Build Mike's 1978 FJ40 Turbo Diesel Refit Project and Cross Country Road Trip!

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Here is an overlay where you can begin to see the significance of the powertrain change:

upload_2018-7-28_23-35-22.webp


And here we zoom in on the high range gear sets only to see the on road performance:

Mercedes:
upload_2018-7-28_23-37-15.webp


VW:
upload_2018-7-28_23-37-45.webp


Overlay:
upload_2018-7-28_23-38-18.webp

An uglier version of the same thing:
upload_2018-7-28_23-39-9.webp


There you have it. It has enough torque to pickup the front inside tire when i floor it and turn in first now :)

-Mike
 
deliverance said:
What kind of power can you get out of that engine?
Click to expand...
Without doing anything to the engine but a remap it will put out ~180hp/340lb-ft with all the restrictive OE ancillaries intact. Remove all that junk and put a big charge cooler, exhaust, and inlet system and you will make a significant amount more torque. The power will probably stay around 200 unless you throw some more parts to it though. I see over 20psig around 1500 RPM with a bunch of load on it.

Trust me its plenty :)

-Mike
 
Wild guess on your occupation....... Mechanical Engineer :grinpimp:
 
On the first two fills it got around 26mpg. I was pushing it pretty hard on that trip just to see how it held up. It will probably be a little better during normal driving. It's moving a ton of air though so don't expect any miracles! It's a SOA 40 on 37s after all!

The Mercedes got around 14-16 with the bias ply tires and 19-21 with the radials.

The direct injection will be much more efficient at light load such as during trail driving over the IDI Mercedes, and will run much cooler which is nice.

-Mike
 
74fj40 said:
Very cool. I’ve long thought about a tdi swap. Lots of upgrades for plenty of power. Sort of unrelated, but since it appears your a vw fanboy, about 10-15 years ago someone swapped a 2.8 v6 into their fj40.

Project Toy-Audi
Click to expand...
Wow!

I searched and searched and did not see that thread!

I wish some of the pictures still worked!

I wonder how he likes it? A very interesting engine choice! It looks like the old 12v V6, although he describes it as the later 30v V6. They were very reliable engines for their day.

-Mike
 
deliverance said:
26 mpg is insane!
Click to expand...
The small Diesel engines are nice like that. Unlike their gasoline counterparts they maintain optimum break specific fuel consumption into their higher load regions because they don't have to worry about requiring enrichment for catylist over temp protection, knock, etc. Not to mention the pumping loss gained from not needing a air inlet throttle valve to control torque output! Additionally not a lot of friction from the reciprocating/rotating assembly on an engine so small and simple like this one which further allows for efficiency.

The engines of this vintage are nice because the emissions equipment weren't quite fully integrated into their base architecture, thus are easily removed, yet they had the technology to reach the torque output and efficiency we desire (from variable geometry turbochargers, advanced direct injection, etc. :)

-Mike
 
Godfather90 said:
The small Diesel engines are nice like that. Unlike their gasoline counterparts they maintain optimum break specific fuel consumption into their higher load regions because they don't have to worry about requiring enrichment for catylist over temp protection, knock, etc. Not to mention the pumping loss gained from not needing a air inlet throttle valve to control torque output! Additionally not a lot of friction from the reciprocating/rotating assembly on an engine so small and simple like this one which further allows for efficiency.

The engines of this vintage are nice because the emissions equipment weren't quite fully integrated into their base architecture, thus are easily removed, yet they had the technology to reach the torque output and efficiency we desire (from variable geometry turbochargers, advanced direct injection, etc. :)

-Mike
Click to expand...

I probably missed it, but what year was it from? Awesome build by the way.
 
Out of the box... out of the park!
 
Godfather90 said:
Here is an overlay where you can begin to see the significance of the powertrain change:

View attachment 1755015

And here we zoom in on the high range gear sets only to see the on road performance:

Mercedes:
View attachment 1755016

VW:
View attachment 1755017

Overlay:
View attachment 1755018
An uglier version of the same thing:
View attachment 1755019

There you have it. It has enough torque to pickup the front inside tire when i floor it and turn in first now :)

-Mike
Click to expand...
o_O beyond my little brain LOL
 
Very awesome.
 
Godfather90 said:
Here is an overlay where you can begin to see the significance of the powertrain change:

View attachment 1755015

And here we zoom in on the high range gear sets only to see the on road performance:

Mercedes:
View attachment 1755016

VW:
View attachment 1755017

Overlay:
View attachment 1755018
An uglier version of the same thing:
View attachment 1755019

There you have it. It has enough torque to pickup the front inside tire when i floor it and turn in first now :)

-Mike
Click to expand...

Did you use Excel to make those charts?
 
These are a combination of a few plots I've found online. Averages of a few chassis dynogaph results from vehicles with re-calibrated ECU's and a base engine that is similar to mine. Not exactly like mine with the additional things I've done, but close enough for this type of deal. Not the ideal way to do it but its the best I could do with what I had, and I just wanted to have a general idea of what I was dealing with before taking the plunge!
 
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