1999 S10 ZR2 TDI Swap - S-10 Forum
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post #1 of 42 Old 05-16-2018, 10:54 AM Thread Starter
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Lightbulb 1999 S10 ZR2 TDI Swap

So I've decided that over next year or two I want to Diesel swap my truck with a VW TDI. The purpose of this thread to start off is research and information gathering. I've got a bunch of info from TDI gurus on getting the drive train working stand alone, but I want some input from the s10 guys on getting factory stuff working. I'm not planning on buying/starting anything until I feel confident enough that I have sufficient information to tackle most of the issues that may arise.

The Plan:

BHW 2.0 TDI from a Passat (accessories are already longitudinal/Best PD engine in available in the US pending a BSM delete)

I currently drive a Passat TDI sedan with a stage 2 tune/5 speed swap and am netting about 175hp/305ftlb, On the truck the plan is to build up another engine with a bigger turbo (BV43) and try to make around 200/350ftlb. That's slightly more power and a ton more torque than the 4.3. You can build them to have more but then you're messing around with injectors/camshafts and other stuff. Id rather just safely "max out" the stock internals.

Malone Standalone tuned ECU

TDConversions SBC pattern adapter plate/starter (makes the back of the TDI look like a SBC)

Rebuild the 4l60e thats in there now


Things I'm concerned with/need info on:

Accessories...am I limited to running the stock VW accessories? For instance how would I still have power steering and a vacuum system? Would I just need to make sure that the VW power steering pump is rated for the same PSI?

S10 electronics...are my airbags and other safety systems going to need modification/reprogramming to work? I know I can tune the ABS sensors out of the VW ecu so it will let the engine run, but is there any way to retain a working abs system?

Transmission...Gearing for a diesel is different than a gas. Would I benefit in swapping the stock planetary to a 2.84 quick ratio one? That seems to bring the gear ratios more in line with what my 5 speed Passat has, but i know the differential gear ratios come into play and i don't know how any of that works other than one side spins x times for the other side. My truck has 3.73 gears and stock size tires (31in I believe?)

Trans TCU...I was planning on getting a USshift Quick 4, they seem to have the best support should something go wrong/I need any help. The megashift was another option that seems less expensive but their site blows, and support seems to be non existant.

Any information would be appreciated, I'm sure more questions will come up lol. Looking forward to documenting everything and getting this ball rolling.
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post #2 of 42 Old 05-17-2018, 02:06 AM
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Re: 1999 S10 ZR2 TDI Swap

Nice to see someone thinking of trying something different. IF you have the place, equipment, ability and money to do this. Definitely not something you want to pay someone else to do. Unless cost is not an issue.
Why a TDI? The fact that you already drive one isn't a compelling reason. More of a "that's what I'm familiar with" thing. Not the best way to choose what motor to use.
First problem I see is that most of the gauges in a 99 ZR2 are fed their info from the PCM. By using a stand alone on the engine you'll be leaving them blind. You need to get hold of a complete 99 ZR2 wiring diagram to see how a lot of the systems work. 98 up S10's have a fairly complex integration of various modules. Not like a 2018 vehicle by any means, but it has multiple inter dependencies.
Give Current Performance (CPW) a call and see if they have any suggestions.
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post #3 of 42 Old 05-17-2018, 08:59 AM Thread Starter
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Re: 1999 S10 ZR2 TDI Swap

Quote:
Originally Posted by oldeerslayer View Post
Nice to see someone thinking of trying something different. IF you have the place, equipment, ability and money to do this. Definitely not something you want to pay someone else to do. Unless cost is not an issue.
Why a TDI? The fact that you already drive one isn't a compelling reason. More of a "that's what I'm familiar with" thing. Not the best way to choose what motor to use.
First problem I see is that most of the gauges in a 99 ZR2 are fed their info from the PCM. By using a stand alone on the engine you'll be leaving them blind. You need to get hold of a complete 99 ZR2 wiring diagram to see how a lot of the systems work. 98 up S10's have a fairly complex integration of various modules. Not like a 2018 vehicle by any means, but it has multiple inter dependencies.
Give Current Performance (CPW) a call and see if they have any suggestions.
Yeah these swaps are definitely time/labor intensive, and not cheap. I think the guys on the TDI swapped Trucks facebok page say their average costs are about 10k. Considering a new diesel ZR2 Colorodo is about 5 times that, id say its worth it. Plus you cant buy small trucks anymore in general let alone a diesel, which blows. There are a few s10s out there with ALH engines in them in Canada from what I've seen but details on things like weather they used the VW cluster and just shoved it in there etc. are sparse. Definitely not going to be paying anyone to do it though that would be financial suicide haha

I have several reasons for wanting to use a TDI, but the main 3 are power density, power efficiency, and reliability. Sure I could try to do a 4bt or similar, but that engine is massive both in size and weight. To build up that engine would probably also be expensive, if there even is a way to tune or modify them (I don't know). In that scenario I wouldn't net much fuel gains either due to the extra weight. The TDI is a tiny little motor that can be setup to produce gobs of torque with just software, Its lighter than the 4.3, and its diesel so its inherently much more efficient. Most guys are claiming low 30s for their mpg's in tacos and other 4x4 trucks, which I definitely believe (I get almost 40 in the Passat with a manual). I have to check the stickers on both but the s10 only weighs a few hundred pounds more than my Passat as is, so that gives me a good frame of reference for how it will perform with the slight extra net weight.

I'm not looking to have a race truck, if that were the case an LS engine would be my choice. I want an efficient little work truck, that I can use for around the house/to tow small trailers every now and then. With the increased torque I think it'll be quicker/more fun than stock anyways.

I have a Hanes manual that has some diagrams but I've been searching through here and other sites to find high res PDFs of everything, I have to organize what I have and start going through each system independently. The good thing is that I have my old 01 Blazer still that i ripped the transmission out of and stuck in the s10. I can use all the wiring/systems from that to test on a bench, and verify that stuff works before the final install.

I took a look at CPWs site, I'm wondering if they would so something similar to what they do when you use a LT1 engine on a 98+ truck

From their site:

"The trucks that came with a PCM mounted on the overflow bottle under the hood will require both the stock truck computer and the ECM from the engine IF you are installing an LT1 engine AND you intend to keep all of the factory truck functions......When complete, the stock truck computer will control things like the cruise control, ABS, speedo, etc. The computer for the engine will pretty much just run the engine and control the electric fans."

Knowing the I/O from the VW ECU, maybe with a few data converters/transducers, a similar setup can be had.
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post #4 of 42 Old 05-18-2018, 08:25 AM Thread Starter
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Re: 1999 S10 ZR2 TDI Swap

So I emailed CPW and maybe it was because I was talking to a sales guy, but the communications from them gave very little detail on what exactly they could do.

Basically they said they could make a "dash integration harness" which seemed cool (obviously they would have nothing to do with the VW side, that will be a standalone system), but the guy told me that it literally will only run the gauges, nothing else...for $225. He was kind enough to send me the instructions for it, but that just left me more confused because the instructions say that it would let you use everything in the truck, ABS, cruise etc. (per the instructions attached here)

"This harness system will provide all of the available connections for the recipient vehicle’s electrical system to control the factory gauges, starter, A/C, ABS, cruise control, and any other available signals in to and out of the stock vehicle’s electrical system."


The other confusing part is that it seems like this would only be good for a v8 swap or a swap where you're still using the chevy computer, due to the connectors used as well as just the general lack of information on the types of input signals needed for it, it just seems like this is a single purpose thing that they just want to sell me...the only specific signal defined in there is the speedo as a 4000 pulse per mile signal.

Guess I have more digging to do. Am I just going to have to probe all the inputs to the gauges and everything to see if I can generate the same signals from the VW ECU? I know the Quick shift 4 has a few outputs I can use as well.
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post #5 of 42 Old 05-21-2018, 12:33 PM
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Re: 1999 S10 ZR2 TDI Swap

Hallo d0u8l3m

First of I have to say TDIs would be a grate idea to be used in a pick up. I does not depend which one 1.9 or 2.0 both have a lot of torque for their size and are very efficiently.
The first problem I see is that as I know there is no engine of this type used in an rear wheel powered car or truck. So do you think it is really easy to find a transmission that fits on the engine? Than you have the security system on the engine. The ECU is normally married to the instrumental panel and the key, so you have to use them all. And what about the communication with systems like ABS and so on? Is this possible?
I think it is easier to use the whole drive train from one donor when you do something like this, but it is just an idea.
So long and good luck with this project
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post #6 of 42 Old 05-21-2018, 01:08 PM
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Re: 1999 S10 ZR2 TDI Swap

I had a 2015 Golf TDI, and you are right about the power and torque. I had a Malone stage 2 tune on mine, and it was fast with no change in fuel mileage. Power was around 200 at the wheels, and torque was almost 350. I had to be very light on the go pedal on wet pavement. I thought about trying to find one to swap into my Datsun 620, but decided I wasn't up to that much work, and expense, so sold it, and bought my S10. Good luck, and I hope to see this one running!

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post #7 of 42 Old 05-21-2018, 01:15 PM
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Re: 1999 S10 ZR2 TDI Swap

lots of plans, lets see some work! I love the idea of a small diesel swap
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post #8 of 42 Old 05-21-2018, 01:55 PM
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Re: 1999 S10 ZR2 TDI Swap

best bet is to use both systems
S10 to keep all the body stuff ABS,airbag ac etc
make the PCM think is has a 4.3 in it.
Do the TDI as a stand alone and dont worry about any interface with the body,other than power on power off and charging.
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post #9 of 42 Old 05-21-2018, 06:41 PM Thread Starter
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Re: 1999 S10 ZR2 TDI Swap

Quote:
Originally Posted by Arnd View Post
Hallo d0u8l3m

First of I have to say TDIs would be a grate idea to be used in a pick up. I does not depend which one 1.9 or 2.0 both have a lot of torque for their size and are very efficiently.
The first problem I see is that as I know there is no engine of this type used in an rear wheel powered car or truck. So do you think it is really easy to find a transmission that fits on the engine? Than you have the security system on the engine. The ECU is normally married to the instrumental panel and the key, so you have to use them all. And what about the communication with systems like ABS and so on? Is this possible?
I think it is easier to use the whole drive train from one donor when you do something like this, but it is just an idea.
So long and good luck with this project
Actually getting the engine to bolt to the stock 4l60e is pretty easy with the adapter from TDConversions, you bolt it to the back of the TDI and then the trans bolts to that with the SBC pattern. I also don't need to worry about the immobilizer as that can be tuned out. ABS and the other stuff is what im trying to figure out now. Been going through wiring diagrams but they don't say what types of signals are running.

Quote:
Originally Posted by joedoh View Post
lots of plans, lets see some work! I love the idea of a small diesel swap
Haha planning is the first step, I wont be able to start anything anytime soon, but the plan is to get the drivetrain and all the systems from the s10 working together on the bench, then I can just throw it into the truck and worry about just the fabrication of motor mounts etc.

I might start ripping the blazer apart soon to start figuring out how everything works, though ill take pics of all that.

Quote:
Originally Posted by dime-dozen View Post
best bet is to use both systems
S10 to keep all the body stuff ABS,airbag ac etc
make the PCM think is has a 4.3 in it.
Do the TDI as a stand alone and dont worry about any interface with the body,other than power on power off and charging.
That's basically what I want to do but I have no clue on how to mess with the chevy PCM, I have the old black box in the truck now and was gonna use the newer silver one from my blazer to run the swap because those you can code with hp tuners, but still have to read up on how to program it. Are there a select set of signals that the chevy pcm needs to run, besides power and charging?

Can anyone chime in on how this would be done?

I think I have a general idea of how the blocks will work together, VW ecu running standalone, quick 4 running the transmission, and the s10 pcm to do the body stuff, unless there's a way to get that to run the trans as well, but i doubt it.

Also is that CPW harness gonna be helpful at all or should I just make my own?

Thanks!
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post #10 of 42 Old 05-23-2018, 10:40 PM Thread Starter
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Re: 1999 S10 ZR2 TDI Swap

So I found a page that someone made showing how they actually got the 0411 PCM to operate the trans standalone. Im thinking it's worth trying, I just have to decide if I wanna get hptuners. I'm guessing if what he says is right about the pcm only needing RPM, throttle, and crankshaft signals, I'm sure there's a way to generate those from the VW ECU, just need to see if it can read/convert them.

https://sites.google.com/site/sloppy...ans-controller

Thoughts? Probably gonna start ripping all the wiring out of the Blazer this weekend if I get a chance. Need to swap the PS pump in the truck first lol
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post #11 of 42 Old 05-23-2018, 11:26 PM
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Re: 1999 S10 ZR2 TDI Swap

You might get lucky and the Crankshaft Position Sensor on the VW is already a 24x or 58x signal. If not you'll have to rig up some sort of sensor to read whatever signal the PCM (trans controller) you decide on. If the stock TPS from the VW doesn't work that seems like there could be a work around with a factory GM TPS too.

On paper that's really all you need to setup the standalone transmission controller.

If that's all you need HPTuners for sending your PCM off to someone who already has the software could be much cheaper.
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post #12 of 42 Old 06-04-2018, 11:22 AM Thread Starter
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Re: 1999 S10 ZR2 TDI Swap

So I contacted HP Tuners, they said I wouldn't be able to put the 99 VIN into the newer PCM with their software.

Guess this only matters for emissions, Ill have to find out if I can use the VW ECU to get emissions done but im pretty sure the correct vin needs to be in the ECU. Does anyone have experience with emissions testing your swaps in CT? They only state that the test is via the OBD port no specifics.
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post #13 of 42 Old 06-10-2018, 09:45 PM Thread Starter
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Re: 1999 S10 ZR2 TDI Swap

So I finally found a donor Passat TDI for a steal that I couldn't pass up . It has a bad torque converter (VERY common on these), but other than that seems like a very healthy candidate for my swap. It has about 211k on the clock. I'm going to be sending in an oil sample for testing to get a better idea on the engines health, but other than needing the balance shaft removed I think its fine. Towed her home with the s10 no sweat! I love this truck, its so versatile. Having more torque and fuel efficiency will be great though because it ATE through almost 2 tanks of gas =[ (about an hour drive each way)

Pics so you know it happened lol



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post #14 of 42 Old 06-12-2018, 10:22 AM
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Re: 1999 S10 ZR2 TDI Swap

I am intrigued by this swap. I have had several TDIs over the years, currently in a 2004 Passat TDI that I did a manual swap on. I think a TDI s10 will be a great balance between versatility, fun, and fuel economy. I had considered a regular cab short box s10 with a TDI swap. I believe they could get over 40 MPG since they weigh less than a Passat and have less rolling resistance.
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post #15 of 42 Old 06-13-2018, 10:19 AM Thread Starter
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Re: 1999 S10 ZR2 TDI Swap

Made a Preliminary swap parts list, any input is appreciated.
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post #16 of 42 Old 06-13-2018, 01:56 PM Thread Starter
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Re: 1999 S10 ZR2 TDI Swap

Talked to Dave over at fast forward automotive up in Canada about the signals I need for the 0411 PCM and got this response

Quote:
Throttle Position
As you know, TDIs are drive by wire, so the only throttle position is the output from the accelerator pedal. 0% is 0.35V and 100% is 4.00V. Assuming the input of that device is high enough impedance not to interfere with the actual signal going to the ECU you could use that.

Crank Shaft Position
The TDI doesn't have a signal like that at all and it is very important to the ECU so I wouldn't mess with it. You would have to install a cog of sorts to the crank shaft pulley and use the universal VSS that we sell to count the 24 teeth on said cog, or a lower count of teeth an the VSS Korrekt to multiply the count up again. You could also just use the tachometer signal (2 pulse per revolution) and multiply it by 12 with the VSS Korrekt.

Vehicle Speed Sensor
Again the universal VSS and the VSS Korrekt would be your friend here.

With all this being said, I've never done this exact setup before, so I could be completely right or completely wrong.
This at least gets me started, on figuring out how to make this all work. Ill have to do some more digging and probing to figure it all out.

It looks like as long as I can scale the throttle position via tuning software, that will work, the main issue would be the crankshaft position, which im guessing as long as its a 5v square wave with 24 or 58 pulses per period that will work too. Any input on this?
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post #17 of 42 Old 06-19-2018, 12:38 PM Thread Starter
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Re: 1999 S10 ZR2 TDI Swap

Ended up sending in the 0411 PCM from the blazer to LSX Power Tuning out in Texas to get the VIN changed to the s10 vin. Then ill order the new MPVI2 from HP tuners and should be able to licence it without it bitching about the 99 VIN. Should be there Friday.

Also did some messing around with this calculator, and at 75mph it says ill actually end up with a slightly lower RPM than the manual trans in my sedan, which i'm all for.



This means I'm probably gonna stick with the stock gear ratios, but I'm gonna upgrade the planetaries to the 5 pinon ones. Also looking at getting a Hughes Performance HP3789 rebuild kit and possibly a new torque converter from them after I test how the stock one I have runs. The stock stall on mine is just over 2k rpm, but its pretty old and has high miles on it so if that stall speed works, ill save some money and get a new stock one. Though the hughes one seems a bit beefier so if its not that much more ill do that.

Gotta tidy up the garage and organize everything so I can throw the blazer in there and gut the rest of the wiring out of it. Then once that's done the wagon is next. Ill take pics when that gets going. Life has been busy busy busy.

If anyone needs parts off the blazer too let me know!
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post #18 of 42 Old 06-21-2018, 01:00 AM
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Re: 1999 S10 ZR2 TDI Swap

Cool project, can't wait to see more of it.
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post #19 of 42 Old 07-02-2018, 09:55 AM Thread Starter
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Re: 1999 S10 ZR2 TDI Swap

Finally got my MPVI2 and my PCM back to start using HPTuners! I decided to just order the PCM connectors to make my bench harness that way, because after I moved the blazer into the garage and started taking out the wiring, there was a field mouse in there chilling and staring me down...needless to say im too slow to catch that little bugger so I didn't wanna leave the truck in the garage with him running around in there lol.
I took an old D-Link router apart and started modifying the case to make a interface box to make my life easier. Gotta go get a smaller 2A fuse but its basically just a box to hold the obd port and have a few switches for power and ignition power. I also took the power jack from it so I dont have to ruin a good 12V power cable. (I use them all the time)

Here's some pictures:






Heres the diagram for anyone that might need it (credit: gmtruckcentral)

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post #20 of 42 Old 07-02-2018, 01:21 PM
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Re: 1999 S10 ZR2 TDI Swap

Envious of you guys that have that skill set...
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post #21 of 42 Old 07-02-2018, 01:51 PM Thread Starter
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Re: 1999 S10 ZR2 TDI Swap

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Envious of you guys that have that skill set...
Haha, with the internet you can do anything with enough research and patience IMO
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post #22 of 42 Old 07-02-2018, 01:58 PM
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Re: 1999 S10 ZR2 TDI Swap

Research...when I have to....patience...another story...lol
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post #23 of 42 Old 07-03-2018, 12:27 AM Thread Starter
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Re: 1999 S10 ZR2 TDI Swap

SUCCESS

My interface box works perfectly. It gave me a scare because the freaking MPVI2 had a firmware update and for whatever reason until I re-synced it and updated it, it wasn't responding.

I was able to read the 0411 PCM, verify that LSX Power tuning put the S10 VIN in there, licence it with said VIN, and decided to turn VATS off and write that to it as a test. Im so flippin excited, when things work its such a confidence booster lol



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post #24 of 42 Old 07-03-2018, 09:32 AM
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Re: 1999 S10 ZR2 TDI Swap

So this lets you power up the 0411 outside the vehicle? Then you can hook up your tuning software and read, program, etc. while on a bench (table)? What am I missing here, why would you do that, to work in a/c? I think it's useful you can do it but why do it?
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post #25 of 42 Old 07-03-2018, 09:58 AM
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Re: 1999 S10 ZR2 TDI Swap

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So this lets you power up the 0411 outside the vehicle? Then you can hook up your tuning software and read, program, etc. while on a bench (table)? What am I missing here, why would you do that, to work in a/c? I think it's useful you can do it but why do it?
I see why you're doing it. I tried to edit the post above but that was a lost cause. Good luck, way over my head.
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post #26 of 42 Old 09-02-2018, 01:09 PM Thread Starter
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Just a small update, been a busy Summer. Got the TDI drivetrain pulled. Gonna give it a quick wash and get it on the stand for the BSM delete and to inspect the camshaft. So glad to finally have this out, gonna pull the rest of the wiring from the car and clean my garage now lol
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post #27 of 42 Old 12-03-2018, 03:03 PM Thread Starter
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Re: 1999 S10 ZR2 TDI Swap

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post #28 of 42 Old 04-29-2019, 10:41 AM Thread Starter
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Re: 1999 S10 ZR2 TDI Swap

Sorry guys been meglecting s10forum lately lol here are the last few updates i made on the truck that I posted to TDIClub. Its a slow process but at least its moving forward =]

Haven't made too much progress as of late, life has a way of doing that huh. Figured I'd throw some pics up since we all love pictures lol.

Almost finished with the BSM delete, just some buttoning up left/ the timing belt.



Drivetrain sittin pretty




Still chugging away at the wiring, this is all the truck body wiring. I'm stripping all the plastic loom and crap tape, as well as cleaning every wire with some goo-gone and re-wraping it all in the good tesa tape VW uses.



Also been screwing around with using a W8 cluster in the truck, I got one for my car and when I realized how easy it was to basically turn the FIS screen into a scan gauge, it got me wanting to try to fit it in the truck.




Started tearing apart the S10! got the interior gutted and the front clip removed.



I'm working on getting the cab and bed removed so I can start prepping everything for primer and "paint"

Heres all the Raptor I got =D Entire body will be blue, and underneath and all the plastics will be black.



Ive been soaking all the fasteners in krud kitter rust remover, and everything has been coming out great! Im gonna scuff everything up and give a quick coat of flat black paint to try to preserve them longer.





Also decided im gonna install a 2" body lift to prevent the oil pan from interfering with the front diff. I think the extra space will make things a lot easier in general anyways.



Ive been lucky so far that the cab only has some surface rust to deal with. The right fender is also pretty much ok. However both inner fenders have some spots rusted through and the driver fender has rust at the very bottom where it meets the cab. So I guess I have to decide if these can be repaired or if I can find replacements. They are ZR2 specific which makes finding new ones almost impossible but im gonna keep searching a bit. Either that or guess i can pick up a welder and start to learn how to weld lol.



Ive also been on the hunt for smaller mirrors for the truck similar to the street scene ones that were made back in the day with turn signals in them. The stock S10 mirrors are way larger than they need to be and with me being so short they kinda block some of my view, so I decided to try the Passat mirrors for fun and I kinda really dig the look, and its very functional. I think im gonna model up some adapters and 3D print them to mount them.

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post #29 of 42 Old 04-30-2019, 03:19 AM
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Re: 1999 S10 ZR2 TDI Swap

Are you going to mate the VW engine to the S10 trans and TC or use a VW trans and TC?
You seem to have a good handle on most of the wiring challenges, but I'm curious about how the nuts and bolts will fit together.
Do you plan to build your own motor and trans mounts? What about exhaust and cooling?
On most swaps this has already been done by a 1000 other people. In your case this is all new and would love to hear what your plan is.

My SO just sold her Audi A6 Avant Quattro. Happiest day of my life. No more VCDS. No more dozen idiot lights every time I start the thing. Good riddance. So not being a big fan of the Volkswagen Audi group, I'm interested to see how your project goes.
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post #30 of 42 Old 04-30-2019, 11:37 AM Thread Starter
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Re: 1999 S10 ZR2 TDI Swap

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Originally Posted by oldeerslayer View Post
Are you going to mate the VW engine to the S10 trans and TC or use a VW trans and TC?
You seem to have a good handle on most of the wiring challenges, but I'm curious about how the nuts and bolts will fit together.
Do you plan to build your own motor and trans mounts? What about exhaust and cooling?
On most swaps this has already been done by a 1000 other people. In your case this is all new and would love to hear what your plan is.

My SO just sold her Audi A6 Avant Quattro. Happiest day of my life. No more VCDS. No more dozen idiot lights every time I start the thing. Good riddance. So not being a big fan of the Volkswagen Audi group, I'm interested to see how your project goes.
Im using a TDConversions adapter plate to use the 4l60e and stock torque converter. Its a two piece adapter with another adapter for the flexplate. Im still working on using the stock PCM as a standalone trans controller, I think i have it all programmed correctly but I still need to figure out how to feed it engine RPM. Im gonna use the stock 4.3 reluctor wheel and sensor external to the engine so that I dont need to deal with any electrical loading issues, but im still not sure how to mount it to the crank; Or mount it in general because I was also thinking of mounting it on the AC pully and compensating the signal either in the PCM tuning or with another dakota digital box.

I'm gonna use the stock passat hydraullic mounts for dampening, and either try to use/modify the stock mounts from both vehicles, or have something fabbed up. Id love for it to line up with the stock engine mount spots so i dont need to touch the frame but if not ill probably modify the frame so I can bolt a mount to it. Theres only the one rear trans mount and I can just use the stock one, i might need a shim/spacer to raise it up though.

Exhaust is just gonna be the stock cat/downpipe unit form the Passat and a straight pipe back. Cooling system will stay mostly stock with the s10 rad and hose adapters, the radiators are basically the same size but i want to keep the s10 auto trans cooling (with a smaller trans cooler added in) and use the engine oil cooler for power steering cooling, instead of that crap little metal tube they have outside the radiator core support.

Surprised to see you didn't like the Audi/VCDS. VCDS has been a great tool to have, and nothing compares on the GM side unless you get a Tech 2, which even then is so old and dated compared to VCDS.

German cars are very tedious to maintain though, and will start to go if not cared for meticulously. Certain generations are also known for wiring issues...one thing that VW group can never seem to get 100% right.
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post #31 of 42 Old 05-14-2019, 08:57 AM Thread Starter
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Re: 1999 S10 ZR2 TDI Swap

I finally got the truck completely torn apart.





Unfortunately I found some issues with the frame. At some point there was an issue with the robot that welded a section of the lower control arm mounts for the ZR2 model trucks (since they have different mounting points) and it would be off, which would then crack over the years from use. Also have two rear cab mounts with issues =[












So now I have to figure out how to get this taken care of. I found a metal fab shop that I might have do it. I think once its fixed ill try to make a brace similar to this one:

https://www.s10forum.com/forum/f178/...lution-825233/

So now while I wait on getting the frame fixed I guess ill focus on body work on the cab and bed.
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post #32 of 42 Old 05-14-2019, 10:40 AM
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Re: 1999 S10 ZR2 TDI Swap

thanks for the detailed pics of the frame cracks
Im gonna put a link to it here


https://www.s10forum.com/forum/f178/...-crack-846985/
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post #33 of 42 Old 05-15-2019, 08:58 AM Thread Starter
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Re: 1999 S10 ZR2 TDI Swap

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thanks for the detailed pics of the frame cracks
Im gonna put a link to it here


https://www.s10forum.com/forum/f178/...-crack-846985/
Oh, I didn't even see that you were looking for pics. No Prob, I'm leaning towards fixing it myself so hopefully Ill have some more with it fixed.
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post #34 of 42 Old 06-19-2019, 11:01 AM Thread Starter
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Re: 1999 S10 ZR2 TDI Swap

Got another small update =]

Finally figured out how I'm going to feed the s10 computer the crank signal of the engine. I designed an adapter/spacer to mount the tone wheel of the s10 crank sensor to the TDI crank pulley, and 3D printed it. (note the pic is V2 and i forgot to open the middle hole on that top layer in solidworks before I printed it, the hole is there tho lol)

I'm on V3 and that version one is almost perfect, just need to take final measurements and make a drawing to have it machined.



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post #35 of 42 Old 06-20-2019, 02:24 PM
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Re: 1999 S10 ZR2 TDI Swap

I'm not really a diesel guy, but the ones I've had experience run at a much lower RPM range than the gas engines I've seen. Are you going to have to use some sort of buffer type circuit to simulate the higher RPM of the gas engine the original computer want's to see?

Seems like it would never shift if the RPM's are in the low 3k range.

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post #36 of 42 Old 06-20-2019, 11:50 PM
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Re: 1999 S10 ZR2 TDI Swap

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I have boxes of bolts from these trucks. I dismantle the crap outta them,and throw their bolts into a box for each truck...most the trucks I work with are from Florida,Alabama,and Mississippi. The bolts&hardware coming off these trucks are very nice.. most are still grey. I’d be willing to help you out if you need some hardware for this project instead of spending time trying to clean up what you have.. Body bolts,core support and shock clips....stuff like that. Unfortunately I pretty much only have hardware from 2wd tho. I can look at any bolt from one of these trucks,and tell you exactly where it’s from,lol. That’s how many I’ve torn apart.

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I turned mine into an Oldsmobile, bitches love Oldsmobiles.
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post #37 of 42 Old 06-21-2019, 12:11 PM Thread Starter
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Re: 1999 S10 ZR2 TDI Swap

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Originally Posted by JayinMI View Post
I'm not really a diesel guy, but the ones I've had experience run at a much lower RPM range than the gas engines I've seen. Are you going to have to use some sort of buffer type circuit to simulate the higher RPM of the gas engine the original computer want's to see?

Seems like it would never shift if the RPM's are in the low 3k range.

Jay
Well since I'm using the stock tone wheel, the sensor should read the RPM accurately, I think the redline is at around 5500RPM for the TDI. As for the trans shifting I'm going to be changing all of the shift tables with HPTuners to make sure that it shifts at the appropriate RPM, no need to simulate anything, just a tune should be fine (I hope).

Quote:
Originally Posted by BravadaX View Post
I have boxes of bolts from these trucks. I dismantle the crap outta them,and throw their bolts into a box for each truck...most the trucks I work with are from Florida,Alabama,and Mississippi. The bolts&hardware coming off these trucks are very nice.. most are still grey. Iíd be willing to help you out if you need some hardware for this project instead of spending time trying to clean up what you have.. Body bolts,core support and shock clips....stuff like that. Unfortunately I pretty much only have hardware from 2wd tho. I can look at any bolt from one of these trucks,and tell you exactly where itís from,lol. Thatís how many Iíve torn apart.
Nice! I definitely appreciate that offer!!! You'll probably be hearing from me when I'm ready to begin assembly then haha. Plan is to finish painting everything and fix my frame first. Then I'll sort out what I have and what needs replacing.

I was reading your thread, and wanted to ask why you had so many S10s but I figured it was just your hobby, and they probably make you some nice side cash since there are quite a few people who still want a truck smaller than the new "midsize" trucks. I still cant believe how large they all have gotten. Murica I guess lol.
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post #38 of 42 Old 06-21-2019, 01:17 PM
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Re: 1999 S10 ZR2 TDI Swap

yeah,itís a hobby. Iíve always had them since I was 15. I started with box bodies,and bought my first second gen about 15 years ago..

I canít say I sell enough of them to make any tangible income from them. Now that Iíve built the fleet back up I will start selling off the not as nice trucks.

I was a technician for a very long time,and now that Iím retired it keeps me busy. I do sublet work for the company I left tho..they call me up,and I show up in one of my S10ís with a bag of tools to diagnose or repair whatever it is theyíre trying to sell or fix anotherís mistakes. Lately itís been a bunch of evaporator cores on random vehicles. They go bad on everything nowadays,and nobody around here does them but the dealerships. Doing so many lately that I havenít had time to work on my trucks!

Yesterday I did one on a 2010 F150. I believe Iím doing one on a Lincoln SUV tomorrow..last week I did one on a Chrysler 200,and an engine in a dodge truck. It pays better then fixing S10ís,lol. I charge around $500-$1,000 per evaporator core depending on the vehicle..$500-$2,000 for a motor installation..then they charge whatever they charge.

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I turned mine into an Oldsmobile, bitches love Oldsmobiles.
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post #39 of 42 Old 06-21-2019, 02:24 PM
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Re: 1999 S10 ZR2 TDI Swap

For some reason, I have not gotten notifications of new posts to this thread but I caught up today.

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post #40 of 42 Old 06-23-2019, 07:36 PM Thread Starter
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Re: 1999 S10 ZR2 TDI Swap

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Originally Posted by BravadaX View Post
yeah,it’s a hobby. I’ve always had them since I was 15. I started with box bodies,and bought my first second gen about 15 years ago..

I can’t say I sell enough of them to make any tangible income from them. Now that I’ve built the fleet back up I will start selling off the not as nice trucks.

I was a technician for a very long time,and now that I’m retired it keeps me busy. I do sublet work for the company I left tho..they call me up,and I show up in one of my S10’s with a bag of tools to diagnose or repair whatever it is they’re trying to sell or fix another’s mistakes. Lately it’s been a bunch of evaporator cores on random vehicles. They go bad on everything nowadays,and nobody around here does them but the dealerships. Doing so many lately that I haven’t had time to work on my trucks!

Yesterday I did one on a 2010 F150. I believe I’m doing one on a Lincoln SUV tomorrow..last week I did one on a Chrysler 200,and an engine in a dodge truck. It pays better then fixing S10’s,lol. I charge around $500-$1,000 per evaporator core depending on the vehicle..$500-$2,000 for a motor installation..then they charge whatever they charge.
Honestly that sounds like the perfect way to retire. Chilling in Florida, enjoying the weather and working on these neat machines making money.....


Not really an update but, for ***** I decided to cut out the Jimmy Sunroof roof panel. I've always wanted a sunroof in the truck since I got it, and the Jimmy happened to have one. Whats everyone's opinion on how hard it would be to replace the front half of the S10 roof panel and weld the seam in the back with the Jimmy panel?? I'm guessing you'd drill out all the spot welds, peel back/cut the S10 skin, fit the replacement in , re-weld where all the spot welds were/the seam across the back of the roof, seam-seal the shit out of it, and do some body work on top?? Whats your thoughts?

This is admittedly probably over my current abilities, but part of me still seems to think I can get it done lol...just an idea here are some pics to get an idea of what I'm talking about. This would be the perfect time to do this since I have the cab stripped to nothing right now to fix all the rust.





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post #41 of 42 Old 06-23-2019, 09:19 PM
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Re: 1999 S10 ZR2 TDI Swap

You could do it that way. But me I'd just cut a hole in the s10 roof and move all the parts from the Jimmy roof over. Keep us updated with pictures either way you go I know you can do it from the work I've seen you do. But keep in mind if that one slides back under the roof be sure you have enough room for it to go back. If it is one that just tilts up then placement isn't a factor.

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post #42 of 42 Old 06-24-2019, 09:02 AM Thread Starter
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Re: 1999 S10 ZR2 TDI Swap

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You could do it that way. But me I'd just cut a hole in the s10 roof and move all the parts from the Jimmy roof over. Keep us updated with pictures either way you go I know you can do it from the work I've seen you do. But keep in mind if that one slides back under the roof be sure you have enough room for it to go back. If it is one that just tilts up then placement isn't a factor.

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Thanks for the vote of confidence, I appreciate that!!!! With the way the panel has a stamped lip and other pieces welded to it I think It'd be easier and cleaner to use the actual panel. It's one that slides back, but the way they designed the end-stops is super nice because I can just trim the tracks a few inches and re-drill new holes for the stops to mount. I think with it trimmed the glass should only stick out an inch or two which I'm totally fine with. I think this week Ill start cleaning up the Jimmy panel and remove all the extra metal since I just chopped it off at the pillars. That'll at least give me an idea of how this will work.

My Dad is coming over next week to help me weld my frame, since I'd rather a pro do structural stuff, he's already told me not to bother with the sunroof but lets see if I can convince him to help me with it anyways lol.
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