TDI Swapped Toyota Pickup Turbo/Intercooler Breakdown!

Here at Paul's Performance, we show you today, Paul breaking down the way he custom built his cooling system, pipe routing, turbo piping, and intercooler mounting and pipe routing!
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- Paul and Samuel
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PARTS:
Turbo Map Sensor Flange Kit TDI:
www.amazon.com/dp/B07GZHGN43?...
1"-3" Aluminum Bullbar Mounting Bracket Clamps:
www.amazon.com/dp/B07K72KQ92?...
Universal 2 Inch Intercooler Pipe Piping:
www.amazon.com/dp/B092JJ6CW1?...
5" Side-Mount Intercooler + Fan:
www.ebay.com/itm/265589611705...
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MUSIC: KEDELA - ASTRAL
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[@drmc77]

love it

[@shanephitides8565]

Paul you did an amazing job. Thank you for posting such an informative video. I have just purchased a 1999 4x4 Tacoma 2.7 manual with 320,000 miles. I want to do this swap and leave it stock , not after the power so much just fuel efficiency for long road trips . How many miles per gallon can I expect if I go with a 1.9 TDI swap? Thank you for your time .

[@paulsperformance]

Mine has 4.11 gear ratio currently. I get 25mpg with that. My rpm is high at highway speed. Roughly 2700-3000 at 70mph. I’m planning on changing my gears out now that I have power to a 3.58 or 3.73 so I can get higher speed and better mpg. The factory be trans has a final gear ratio of 3.55 so I’m prolly going to do the 3.58 gears and hopefully they will put me into the 30+ mpg range with big tires

[@shanephitides8565]

Thank you for the quick reply Paul I read that some guys are getting 40 miles per gallon. What stock tires and the stock transmission I have is 35 + miles per gallon possible?

[@paulsperformance]

Possibly. The rear end gear ratio I think is what’s killing me and also the 33 inch tires. I will make a video when I do my gear ratio swap and update you on the mpg gain.

[@shanephitides8565]

Thank you Paul

[@TDISwap]

What are you intake air temps and EGT temps with that intercooler inside the engine bay? That would be the only concern. I have a TDI swapped CJ7 and in the process of doing an XJ, but realize that hose trucks have limited space for an intercooler.

[@paulsperformance]

Sorry for late response. I don’t have an accurate IAT reading currently because my sensor is pre intercooler because I didn’t have enough pipe to mount it on post cooler. I’m prolly gonna move it and mount it on the intercooler whenever I get around to wanting to fab in the flange there or install a IAT gauge in my pillar. I do however have egt gauge and I usually stay 3-400 range. Max I’ve seen at WOT 3000 rpm was right below 500. Have never had it go above on my gauge.

[@TDISwap]

@@paulsperformance So you have a stand alone IAT sensor? You're not talking the MAP sensor for the ECU are you? Your EGTs are off. Like WAY off. I can easily hit 1500F when pushing it, and I cruise at 900-1000F with a waste gated turbo. With my GTD1756 I'll be around the same, and @ 34 PSI should be around 1650F. The highest I've seen is 1650F on any of my turbos with a good tune (VNT17, GTB2060, GTD1756 and HE200WG). You should have it pre-turbo for the best results. But it's your build. Have fun with it. Be careful without having accurate measurements. You could hurt the motor.

[@paulsperformance]

I don’t have a stand alone IAT yet. Just the factory MAP sensor. And I have my EGT gauge at the exhaust manifold currently not on the turbo outlet. I only run about 22 PSI max but mine is still all stock. Those egt readings seem high to me as usually anything over 1300 is too hot. Even my Powerstroke doesn’t run that hot on egts. Where is your probes?

[@TDISwap]

@@paulsperformance I've built more than half a dozen of these motors, I'm a retired diesel mechanic, have swapped my CJ7, and in the process of doing an XJ (both on my channel). I run a FB group teaching people how to do the wiring on them. Needless to say I have a good idea on them, lol My probes are before the turbo in the manifold, where they should be. The GT series of turbos (first gen VNTs that came in the VNT15 format) were rated to 1650F sustained temp. I ran my VNT17 down in Miami to 1650 and held it there, all the time. The Holsets that my buddies have run in the ALH have hit 1800F degrees for short bursts without issue. I've hit 1625F pushing the CJ pretty hard with my HE200WG. The GTD series of turbos is good to about 1900F (I believe, maybe 1850F). My Cummins Titan XD would see 1450F in the mountains when driving. If this was an OM617, then 1450F is about as far as you want to push them so you don't cause an issue. VW TDIs are different than some of the older trucks. As far as the MAP/IAT, you're probably causing some issues as the ECU is looking at IAT for fueling. Since you're pre-intercooler, your temps are going to be high, and fueling reduced. I would suggest you get it where is should be when you have the opportunity. I'm going to guess you get heat soaked pretty quickly without adequate air flow. IN any case, enjoy the swap. They are a ton of fun.

[@paulsperformance]

@@TDISwap ahh okay and yeah I’d like to mount it on the post side of the intercooler. I just need to find time to get it out and get it welded up. I’ve had the truck swapped for over a year now. It runs pretty good but I’m still trying to perfect everything. I do want to go ahead now and move my sensor and see if it changes anything. What is your group name? I have another ALH engine I plan on rebuilding for more power to go in this once this one is wore out. Whats the best turbo/injector option for a daily driver you have used/seen in these?