the scan made a CAD model of it and translated the bore location for the input shaft bearing to the front plane of the bell housing.

This is what I ended up with; all the bell housing bolt hole locations with the input shaft bearing bore in the same plane:

For manufacturing I had the rough plate laser cut from 1/2" HRPO steel plate along with the clearance holes for bolts. The tapped holes and the dowel pin/sleeve holes I had drilled/tapped/reamed as necessary by a local machine shop.

 

[AirheadNut]

Here's the drawing of the industrial TDI. The block is pretty much the same as any 8-valve VW diesel.

 

[Fantastika]

Interesting approach with the bellhousing, didn't consider that as an option, thanks!

Here's the drawing of the industrial TDI. The block is pretty much the same as any 8-valve VW diesel.

Now this does worry me, with the drawing scaled correctly it looks slightly off from my scan, and the scan is correct as the plywood test fit perfectly

 

[Fantastika]

I scanned the transmission without the input shaft, the guy who did the scan made a CAD model of it and translated the bore location for the input shaft bearing to the front plane of the bell housing.
View attachment 4082497

This is what I ended up with; all the bell housing bolt hole locations with the input shaft bearing bore in the same plane:
View attachment 4082498

For manufacturing I had the rough plate laser cut from 1/2" HRPO steel plate along with the clearance holes for bolts. The tapped holes and the dowel pin/sleeve holes I had drilled/tapped/reamed as necessary by a local machine shop.
View attachment 4082500

What clutch setup did you use?

 

[AirheadNut]

I have a 5VZ spec clutch, the Centerforce II model. It has held up pretty well but I think the pressure plate springs are too strong for the clutch hydraulic system, I keep having issues where the clutch seems like it doesn't fully disengage. Others I have spoken to with TDI swaps have experienced similar issues. For the upcoming swap I am considering looking at using a factory 1KZ clutch and pressure plate, it is already designed for a torquey 4-cylinder diesel instead of a petrol V6. Need to figure out if the clutch will bolt to my flywheel and if it can hold ~300-320ft-lbs torque.

 

[Fantastika]

I have a 5VZ spec clutch, the Centerforce II model. It has held up pretty well but I think the pressure plate springs are too strong for the clutch hydraulic system, I keep having issues where the clutch seems like it doesn't fully disengage. Others I have spoken to with TDI swaps have experienced similar issues. For the upcoming swap I am considering looking at using a factory 1KZ clutch and pressure plate, it is already designed for a torquey 4-cylinder diesel instead of a petrol V6. Need to figure out if the clutch will bolt to my flywheel and if it can hold ~300-320ft-lbs torque.

And for the flywheel? Modified toyota or something custom?

 

[AirheadNut]

Currently using a custom flywheel, I believe it is a Toyota flywheel drilled for the VW crankshaft. It came with my original adapter kit and I reused it for my adapter. For the upcoming swap I will be using a thick adapter plate that requires a crank spacer and uses a stock Toyota flywheel.

 

[Fantastika]

Currently using a custom flywheel, I believe it is a Toyota flywheel drilled for the VW crankshaft. It came with my original adapter kit and I reused it for my adapter. For the upcoming swap I will be using a thick adapter plate that requires a crank spacer and uses a stock Toyota flywheel.

Actually why did you move away from the ACME adapter? Re drilling the flywheel seems like a risky move, i doubt i could get the holes to be precise enough for to not vibrate like crazy

 

[AirheadNut]

The ACME plate doesn’t use the correct dowel pins to locate the engine and transmission, and instead relies on a couple of the clearance bolt holes in the bellhousing which are not accurate. I’ve heard of people measuring over 0.100” runout with them.

I would agree that drilling a flywheel seems tricky, but there aren’t many options with a thinner adapter plate where you can’t fit a crank spacer.