[absalom]

Well, I'm back in the saddle again and it feels fantastic. After selling the last 4runner to get a client hauler, I've longed for the day that I'd own another 3rd gen.

The past few years have brought about some amazing life changes:

(My wife, son, and I in Tempe)



(A few sordid affairs with two German barnstormers)





She's a 2002 4x4 SR5 Sport Edition with mandatory sunroof in glorious Thundercloud Metallic. Over 242,000 miles, all service records from a single owner. Runs like a top with no mechanical issues at all!

Now, most buyers would be put off by the mileage but it allowed me to pick up this beauty for 1/2 what I sold my last truck for. Plus, the engine and tranny are being pulled almost immediately to make way for the swap!

This truck will be a tribute to my sorely missed 2000 in Desert Dune. Similar lift, armor, interior mods, etc. Except everything will be cranked to 11! 35's, more power, bigger brakes, better suspension, better lockers and much more! Part DD/part expedition hauler, this thing will be able to do it all. I learned a LOT (thanks in part to the amazing folks on this forum) with my last build, and this build will reflect that.

(How she looked the day we picked her up)



The mileage is hardly a concern as I'll be swapping out the 5VZ for a diesel! Specifically a BEW TDI from a 2004-2006 Jetta/Golf. I'll also be replacing the auto with a R150F via an ACME adapter.

From the factory, the TDI puts out a gentle 100hp/177 ft lbs. However, with the help of some very talented folks on the TDIclub forum, this motor will eventually put out no less than 200 hp and 385 ft lbs of tree stump yankin' torque. All while hopefully netting between 25-35 mpg's, and being amazingly reliable. As we plan to move to Colorado in the near future, having a turbo will negate altitude power losses.

(A much cleaner version of what I'll be installing!)




Now, the truck currently rides like a tank, in the firmest way possible. A spacer lift up front and some SkyJacker springs out back make driving a chore. The BFG A/T's are completely unbalanced and the steering is seeing lots of slop. I applaud the PO for being able to tolerate driving the truck like this for so long, he's a brave man.

Build Strategy

Stage 1 - DONE! (Post #40)

• TRD Coils YY/YB
• Bilstein 5100's
• LC 8 Wraps
• Monroe Sens-a-Tracs
• Light Racing Adjustable UCA's
• All New Steering Components
• 4x Innovations Sliders w/ Kickout
• Tundra Brake Conversion

Stage 2

• BEW TDI Motor
• R150F Transmission
• PD150 Injectors
• PD150 Intake
• Rocketchip Tune Stage 4
• Southbend Clutch
• GTB1749VB Turbo

Stage 3

• Level 8 Strike 6 wheels - 16" x 8.5"
• 285 75 16 Treadwright Guard Dogs - Load D
• DDM 3" 50w Projectors w/ 4300k bulbs
• Spidertrax Spacers
• King 2.5" Coilovers/shocks

Stage 4

• Engo 9,000 lb Winch
• 4x Innovations F&R Bumper
• Complete Sound Deadening Overhaul
• Retractable LED Light Bar w/ XM-L2 & MT-G2 emitter swaps
• OBA w/ York A/C Compressor
• Burtman Industries Euro Wing
• King 2.5" Coilovers/shocks
• VHF Radio/Whip
• Much, Much More!

I've got an entire pallet of new front end steering components on the way from Rock Auto. I'm also on the hunt for a set of TRD YY/YB coils (the Eibach's on my 2000 were very firm) as well as 8 wraps for the rear. I'll also be doing a UCA swap asap.

I've got very big plans for this truck and I can't wait to show you folks everything along the way. Also, FWIW if anyone in Phoenix/Scottsdale ever needs help wrenching, I'd be more than happy to lend a hand!

[TCMach]

Wooohoo! Glad to see you back in a third gen! I'll be interested to see how your diesel swap goes. Ive got a couple years before I go down the road to more power but a diesel swap has always been high on my list of options.

Where in Colorado are you moving to?

[GSPRunner]

Hopefully those vents on the fenders are staying

[smallfry]

Why a VW diesel why not a D4D?

[4Running Daily]

I'm in Tempe! If you ever need help with the swap or turning a wrench, I'm around.

[absalom]

Originally Posted by TCMach

Wooohoo! Glad to see you back in a third gen! I'll be interested to see how your diesel swap goes. Ive got a couple years before I go down the road to more power but a diesel swap has always been high on my list of options.

Where in Colorado are you moving to?

Thanks bud, it feels great to be back. I love this forum! We'll be moving to the Arvada area. We love how close it is to the mountains and downtown. Colorado is amazing and has a healthy 4x4 community which is a big draw to us (read:me) lol!

Originally Posted by GSPRunner

Hopefully those vents on the fenders are staying

Sadly, they were the first thing to go along with the extra 15 hp they added :/

Originally Posted by smallfry

Why a VS diesel why not a D4D?

Trust me, I get the resistance to not using the factory D4D option on this forum. I fully expect lots of it as the build thread progresses. Originally the plan was an imported HDJ81 (which are now legal) with the 1HDT motor. But I just missed you guys so darn much, I had to get another 3rd gen. Now the pros of using the VW platform:

• Readily available motors
• Massive aftermarket and tuning community
• Huge power potential ( up to 260 hp/450tq on stock internals)
• Adapter kits for this exact swap (R150F>VW 4cyl TD
• OBD2 compliance
• Legendary reliability

VW led the diesel revolution in EU in the 70's and 80's and their motors are widely respected in the diesel community. Say what you will about their electronics (lol, window switches), that company knows how to build a proper diesel. The motor that came before this motor (the ALH) currently resides in my 02' Golf. Sitting at 355,000 miles, it runs like a top and requires minimal maintenance.

Hopefully, by the end of this build thread, when it's all said and done I can get more folks on this forum open to the idea of VW swaps!

[SCRunner12]

You went all the way to Santa Cruz to get that thing? I know that 4runner and was owned by my old football coach. Glad to see it went to a good home and has been plans. What is your time frame for the swap?

[MasonT4R]

Take lots of notes and pictures. Should be interesting to see how this goes. Love to have a diesel in this thing.

Good luck!

[absalom]

Originally Posted by 4Running Daily

I'm in Tempe! If you ever need help with the swap or turning a wrench, I'm around.

Hey man, I'm going to hold you to that I'll supply the beers

Originally Posted by SCRunner12

You went all the way to Santa Cruz to get that thing? I know that 4runner and was owned by my old football coach. Glad to see it went to a good home and has been plans. What is your time frame for the swap?

No way?? Well, if you ever run into him tell him he did a fantastic job maintaining this thing. Yea from Phoenix > Santa Cruz > Sedona > Phoenix in like 36 hours. We were exhausted! Fortunately, we just popped a mattress in the back of the 4runner and voila! portable hotel!

Originally Posted by MasonT4R

Take lots of notes and pictures. Should be interesting to see how this goes. Love to have a diesel in this thing.

Good luck!

Yea, that's one thing I told myself this time around. I'm going to take a LOT more pics and provide more updates during the progress. Pretty excited about the diesel myself. The search begins for a suitable wrecked 04-06 TDI!

[hour]

Werddd I gotta stay up to date on this one.

Good call on Arvada area, it's nice. Nicer than Denver proper that's for sure (where I currently sit) and better bang for your buck. I might be buying a house there in the next month and a half or so, if I don't go further north.

Can't wait to see it all unfold

[MVP]

Subscribed. I gotta see this.

Funny, I just started looking for a 2000-2003 Jetta/Golf TDI for a DD so my runner can retire from that role.

Live in Goodyear/Litch Park, work in Tempe. How far north in Scottsdale are you?

[Jdog]

How very interesting. I am not going to lie, I like the idea of the tdi swap. I am going to have to subscribe to this.

[shootmymime]

Oh fun fun.
If I knew you were in Tempe I would have stopped to have lunch sometime during Christmas. I drove my 4Runner in town to visit some old friends. I also plan on visiting again. So if you ever make it to Vegas hit me up I'm there a lot. (Currently live in a tiny town In idaho)

[1985taylor1925]

I like your plans for the turbo swap. Cant beat better hp, tq and more mpgs. And the sound of a turbodiesel! Definitely subscribed.

[SparkEE]

So many great ideas in this thread so far. I loved the BHW motor in my 05 Passat and those BEWs are much stouter from what I've read. I can't wait to see this unfold. I currently live in Arvada and its a great place. Quiet and pretty close to just about everything