2.5TDI into an 86 Hilux?!

Newbie Joined: Nov 20, 2008 Posts: 12 Location: Cumbria

Hi, I'm an ex Audi owner and current mk2 Hilux 4x4 monster truck owner. Basically I'm looking to merge my two favorite brands.
I've thought about slotting in a 5cyl 2.5 tdi to replace the wheezy 2.4 N/A lump, it's been done before with 1.9tdi engines so there's already a bell housing conversion.
All I'm after at this stage is measurements of the 2.5tdi engine, such as length between front of the crank pulley and flywheel and length between cam belt cover and injector pump timing gear. These measurements need to be from the furthest points to gauge whether I will need to modify the bulkhead.
Also does anyone have a rough estimate for the cost of 2.5 tdi engine?
Thanks in advance.

Posted: Tue Jan 01, 2013 8:29 pm

Interesting idea. I'd been thinking about putting one in my Triumph 2.5PI together with a W58 Supra box but had been told the 1.9TDI bell housing won't fit the 2.5 - where would you get yours from?

I have and A6 2.5TDI but I don't think it'll be very easy to get the measurements you want with the engine in situ. Prepared to have a go but won't be until the weekend.......

Price..... who knows....... depends on your luck and timing I'd say.

This lot.....
http://www.vwaudibreakers.co.uk/breaking-dynamic/index.php

.......had an alleged low mileage AEL (140 hp version) up for sale last autumn - wanted £400 IIRC. Probably without loom, ECU etc though. Best to buy a complete car really though don't break a decent one! Also remember that Volvo used what is more or less the AEL in the 850TDI and S/V70 TDI. Later D5 is Volvos own and completely different.

Cheers

Nick

Newbie Joined: Nov 20, 2008 Posts: 12 Location: Cumbria

Thanks Nick, very helpful info. I found these guys for the Toyota gearbox - 1.9 tdi adapters http://acmeadapters.com/store_engine.php. But that was on the assumption that the 1.9 and 2.5 have the same bell housing bolt pattern. Its looking more like I might end up putting a 1.9 tdi in for cheap and easiness! Even a standard 90bhp 1.9 tdi has more power than my 2.4d (84bhp/115lb/ft).
Thanks again
Paddy

Posted: Sun Jan 06, 2013 8:31 pm

I always thought all "modern" (80- onwards) gearboxes had the same bell housing....

Posted: Sun Jan 06, 2013 8:45 pm

Could well be right.... never had a 1.9 to look at.

For info, there is a Volvo V70 TDI with engine still complete at Lydford Cross Keys on A37 in Somerset. Usually very reasonable.

Nick

Audi Nut Joined: Apr 29, 2007 Posts: 82

5 pot is different block pattern.

go with the 4. the 2.0 tdi is the same as 1.9 but a remapped 130 1.9 will give 175 ish.

HTH

Posted: Tue Jan 08, 2013 6:38 pm

If a newer engine (say from an A4)- be advised if using the ECU, you will need the ECU, instrument binnacle and keys/ sensor- that's how the immobiliser works. You maybe able to get the ECU reprogrammed to bypass that- or try a different management system (such as megasquirt?)

Newbie Joined: Nov 20, 2008 Posts: 12 Location: Cumbria

Thanks for all the reply's people, I'm gonna have to look into the bell housing patterns, my mate has loads of 4/5 pot engines and boxes lying in his barn so I'll start there.
It's looking more and more like I'll be sticking with 4 cylinders at this point, the simpler the better so it will probably be something like a 1z 1.9 tdi. The other factor to take into account is that I really want to get my mk2 Scirocco back out this summer so the Hilux will have to wait till thats done. Also my hilux is my daily and my work vehicle so I'll have to be careful about the timing and have everything ready for the swap.