'84 Toyota 4wd 1Z TDI Swap

Greetings from the High Sierra,

This is my 1st post.

I am putting a '97 Passat's 1Z (175,000 miles) into a 1984 Toyota 4wd extracab with a G52 5-speed transmission. I've rebuilt both axles, replaced seals, bearings, etc..., and installed a rear disc brake conversion from Sky Manufacturing. The Passat rolling chassis sold and goes to Chicago (tomorrow) to receive a '96 Passat's engine.

The TDI swap is the most extensive automotive job I've done to date, so there's a great learning curve. It is so out of my league - that's just motivation for someone like me to see if college really taught me anything. This forum's DIY and FAQ sections have been invaluable. My experience replacing my '99.5 MKIV Jetta's (ALH) timing belt (& idler pulleys, water pump, crankshaft seal, etc...), installing the injector pump Viton o-ring and temp sensor, replacing strut assemblies and shocks, brakes, oil pump o-rings, etc... etc.. has been informed by several key sites, this one included. That car always runs and runs well (various mods make it extra fun).

This swap's on a budget and a timeline. It's mid-winter at 7000 feet with 12' of snow surrounding my house and me with a studded Jetta and loaner Audi wagon (that gets returned soon) to help make it happen. Work will resume soon and I need to be finished! That's what I've got.

What I lack makes it particularly interesting. I gotta admit, though, that I enjoy being resourceful in the face of ambiguity. I can make anything out of wood and make it well, but I have zero metal fab skills and ... don't know how to weld. :ugh Frustrating. I lack a number of tools, but so far, I have made do. My wiring, testing, and troubleshooting skills are developing nicely, too.

So, I am at the point of waiting (2 months almost) on a HD clutch. I have ACME's adapter plate and flywheel and pilot bushing. ACME's great. With the clutch and mating of the transmission to the engine, I'll make a 2.0 kW clockable starter work, and I'll drop the thing in the truck to see if I will have adequate clearances (turbo/starter, alternator/steering box, coolant flange/firewall are the main concerns). I'm identifying, tracing, and labeling wires from the wiring harness on my living room floor (wife likes that a lot) and pinning out the ECM. This is particularly challenging for me but I'm making progress. Engine mounts are going to be from a BMW 3 series.

Here's a very valuable, detailed wiring link, courtesy of GTiTDi on the tdiclub forum:
http://www.a2resource.com/electrical/CE2.html

I am reluctant to mess with the turbo as it spooled loud and clear and worked very well in the Passat, which I drove and got to know over 4 months. I am deleting the EGR stuff and aiming for the race pipe from Dieselgeek (the 1Z is a '97, exempt from CA smog requirements). I'll replace the IP o-ring with a Viton one and do the temp sensor while I'm in the IP. Timing belt kit, new rear main seal, valve cover and oil pan gaskets, too.

I am documenting most everything - PNs, prices, web resources, free online Passat manuals, OEM parts suppliers, @!#$$* parts suppliers, and generally helpful links for the next person who does this. It is only because of others' generous documentation and sharing of information that I took this on. I enjoy fostering self-reliance. I don't enjoy the slow demise of quality I'm witnessing all around me. It's very encouraging to see others taking initiative, continuing learning, innovating, recognizing failure as a great teacher, and building something vs. just buying it. Thanks to everyone contributing to greater automotive knowledge and self reliance.

I'll shut up now and go start labeling Toyota wiring.