1991 Toyota 4Runner TDI Turbo Diesel
I started with a 1991 Toyota 4Runner SR5 4x4 5speed 22re 4 cylinder. After a couple of trips up to the mountains i decided to change it to a diesel. I have always wanted a diesel Toyota or Nissan truck (hard to find in the states) so I made this one.
I started the process of putting a 2000 VW Tdi ALH 1.9 in the truck. Before installing the engine I did a full engine rebuild and installed a new cylinder head complete (new cam, lifters, valve, valve seals, springs and retainers, OE head from spain, not the cheap knock-off). Timing belt, water pump, rollers, belts, main seals, new crank and rod bearings, and a fresh turbo (turbo is a Variable nozzle turbo, VNT from a 2006 tdi jetta), new clutch. At first I decided to go with an all mechanical injection pump. It worked well but control of the turbo and fuel trims meant that it took constant adjustment. Then came a full ECU and harness swap from a 2000 jetta. Now the truck has full boost control, and full fuel timing adjustment. Get in it and turn the key in any conditions. I have started this truck with no issues as low as -15 degrees F. I have installed the next size up nozzles (.205um)
No other true SUV gets the mpg this does, (by true I mean with a real transfer case and low range). The original gas motor was quite slow at the mile high city and got only 15-16mpg. After almost 10,000 miles of testing, tuning and making changes, the average for those miles up to this point is 27.5mpg. These mileage calculations were done without adding the difference of tire size. Running on 31inch tires compared to the stock 28 inch tires. A difference of about 8%, so the truck long term nearly runs 30mpg. I have never seen below 24 mpg and have seen up to 34mpg.
I installed an Old Man EMU lift kit but it was just a bit too high and was affecting the mpg at highway speeds, so I lowered it to a reasonable height, and set it up so it has a perfect 50-50 split for compression and droop in the suspension travel, feels great on and off road. I hated the feeling of constant top-out of the suspension an overly lifted truck.
The truck body is nearly 25 years old, the body has 204,000 miles on it and does show some normal Toyota wear. Clear coat has faded on the hood and roof and dash is cracked. No rust at all. I built this truck to be used not to be a show truck. Just point it at any road and go. Great adventure vehicle, without any auxiliary tanks it gets 400 miles per tank. It has manual windows and locks, fold down rear tail gate with power rear glass.
Here is a list of other parts.
31x10.5 bfg all terrain TA K0
15 inch 4 runner alloys
Warn manual front hubs
Smitty build 10000lbs which with hitch mount cradle and quick disconnect power wires, and 100 foot synthetic cable.
Full 2 inch mandrel bent exhaust with 50 state legal diesel cat
Huge Front mount intercooler,
Optima red top battery.
4 hella 4000 driving lights with clear lens protectors
Two new front cv axles,
Upgraded bucket seats, with adjustable lumbar and bolster for driver's side
Great stereo, with upgraded speakers
Clean Colorado title
I hate to see it go. This is a great truck and I would love to keep it forever but Rally cars are taking over again. I need the garage space.
I have been working on Japanese trucks and cars for my whole life and have been a professional fabricator and Audi VW tech since 2000. I have spent literally hundreds of hours making sure that this conversion is reliable, bullet-proof, and well built. My main focus was not on power or speed, but fuel economy. I would install a lift, or set of tires, or any part and test the 4 runner, if it did not meet my satisfaction then I would do more R&D till it was right. Nothing was overlooked when it came to mpg. Tire size, lift size, aerodynamics, manual front hubs to reduce driving drag, even the off road lights were installed to keep drag down. Winch is removable so you can leave an extra 80 pounds at home unless you need it. Although power was not my main goal, this is the fastest gen 2 toyota I have owned or driven. Zero to sixty is very fast.
More photos on my CL ad.
1991 Diesel Toyota 4Runner
Phone number if need seven.2.zero.2.four.zero.1.5. four.7.
Thanks,
Steve
I started with a 1991 Toyota 4Runner SR5 4x4 5speed 22re 4 cylinder. After a couple of trips up to the mountains i decided to change it to a diesel. I have always wanted a diesel Toyota or Nissan truck (hard to find in the states) so I made this one.
I started the process of putting a 2000 VW Tdi ALH 1.9 in the truck. Before installing the engine I did a full engine rebuild and installed a new cylinder head complete (new cam, lifters, valve, valve seals, springs and retainers, OE head from spain, not the cheap knock-off). Timing belt, water pump, rollers, belts, main seals, new crank and rod bearings, and a fresh turbo (turbo is a Variable nozzle turbo, VNT from a 2006 tdi jetta), new clutch. At first I decided to go with an all mechanical injection pump. It worked well but control of the turbo and fuel trims meant that it took constant adjustment. Then came a full ECU and harness swap from a 2000 jetta. Now the truck has full boost control, and full fuel timing adjustment. Get in it and turn the key in any conditions. I have started this truck with no issues as low as -15 degrees F. I have installed the next size up nozzles (.205um)
No other true SUV gets the mpg this does, (by true I mean with a real transfer case and low range). The original gas motor was quite slow at the mile high city and got only 15-16mpg. After almost 10,000 miles of testing, tuning and making changes, the average for those miles up to this point is 27.5mpg. These mileage calculations were done without adding the difference of tire size. Running on 31inch tires compared to the stock 28 inch tires. A difference of about 8%, so the truck long term nearly runs 30mpg. I have never seen below 24 mpg and have seen up to 34mpg.
I installed an Old Man EMU lift kit but it was just a bit too high and was affecting the mpg at highway speeds, so I lowered it to a reasonable height, and set it up so it has a perfect 50-50 split for compression and droop in the suspension travel, feels great on and off road. I hated the feeling of constant top-out of the suspension an overly lifted truck.
The truck body is nearly 25 years old, the body has 204,000 miles on it and does show some normal Toyota wear. Clear coat has faded on the hood and roof and dash is cracked. No rust at all. I built this truck to be used not to be a show truck. Just point it at any road and go. Great adventure vehicle, without any auxiliary tanks it gets 400 miles per tank. It has manual windows and locks, fold down rear tail gate with power rear glass.
Here is a list of other parts.
31x10.5 bfg all terrain TA K0
15 inch 4 runner alloys
Warn manual front hubs
Smitty build 10000lbs which with hitch mount cradle and quick disconnect power wires, and 100 foot synthetic cable.
Full 2 inch mandrel bent exhaust with 50 state legal diesel cat
Huge Front mount intercooler,
Optima red top battery.
4 hella 4000 driving lights with clear lens protectors
Two new front cv axles,
Upgraded bucket seats, with adjustable lumbar and bolster for driver's side
Great stereo, with upgraded speakers
Clean Colorado title
I hate to see it go. This is a great truck and I would love to keep it forever but Rally cars are taking over again. I need the garage space.
I have been working on Japanese trucks and cars for my whole life and have been a professional fabricator and Audi VW tech since 2000. I have spent literally hundreds of hours making sure that this conversion is reliable, bullet-proof, and well built. My main focus was not on power or speed, but fuel economy. I would install a lift, or set of tires, or any part and test the 4 runner, if it did not meet my satisfaction then I would do more R&D till it was right. Nothing was overlooked when it came to mpg. Tire size, lift size, aerodynamics, manual front hubs to reduce driving drag, even the off road lights were installed to keep drag down. Winch is removable so you can leave an extra 80 pounds at home unless you need it. Although power was not my main goal, this is the fastest gen 2 toyota I have owned or driven. Zero to sixty is very fast.
More photos on my CL ad.
1991 Diesel Toyota 4Runner
Phone number if need seven.2.zero.2.four.zero.1.5. four.7.
Thanks,
Steve
