TJ Diesel TDI conversion MK 2 - Page 3 - Jeep Wrangler Forum
Jeep Wrangler Forum

Go Back   Jeep Wrangler Forum > General Jeep Discussions > Builders Corner

Join Wrangler Forum Today


Reply
 
Thread Tools

Please support our sponsors and let them know you heard about them on WranglerForum.com
Old 09-23-2013, 06:15 PM   #61
Jeeper
 
1979WagoneerLTD's Avatar
 
Join Date: Nov 2008
Location: GA
Posts: 377
Cooling package coming together. Derale cooling systems are US manufactured, and the quality is benchmark. The TJ system is all-inclusive-everything you need gas or other.
Attached Thumbnails
Click image for larger version

Name:	image-3842678515.jpg
Views:	80
Size:	139.5 KB
ID:	372553   Click image for larger version

Name:	image-2856168227.jpg
Views:	94
Size:	137.2 KB
ID:	372561  


__________________
THE MPGp
1979WagoneerLTD is offline   Quote Quick Reply
Old 09-23-2013, 06:17 PM   #62
Jeeper
 
1979WagoneerLTD's Avatar
 
Join Date: Nov 2008
Location: GA
Posts: 377
Fuel cooler is a flexlite. Mount near the airstream so that it will drop fuel temp by 20f before it returns to the fuel tank.
Attached Thumbnails
Click image for larger version

Name:	image-91771404.jpg
Views:	90
Size:	141.9 KB
ID:	372569  

__________________
THE MPGp
1979WagoneerLTD is offline   Quote Quick Reply
Old 09-24-2013, 07:43 PM   #63
Jeeper
 
1979WagoneerLTD's Avatar
 
Join Date: Nov 2008
Location: GA
Posts: 377
Charge air cooler (intercooler) positioning. The TJ has a cramped space fore the condenser, and there just isn't an CAC on the market that will fit. This Behr unit is spec'd for a New Beetle. It will require a shroud to capture outside air, but makes good use of limited space.

Note the correct compressor is installed.
Attached Thumbnails
Click image for larger version

Name:	image-4212553539.jpg
Views:	80
Size:	119.6 KB
ID:	376289   Click image for larger version

Name:	image-1086599147.jpg
Views:	86
Size:	148.9 KB
ID:	376297  

Click image for larger version

Name:	image-207663787.jpg
Views:	79
Size:	121.6 KB
ID:	376305  
__________________
THE MPGp
1979WagoneerLTD is offline   Quote Quick Reply
Old 09-24-2013, 07:47 PM   #64
Jeeper
 
1979WagoneerLTD's Avatar
 
Join Date: Nov 2008
Location: GA
Posts: 377
While I was working I decided to stress the green Wrangler a little; it idled for 7 hours, then I did 5 runs up the mountain, full boost, lugging in 5th. Temp never climbed above 200f, not one hiccup.
__________________
THE MPGp
1979WagoneerLTD is offline   Quote Quick Reply
Old 09-25-2013, 07:43 PM   #65
Jeeper
 
1979WagoneerLTD's Avatar
 
Join Date: Nov 2008
Location: GA
Posts: 377
Charge air cooler tube mock-up.
Attached Thumbnails
Click image for larger version

Name:	image-2711252388.jpg
Views:	81
Size:	150.2 KB
ID:	378809   Click image for larger version

Name:	image-712344166.jpg
Views:	70
Size:	126.0 KB
ID:	378817  

__________________
THE MPGp
1979WagoneerLTD is offline   Quote Quick Reply
Old 09-26-2013, 08:24 PM   #66
Jeeper
 
1979WagoneerLTD's Avatar
 
Join Date: Nov 2008
Location: GA
Posts: 377
Making up the cooling system lines.
Attached Thumbnails
Click image for larger version

Name:	image-2010355581.jpg
Views:	60
Size:	136.2 KB
ID:	381185   Click image for larger version

Name:	image-3248126031.jpg
Views:	61
Size:	134.3 KB
ID:	381193  

Click image for larger version

Name:	image-1261292186.jpg
Views:	63
Size:	109.0 KB
ID:	381201  
__________________
THE MPGp
1979WagoneerLTD is offline   Quote Quick Reply
Old 09-27-2013, 07:25 PM   #67
Jeeper
 
1979WagoneerLTD's Avatar
 
Join Date: Nov 2008
Location: GA
Posts: 377
A/C lines, fuel cooler, degas bottle.
Attached Thumbnails
Click image for larger version

Name:	image-3532487550.jpg
Views:	61
Size:	146.5 KB
ID:	383497   Click image for larger version

Name:	image-1594768472.jpg
Views:	62
Size:	131.2 KB
ID:	383505  

Click image for larger version

Name:	image-429424259.jpg
Views:	69
Size:	131.0 KB
ID:	383513   Click image for larger version

Name:	image-257448560.jpg
Views:	68
Size:	129.0 KB
ID:	383521  

__________________
THE MPGp
1979WagoneerLTD is offline   Quote Quick Reply
Old 09-29-2013, 04:16 PM   #68
Jeeper
 
1979WagoneerLTD's Avatar
 
Join Date: Nov 2008
Location: GA
Posts: 377
A/C liquid/orifice tube line, power steering pressure line. On late 4.0 models, the existing pressure line can be re-used. The pump cannot, however, as the 2.5 Saginaw model with remote reservoir must be used.
Attached Thumbnails
Click image for larger version

Name:	image-3680774302.jpg
Views:	44
Size:	144.6 KB
ID:	389929   Click image for larger version

Name:	image-662179823.jpg
Views:	59
Size:	172.0 KB
ID:	389937  

__________________
THE MPGp
1979WagoneerLTD is offline   Quote Quick Reply
Old 09-30-2013, 05:48 PM   #69
Jeeper
 
superduty_5.9's Avatar
 
Join Date: Jan 2011
Location: Mount Victory, Ohio
Posts: 230
Great build! Love the pics!
__________________
Diesel fumes make me horny!
superduty_5.9 is offline   Quote Quick Reply
Old 09-30-2013, 09:07 PM   #70
Jeeper
 
DermJeep's Avatar
 
Join Date: Jun 2013
Location: Durham, NC
Posts: 71
Are you going to duct fresh air for the CAC from a cowl location or underneath?
__________________
Bull City
DermJeep is offline   Quote Quick Reply
Old 10-01-2013, 04:51 AM   #71
Jeeper
 
1979WagoneerLTD's Avatar
 
Join Date: Nov 2008
Location: GA
Posts: 377
Quote:
Originally Posted by DermJeep View Post
Are you going to duct fresh air for the CAC from a cowl location or underneath?
Yes. The final layout of A/C lines and placement of the air box will determine how much space I have, and where. A 5" Derale fan will provide low-speed airflow.
__________________
THE MPGp
1979WagoneerLTD is offline   Quote Quick Reply
Old 10-01-2013, 04:56 AM   #72
Jeeper
 
1979WagoneerLTD's Avatar
 
Join Date: Nov 2008
Location: GA
Posts: 377
Final placement of radiator hoses and degas bottle.
Attached Thumbnails
Click image for larger version

Name:	image-1239497899.jpg
Views:	47
Size:	106.7 KB
ID:	394809   Click image for larger version

Name:	image-898988976.jpg
Views:	48
Size:	95.8 KB
ID:	394817  

Click image for larger version

Name:	image-4190824991.jpg
Views:	52
Size:	169.4 KB
ID:	394825   Click image for larger version

Name:	image-3099172743.jpg
Views:	53
Size:	152.4 KB
ID:	394833  

Click image for larger version

Name:	image-4151357902.jpg
Views:	50
Size:	165.2 KB
ID:	394841  
__________________
THE MPGp
1979WagoneerLTD is offline   Quote Quick Reply
Old 10-01-2013, 05:52 PM   #73
Jeeper
 
1979WagoneerLTD's Avatar
 
Join Date: Nov 2008
Location: GA
Posts: 377
Mounting for the water separator/fuel filter.
Attached Thumbnails
Click image for larger version

Name:	image-405922143.jpg
Views:	47
Size:	138.4 KB
ID:	396609  
__________________
THE MPGp
1979WagoneerLTD is offline   Quote Quick Reply
Old 10-01-2013, 05:54 PM   #74
Jeeper
 
1979WagoneerLTD's Avatar
 
Join Date: Nov 2008
Location: GA
Posts: 377
Condenser and accumulator in. Test vacuum, held 28" after 30 min deep evacuation.
Attached Thumbnails
Click image for larger version

Name:	image-22266449.jpg
Views:	43
Size:	173.7 KB
ID:	396617   Click image for larger version

Name:	image-2027827773.jpg
Views:	53
Size:	160.8 KB
ID:	396625  

Click image for larger version

Name:	image-2242833324.jpg
Views:	58
Size:	145.3 KB
ID:	396633  
__________________
THE MPGp
1979WagoneerLTD is offline   Quote Quick Reply
Old 10-04-2013, 07:55 AM   #75
Jeeper
 
1979WagoneerLTD's Avatar
 
Join Date: Nov 2008
Location: GA
Posts: 377
This is how I had envisioned the right side underhood to look.

The mass air sensor will be fitting that will fab into the 90o tube, along with a crankcase vent inlet post maf.
Attached Thumbnails
Click image for larger version

Name:	image-1580168684.jpg
Views:	49
Size:	152.6 KB
ID:	403033   Click image for larger version

Name:	image-2934564780.jpg
Views:	55
Size:	166.2 KB
ID:	403041  

__________________
THE MPGp
1979WagoneerLTD is offline   Quote Quick Reply
Old 10-06-2013, 11:14 AM   #76
Jeeper
 
1979WagoneerLTD's Avatar
 
Join Date: Nov 2008
Location: GA
Posts: 377
Pressure test cooling system with regulated air, 18 psi. This Waekon tester is very handy for finding cooling system leaks, checking actual temp.
Attached Thumbnails
Click image for larger version

Name:	image-3371968326.jpg
Views:	53
Size:	191.3 KB
ID:	408457  
__________________
THE MPGp
1979WagoneerLTD is offline   Quote Quick Reply
Old 10-06-2013, 02:24 PM   #77
Jeeper
 
1979WagoneerLTD's Avatar
 
Join Date: Nov 2008
Location: GA
Posts: 377
Power steering reservoir and lines. Fuel cooler and filter assembly plumbing.
Attached Thumbnails
Click image for larger version

Name:	image-4016492171.jpg
Views:	47
Size:	117.3 KB
ID:	408761   Click image for larger version

Name:	image-862237143.jpg
Views:	44
Size:	143.8 KB
ID:	408769  

Click image for larger version

Name:	image-2795610469.jpg
Views:	48
Size:	132.4 KB
ID:	408777  
__________________
THE MPGp
1979WagoneerLTD is offline   Quote Quick Reply
Old 10-07-2013, 03:57 PM   #78
Jeeper
 
1979WagoneerLTD's Avatar
 
Join Date: Nov 2008
Location: GA
Posts: 377
Integrating the Bosch mass air/charge air temp sensor into the existing Jeep air box cover. There's just enough space to fit it into the snorkel opening; you have to cut the old sensor mount out of the MAF housing and trim- out with a dremel.
Attached Thumbnails
Click image for larger version

Name:	image-4292139664.jpg
Views:	42
Size:	101.8 KB
ID:	412033   Click image for larger version

Name:	image-2522685178.jpg
Views:	47
Size:	113.6 KB
ID:	412041  

Click image for larger version

Name:	image-2073709320.jpg
Views:	50
Size:	127.4 KB
ID:	412057  
__________________
THE MPGp
1979WagoneerLTD is offline   Quote Quick Reply
Old 10-07-2013, 08:01 PM   #79
Jeeper
 
1979WagoneerLTD's Avatar
 
Join Date: Nov 2008
Location: GA
Posts: 377
Air intake plumbing. For now, it's a compilation of bends and clamps until I can size something a little more clean.
Attached Thumbnails
Click image for larger version

Name:	image-3745705547.jpg
Views:	58
Size:	130.4 KB
ID:	412457   Click image for larger version

Name:	image-2670623274.jpg
Views:	51
Size:	145.3 KB
ID:	412465  

Click image for larger version

Name:	image-770337511.jpg
Views:	49
Size:	145.6 KB
ID:	412473   Click image for larger version

Name:	image-3013756096.jpg
Views:	59
Size:	118.7 KB
ID:	412505  

__________________
THE MPGp
1979WagoneerLTD is offline   Quote Quick Reply
Old 10-08-2013, 10:06 PM   #80
Newb
 
Join Date: Apr 2013
Posts: 5
awesome build
NYJeep22 is offline   Quote Quick Reply
Old 10-10-2013, 01:18 PM   #81
Jeeper
 
DermJeep's Avatar
 
Join Date: Jun 2013
Location: Durham, NC
Posts: 71
Quote:
Originally Posted by 1979WagoneerLTD View Post
Integrating the Bosch mass air/charge air temp sensor into the existing Jeep air box cover. There's just enough space to fit it into the snorkel opening; you have to cut the old sensor mount out of the MAF housing and trim- out with a dremel.
Nice trick! Any worry that the sensor will impede air flow?
__________________
Bull City
DermJeep is offline   Quote Quick Reply
Old 10-10-2013, 01:54 PM   #82
Jeeper
 
1979WagoneerLTD's Avatar
 
Join Date: Nov 2008
Location: GA
Posts: 377
I reckon no more than the OE MAF housing does.
__________________
THE MPGp
1979WagoneerLTD is offline   Quote Quick Reply
Old 10-13-2013, 07:54 AM   #83
Jeeper
 
1979WagoneerLTD's Avatar
 
Join Date: Nov 2008
Location: GA
Posts: 377
The first step with managing wiring-up the new engine starts long before the swap begins.

Resist temptation to hack, cut, trim, or otherwise modify the existing gas engine harness in any way. Instead, simply disconnect each servo, sensor, and ground one at a time and label. Then unplug from the bulkhead connectors, and store in a safe place.
Attached Thumbnails
Click image for larger version

Name:	image-749267389.jpg
Views:	38
Size:	161.1 KB
ID:	428065   Click image for larger version

Name:	image-502830996.jpg
Views:	36
Size:	164.3 KB
ID:	428073  

Click image for larger version

Name:	image-1337818718.jpg
Views:	41
Size:	159.7 KB
ID:	428081  
__________________
THE MPGp
1979WagoneerLTD is offline   Quote Quick Reply
Old 10-13-2013, 08:08 AM   #84
Jeeper
 
1979WagoneerLTD's Avatar
 
Join Date: Nov 2008
Location: GA
Posts: 377
Fast forward to today.

Reinstall the factory 4.0l harness and PCM as if the gas engine were there. Determine what circuit connectors to be kept: cpm, ckp, hvac compressor, hvac hi, hvac low, cts, alt f&s, oil pres. Remove the plastic cover from the injector rail, remove all of the sheathing and butyl tape carefully, while separating the circuits you want to keep. This process is painstakingly slow and should be done underhood so you can always have a perspective of what will go where on the new engine. Use small wire ties to bundle the individual circuits near the point the cut is made. I make five cuts, each nearest the point of termination or factory splice; the open is covered with liquid butyl and wrapped in tape, then tucked in plastic loom. The reminder is labeled and boxed; no wiring is cut out or lost in this process.
Attached Thumbnails
Click image for larger version

Name:	image-3153899897.jpg
Views:	49
Size:	174.3 KB
ID:	428089  
__________________
THE MPGp
1979WagoneerLTD is offline   Quote Quick Reply
Old 10-13-2013, 08:22 AM   #85
Jeeper
 
1979WagoneerLTD's Avatar
 
Join Date: Nov 2008
Location: GA
Posts: 377
The necessary ingredients for a TDI swap is more than just the engine. In effect, the jeep will operate as if it is a VW TDI, from an engine management standpoint.

So ideally, get the entire salvage car or a COMPLETE powertrain sans transmission. Computer PCM (VW calls it a DDICM) and harness comprise three main parts: the computer itself, a 60 pin connector, a 92 pin connector. There are also two sub-harness for turbo and boost control, which on the VW are located on the firewall.

I located the DDICM in the underhood left, using rubber weatherstrip as a kind of vibration damper.
Attached Thumbnails
Click image for larger version

Name:	image-1441302192.jpg
Views:	39
Size:	138.2 KB
ID:	428121   Click image for larger version

Name:	image-928652994.jpg
Views:	38
Size:	143.3 KB
ID:	428129  

Click image for larger version

Name:	image-2974170523.jpg
Views:	37
Size:	123.5 KB
ID:	428137  
__________________
THE MPGp
1979WagoneerLTD is offline   Quote Quick Reply
Old 10-13-2013, 09:26 AM   #86
Jeeper
 
1979WagoneerLTD's Avatar
 
Join Date: Nov 2008
Location: GA
Posts: 377
This is also the point where a subscription to Mitchell pro-demand is invaluable; both jeep and VW harness breakouts are displayed in a logical fashion using the same format. Connector and component locations are displayed as well as wire colors. The BEW engine management diagram is four pages long. I printed them out on a 30"x42" plotter and pasted the pages on a four sided science project board that I can unfold and place wherever I need for quick reference. Saving the diagrams to an xps is another quick way to get a permanent copy without having to stay on the laptop while working.
Attached Thumbnails
Click image for larger version

Name:	image-3895769207.jpg
Views:	40
Size:	133.1 KB
ID:	428185   Click image for larger version

Name:	image-1851006379.jpg
Views:	46
Size:	145.3 KB
ID:	428193  

Click image for larger version

Name:	image-1472691835.jpg
Views:	43
Size:	140.1 KB
ID:	428201   Click image for larger version

Name:	image-3237332769.jpg
Views:	38
Size:	148.4 KB
ID:	428209  

Click image for larger version

Name:	image-2684583601.jpg
Views:	47
Size:	113.5 KB
ID:	428217  
__________________
THE MPGp
1979WagoneerLTD is offline   Quote Quick Reply
Old 10-13-2013, 09:32 AM   #87
Jeeper
 
1979WagoneerLTD's Avatar
 
Join Date: Nov 2008
Location: GA
Posts: 377
Near-factory grade service manuals for VW are available from Bentley Publishers. The wiring diagrams are what VW calls "current Trac" and are for diagnostic use. They are not what most techs user friendly, but they actually are when you understand how it works.

Wire colors are in deutsch. Another thing to remember is brown is ground in VW electrics.
__________________
THE MPGp
1979WagoneerLTD is offline   Quote Quick Reply
Old 10-15-2013, 06:57 PM   #88
Jeeper
 
1979WagoneerLTD's Avatar
 
Join Date: Nov 2008
Location: GA
Posts: 377
The existing battery cables can be used without any modification. I used a longer bellhousing bolt and extra nut for the engine ground. Chassis ground is accomplished at the negative terminal with strap to the firewall.
Attached Thumbnails
Click image for larger version

Name:	image-323110629.jpg
Views:	50
Size:	130.6 KB
ID:	435289   Click image for larger version

Name:	image-2829916513.jpg
Views:	50
Size:	147.2 KB
ID:	435297  

Click image for larger version

Name:	image-3811213691.jpg
Views:	51
Size:	148.0 KB
ID:	435305   Click image for larger version

Name:	image-1832718306.jpg
Views:	51
Size:	122.3 KB
ID:	435313  

__________________
THE MPGp
1979WagoneerLTD is offline   Quote Quick Reply
Old 10-18-2013, 03:57 PM   #89
Jeeper
 
1979WagoneerLTD's Avatar
 
Join Date: Nov 2008
Location: GA
Posts: 377
Cool eh? No, not really. This is a great example of how corrosion can set in a wire, even though the area is 12" away from the nearest connector.
Attached Thumbnails
Click image for larger version

Name:	image-369391712.jpg
Views:	44
Size:	97.2 KB
ID:	442930  
__________________
THE MPGp
1979WagoneerLTD is offline   Quote Quick Reply
Old 10-20-2013, 01:45 PM   #90
Jeeper
 
1979WagoneerLTD's Avatar
 
Join Date: Nov 2008
Location: GA
Posts: 377
This is the variable geometry turbo and intake runner solenoid assembly , as well as the bracket and wiring. This is located on the firewall of the donor car, which will likely not be included in engine purchase unless you specifically tell them too. This goes for the 60 and 94 pin harnesses and the throttle-by-wire connector pigtail.
Attached Thumbnails
Click image for larger version

Name:	image-922331845.jpg
Views:	28
Size:	193.2 KB
ID:	447450   Click image for larger version

Name:	image-2296649363.jpg
Views:	32
Size:	161.0 KB
ID:	447458  

Click image for larger version

Name:	image-1549812745.jpg
Views:	31
Size:	193.3 KB
ID:	447466   Click image for larger version

Name:	image-2700618146.jpg
Views:	26
Size:	132.7 KB
ID:	447474  

Click image for larger version

Name:	image-1500106728.jpg
Views:	25
Size:	162.7 KB
ID:	447482   Click image for larger version

Name:	image-277333751.jpg
Views:	30
Size:	119.7 KB
ID:	447490  

Click image for larger version

Name:	image-2916894853.jpg
Views:	26
Size:	96.6 KB
ID:	447498   Click image for larger version

Name:	image-1831612939.jpg
Views:	27
Size:	96.6 KB
ID:	447506  

Click image for larger version

Name:	image-4264960980.jpg
Views:	25
Size:	154.8 KB
ID:	447514  

__________________
THE MPGp
1979WagoneerLTD is offline   Quote Quick Reply
Reply

Quick Reply
Message:
Options

Register Now

In order to be able to post messages on the Jeep Wrangler Forum forums, you must first register.
Please enter your desired user name, your email address and other required details in the form below.
User Name:
Password
Please enter a password for your user account. Note that passwords are case-sensitive.
Password:
Confirm Password:
Email Address
Please enter a valid email address for yourself.
Email Address:

Log-in

Human Verification

In order to verify that you are a human and not a spam bot, please enter the answer into the following box below based on the instructions contained in the graphic.



Thread Tools

Posting Rules
You may post new threads
You may post replies
You may not post attachments
You may not edit your posts

BB code is On
Smilies are On
[IMG] code is On
HTML code is Off
Trackbacks are Off
Pingbacks are Off
Refbacks are Off




» Featured Product

All times are GMT -5. The time now is 06:34 AM.



Jeep®, Wrangler, Liberty, Wagoneer, Cherokee, and Grand Cherokee are copyrighted and trademarked to Chrysler Motors LLC.
Wranglerforum.com is not in any way associated with the Chrysler Motors LLC