Video Part 5 - Exhaust Manifold Fabrication

Engine runs!

It runs!! The TDI 4Runner fired right up tonight with minimal cranking! clack clack clack clack clack clack clack clack clack clack!!!!  After the injection pump was fully powered & a few other sensors were installed, the engine came to life in less than a second of cranking.. no sputtering about it! Pretty sweet for a diesel. Not even loud at all straight out of the turbo with no exhaust. Still a LOT of work left to do before it's street ready, but at least now I know the engine is good. Been over a year since I bought the engine. Nice to see some big progress. Combusted diesel sure smells good :-D
More videos to come soon... lots of footage, just have to make time to edit it. The videos aren't made to be entertaining - it is mostly for documentation purposes and for those wanting to build something similar.

Video Part 4 - Clutch & Other Comments

Video Part 3 - Building the Engine Mount

Hose fabrication

I've been pretty busy and haven't posted much recently, but I have been working steadily on the 4Runner project. I'm now down to the smaller details - power steering lines, oil lines, fuel system, etc.

I removed the fuel tank last week and found it was fully of rust. Way more than I would ever spend time cleaning. I bought a new tank for a great price from Rock Auto. While waiting on the tank to arrive, I have been making the power steering pressure lines, turbo oil return line, and started the fuel system.

For fuel, I am using a Holley Blue electric external pump with an external regulator. I also went to a 2 micron external fuel filter instead of using the factory VW filter. All lines are 3/8" with the last 1.5 feet to the injection pump being 5/16".

I have also started editing and posting videos from the build.. the first 2 parts have been uploaded to Youtube - check my other blog posts for the link. More videos to come as time allows.

Power steering pressure lines.

Need custom power steering lines? No problem, just TIG a -6 AN fitting to the hard lines and fabricate as needed.

Routed the -6 AN power steering pressure lines over the engine mount to be sure there is plenty of room for the radiator and intercooler.

Aftermarket 2 micron filter/water separator setup is on the right. This is easier to install and work with than the factory filter. Also easy to find replacement filters.

Turbo oil return is -8 AN. I will probably change the fittings to remove the level spot in the line.

Pyrometer (EGT) and turbo oil feed line are installed.

I created a bracket for the Holley Blue pump and regulator from u-bolts and bar stock. This bolts to the frame rail on the passenger side.

 

Video Part 2 - Transmission mount

Video Part 1 - Toyota Engine Removal