Don't overthink it. Take the timing cover off, and lay the engine face down on some blocks of wood. Shim it as necessary.
Fj60 1.9tdi swap
- Thread starter Frankster
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- #22
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- #23
Looking good. I can't tell from the photos, are you using the locating dowel sleeves on the TDI and the dowel pins on the bell housing? Those are critical for keeping everything in alignment. When I made my own adapter plate I ended up getting a set of Toyota spec offset dowel pins for the bell housing side of the plate, then when assembling everything I mounted an empty bell housing and transmission case onto the engine and used a dial test indicator to adjust the offset pins and minimize runout.
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- #25
I'm using the stock Toyota dowels on the transmission side, but the engine side only the two sleeves as there is no dowels. Very tight fit though.
Yeah, the VW just uses those two sleeves. On my adapter I had all the bolt holes laser cut, a couple of them drilled and tapped and the locating dowel holes on both sides drilled and reamed for precision. Very snug fit.
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- #27
I'm using an electronic scale on the transmission for vertical alignment and a spirit level for horisontal. Hope it gets me close enough. If it doesn't, we try again. My H42 is so old and worn, if it fails I'll pop in a H55 and try a different strategy 
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Baie mooi!
I am after a nice 62 with a 1UZ and have wondered if a 1.9 would be strong enough.
Where about are you?
I know of a guy in Montana, Pretoria that did a 1.9 into a Disco 2. He seems happy with the conversion. I can put you in contact with him if you would like to.
Also know a guy that understands adaptor plates.
I am after a nice 62 with a 1UZ and have wondered if a 1.9 would be strong enough.
Where about are you?
I know of a guy in Montana, Pretoria that did a 1.9 into a Disco 2. He seems happy with the conversion. I can put you in contact with him if you would like to.
Also know a guy that understands adaptor plates.
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- Thread starter
- #29
I'm using an electronic scale on the transmission for vertical runout and a spirit level for horisontal. Hope it gets me close enough. If it doesn't, we'll we try again. My H42 is so old and worn, if it fails I'll pop in a H55 and try a different strategy
I'm in Kempton Park. This is my first adapter so still lots to learn. Power wise, I'm not too worried. I have a VW Amarok with a CR 2.0 tdi and it is only a 90kw. I load a ton on the back and it weighs about 1850kg. No problem doing highway speeds. My FJ60 will weigh about the same with the tdi installed. The 3F is like 300kg and the tdi is 160kg. The tdi is very efficient so I expect to get 10km/l or maybe a bit better. I'll be the test subject on this one and let you know how it does
Cool swap!
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- #31
I'll have to do the same. My initial plan is not going to work. Now to find an empty case is the hard part
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- #32
Is this lean angle how the transmission sit in a 60 series normally or do the engine pull it up in the one side when mounted? Should acount for the lean on my adapter?
View attachment 4077626
View attachment 4077626
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- #33
Small update. Ready to check runout and adjust
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- #34
Got the runout to a hair under 0.005". Was no joke with this setup, but I'm stoked!
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- #35
Adapter done. Time for final assembly
FYI here is the ALH bolt pattern. All the inline VW engines for the past couple decades have used the same pattern.
forums.tdiclub.com
.stp Files of ALH
Does anyone have access to .stp files for the bellhousing bolt pattern of the ALH? I’ve commissioned a machine shop to build my adaptor plate (ALH will be mated to Subaru TY751 6mt) and they asked if I could find the .stp files so I didn’t have to bring my ALH block to them for blueprinting. I’m...
Also pretty sure all the newer VW diesels run a dual mass flywheel to help smooth things out.
Did some research and some people run dual mass while others run single. There didn’t seem to be much difference.
Did some research and some people run dual mass while others run single. There didn’t seem to be much difference.
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It’s probably too late now. It the VW Vanagons from 80-90 used a 4 speed with a removable bell housing. That house should also match the tdi pattern. So could be another path for building an adapter. Last thought is there are tadapter plates for the VW engine for some of the Toyota pickup truck engines.
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- #40
Hi. Yes, keeping the VGT if I can control it mechanically. If not, will switch to WG.