TJ Diesel TDI conversion MK 2 - 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 07-07-2013, 09:57 PM   #1
Jeeper
 
1979WagoneerLTD's Avatar
 
Join Date: Nov 2008
Location: GA
Posts: 378
TJ Diesel TDI conversion MK 2

Some of you might've followed the "My Diesel TJ" build in the TJ forum. For this conversion, I'll be doing a more thorough build follow here.

The subject Jeep is an 04 TJ Rubicon NV 3550 with air conditioning. Pictures, as well as other nuggets, will be forthcoming in the following few days.

This build will vary slightly from the MK 1 TJ in that I will better detail and photograph the wiring installation, the fuel delivery system, the intercooler, welding/fabrication, and system integration. The Jeep is 100% stock and unlifted.

__________________
THE MPGp
1979WagoneerLTD is offline   Quote Quick Reply
Old 07-09-2013, 07:17 AM   #2
Jeeper
 
1979WagoneerLTD's Avatar
 
Join Date: Nov 2008
Location: GA
Posts: 378
Both TDI Jeeps, the green is my completed unit MK l, with the white Rubi subject of this build thread.
Attached Thumbnails
Click image for larger version

Name:	image-3906465831.jpg
Views:	488
Size:	172.6 KB
ID:	270615  

__________________
THE MPGp
1979WagoneerLTD is offline   Quote Quick Reply
Old 07-09-2013, 07:23 AM   #3
Mr. Little Tires

WF Supporting Member
 
gixxerphil's Avatar
 
Join Date: Dec 2010
Location: Auburn, Al
Posts: 30,556


I would love to throw a diesel in my 79 Wagoneer
__________________
Every time I see a color matched hard top, I want to rattle can it.
gixxerphil is online now   Quote Quick Reply
Old 07-11-2013, 07:02 AM   #4
Jeeper
 
1979WagoneerLTD's Avatar
 
Join Date: Nov 2008
Location: GA
Posts: 378
The front sheetmetal removed, the job becomes very manageable.
Attached Thumbnails
Click image for larger version

Name:	image-269910577.jpg
Views:	436
Size:	143.2 KB
ID:	271323  
__________________
THE MPGp
1979WagoneerLTD is offline   Quote Quick Reply
Old 07-11-2013, 11:22 AM   #5
Jeeper
 
1979WagoneerLTD's Avatar
 
Join Date: Nov 2008
Location: GA
Posts: 378
Click image for larger version

Name:	image-2029631917.jpg
Views:	709
Size:	149.1 KB
ID:	271377

Engine is removed, transmission will drop with skid.
__________________
THE MPGp
1979WagoneerLTD is offline   Quote Quick Reply
Old 07-11-2013, 11:24 AM   #6
Jeeper
 
1979WagoneerLTD's Avatar
 
Join Date: Nov 2008
Location: GA
Posts: 378
Click image for larger version

Name:	image-4051415397.jpg
Views:	915
Size:	177.4 KB
ID:	271378

1.9 BEW TDI standing-by for adapters and other modifications that will accommodate a longitudinal installation into Jeep.
__________________
THE MPGp
1979WagoneerLTD is offline   Quote Quick Reply
Old 07-11-2013, 11:25 AM   #7
Jeeper
 
1979WagoneerLTD's Avatar
 
Join Date: Nov 2008
Location: GA
Posts: 378
Click image for larger version

Name:	image-949153448.jpg
Views:	689
Size:	130.6 KB
ID:	271379

This is an example of an unsatisfactory weld. Do not do this.
__________________
THE MPGp
1979WagoneerLTD is offline   Quote Quick Reply
Old 07-11-2013, 11:27 AM   #8
Jeeper
 
NCJeepin's Avatar
 
Join Date: Apr 2011
Location: Connelly Springs, North Carolina
Posts: 3,784
Sub'd. I want to do a diesel swap sometime in the future!
__________________
When in doubt, power out!
NCJeepin is offline   Quote Quick Reply
Old 07-12-2013, 05:27 PM   #9
Jeeper
 
Join Date: Apr 2012
Posts: 16
Thanks for taking the time to do this

Make sure to comment on stuff you will do this time around that improved the process/costs/pita factor. I have been itching to put a diesel in the wife's LJ, I have a 4bt in my Scrambler so I'm already a diesel Jeep fan
ipboxman is offline   Quote Quick Reply
Old 07-12-2013, 06:05 PM   #10
Jeeper
 
Zombiekiller's Avatar
 
Join Date: Feb 2011
Location: North Carolina
Posts: 2,110
sub'd
__________________


ask me about cheap LEDs


check out my build thread at:
http://www.wranglerforum.com/f118/94...ow-150842.html
Zombiekiller is offline   Quote Quick Reply
Old 07-12-2013, 06:14 PM   #11
Jeeper
 
Wondertwin1's Avatar
 
Join Date: Sep 2011
Location: Northwest Florida
Posts: 755
I want to put a TDI in my jeep so bad. Please please please make this almost dummy proof.
__________________
I woke up this morning with good intentions, then idiots happened
Wondertwin1 is offline   Quote Quick Reply
Old 07-12-2013, 06:33 PM   #12
Jeeper
 
Join Date: Dec 2012
Posts: 2,631
Sub'd AGAIN!! last thread was awesome!!
RevCo666 is offline   Quote Quick Reply
Old 07-12-2013, 10:32 PM   #13
Jeeper
 
1979WagoneerLTD's Avatar
 
Join Date: Nov 2008
Location: GA
Posts: 378
I will do my bestest!!!

These are the physical conversion components, including billet flywheel spacer, bell housing plate. I measured them in mm for documentation purposes, as shown.
Attached Thumbnails
Click image for larger version

Name:	image-3683885677.jpg
Views:	386
Size:	105.4 KB
ID:	271981  
__________________
THE MPGp
1979WagoneerLTD is offline   Quote Quick Reply
Old 07-12-2013, 10:37 PM   #14
Jeeper
 
1979WagoneerLTD's Avatar
 
Join Date: Nov 2008
Location: GA
Posts: 378
Clutch, pressure plate, flywheel are basic Jeep parts found on the original truck. LUK clutch and PP, Chinese flywheel from auto parts store.
Attached Thumbnails
Click image for larger version

Name:	image-722222874.jpg
Views:	258
Size:	147.5 KB
ID:	271985  
__________________
THE MPGp
1979WagoneerLTD is offline   Quote Quick Reply
Old 07-12-2013, 10:51 PM   #15
Jeeper
 
1979WagoneerLTD's Avatar
 
Join Date: Nov 2008
Location: GA
Posts: 378
Quote:
Originally Posted by ipboxman View Post
Thanks for taking the time to do this

Make sure to comment on stuff you will do this time around that improved the process/costs/pita factor. I have been itching to put a diesel in the wife's LJ, I have a 4bt in my Scrambler so I'm already a diesel Jeep fan
The changes will be:

Air/air intercooler
Air/air fuel cooler from VW
Easier access to timing belt
Air conditioning
TJ era alternator

Possible inclusions are:

Cruise control
CAN gateway
__________________
THE MPGp
1979WagoneerLTD is offline   Quote Quick Reply
Old 07-12-2013, 10:56 PM   #16
Jeeper
 
1979WagoneerLTD's Avatar
 
Join Date: Nov 2008
Location: GA
Posts: 378
Oh, and I must acknowledge the mods and contributors over at the TDI forum. If any of you are interested in VW diesels, the that is a great place to go for information. I'll also plug a vendor, Kerman TDI, for all manner TDI parts, computer programming, and advice.
__________________
THE MPGp
1979WagoneerLTD is offline   Quote Quick Reply
Old 07-15-2013, 01:32 AM   #17
Jeeper
 
dukes-o-hazard's Avatar
 
Join Date: Jul 2013
Location: White Mtns. AZ
Posts: 72
This is cool, looking fwd to the rest of the build, I've read else where these conversion will net about 40mpg, is this accurate? Also, I've read that they don't last very long while under a load, towing, heavy off-roading, etc...
__________________
Bombing for peace is like F*cking for virginity!
dukes-o-hazard is offline   Quote Quick Reply
Old 07-15-2013, 05:31 AM   #18
Jeeper
 
1979WagoneerLTD's Avatar
 
Join Date: Nov 2008
Location: GA
Posts: 378
Quote:
Originally Posted by dukes-o-hazard View Post
This is cool, looking fwd to the rest of the build, I've read else where these conversion will net about 40mpg, is this accurate? Also, I've read that they don't last very long while under a load, towing, heavy off-roading, etc...
The first Jeep I placed a TDI in achieved 25 mpg average. That's realistic observation, not "girlfriend inches".

Powertrain life expectancy is comparable with the OE gas engines at least, and runs in proportion with operator diligence, maintenance, and stupidity.
__________________
THE MPGp
1979WagoneerLTD is offline   Quote Quick Reply
Old 07-15-2013, 05:44 AM   #19
Rock-Rubber

WF Supporting Member
 
GoldenSahara00's Avatar
 
Join Date: Aug 2010
Location: SCPA
Posts: 16,744
Following along.
__________________
Ryan - A good eye, a light foot, and a smart rig.
Bolt-ons are boring
AMERICAN JEEPER
My Build - http://www.wranglerforum.com/f118/pr...a00-74622.html
Rausch Creek Trip: 2014 Trip Coming Soon
GoldenSahara00 is offline   Quote Quick Reply
Old 07-16-2013, 03:27 AM   #20
Jeeper
 
dukes-o-hazard's Avatar
 
Join Date: Jul 2013
Location: White Mtns. AZ
Posts: 72
Nice, I figured the 40mpg's were a bit of a stretch, do to a number of factors the jeep has working so hard against it. That's what I get for indulging in internet blogs and magazine folklore! What is to be done with the unsatisfactory welds? The suspense is killing me!
__________________
Bombing for peace is like F*cking for virginity!
dukes-o-hazard is offline   Quote Quick Reply
Old 07-16-2013, 06:04 AM   #21
Jeeper
 
1979WagoneerLTD's Avatar
 
Join Date: Nov 2008
Location: GA
Posts: 378
I reckon a stock Wrangler TDI would do a little better, and 25 was formerly unrealistic in. Wrangler. It is nice to trail without being so dependent on carrying extra fuel.

The boogers were globbed on without any shielding gas or surface prep; already knocked them off with a hammer. When I get to placing the engine and tranny back in, I will discuss how I do final positioning. If the stock belly pan skid is used, then just keep the tranny where it was placed with the gas engine, and position the engine and mounts accordingly. A few tack welds, then remove everything. Pineal prep, burn, prep, paint, and install.
__________________
THE MPGp
1979WagoneerLTD is offline   Quote Quick Reply
Old 07-16-2013, 03:35 PM   #22
Jeeper
 
1979WagoneerLTD's Avatar
 
Join Date: Nov 2008
Location: GA
Posts: 378
This isn't relevant to this build, but I want to touch on it while I have multiple engines on the floor and the TJ blown apart.

I measured and compared the 1.9 and 2.0 "clean diesel" engine/transmission bolt pattern and crankshaft and it would appear that they the same. This is important, because the 2.0 is what I want to do next, since it is the current VW diesel, very compact and powerful, readily available, and even more robust on the bottom end.
Attached Thumbnails
Click image for larger version

Name:	image-2637988472.jpg
Views:	196
Size:	186.8 KB
ID:	273613   Click image for larger version

Name:	image-4114386451.jpg
Views:	220
Size:	157.7 KB
ID:	273614  

__________________
THE MPGp
1979WagoneerLTD is offline   Quote Quick Reply
Old 07-18-2013, 12:54 PM   #23
Jeeper
 
Join Date: Jan 2010
Location: Van Buren
Posts: 568
Images: 8
I'm lovin these builds but I'd like to see a 3.0l from a tourag with some go fast goodies stuffed in a jeep
jmcc75 is offline   Quote Quick Reply
Old 07-18-2013, 01:00 PM   #24
Jeeper
 
Join Date: Dec 2012
Posts: 2,631
All I know is this: If I win some extra money, I'm hiring someone to make this conversion for me.
RevCo666 is offline   Quote Quick Reply
Old 07-19-2013, 03:02 PM   #25
Jeeper
 
1979WagoneerLTD's Avatar
 
Join Date: Nov 2008
Location: GA
Posts: 378
Quote:
Originally Posted by jmcc75 View Post
I'm lovin these builds but I'd like to see a 3.0l from a tourag with some go fast goodies stuffed in a jeep
That would be cool. It was one of the original six engines I listed as a candidate, but it has more limited aftermarket support. The 3.0 VM is a nice plant that will likely have a backfit conversion for the JK, courtesy of AEV, Banks, etc. That will be really Neato.
__________________
THE MPGp
1979WagoneerLTD is offline   Quote Quick Reply
Old 07-26-2013, 11:14 PM   #26
Jeeper
 
Join Date: Jan 2010
Location: Van Buren
Posts: 568
Images: 8
I need more build!!! lol
jmcc75 is offline   Quote Quick Reply
Old 07-27-2013, 01:11 PM   #27
Jeeper
 
1979WagoneerLTD's Avatar
 
Join Date: Nov 2008
Location: GA
Posts: 378
I'm in a holding pattern for a few weeks while the machine shop builds a few more components. One of the changes I want to integrate into the follow on builds is a thicker plate by .5", which required me to redraw the adapters. I'd also like to use a more common starter that can be bought from an everyday parts vendor like rock, the zone, or national.

Stay tuned, as I'm gonna drop the fuel tank next week and go over what needs to be done to accommodate the fuel return using the canister line and rollover valves.
__________________
THE MPGp
1979WagoneerLTD is offline   Quote Quick Reply
Old 08-06-2013, 09:41 PM   #28
Jeeper
 
1979WagoneerLTD's Avatar
 
Join Date: Nov 2008
Location: GA
Posts: 378
New Garrett VNT 17 turbo. This unit provides more effective aspiration at higher engine RPM's than the stock unit.

The donor engine required a new turbo, and the VNT 17 was only like $30 more than the stock unit.
Attached Thumbnails
Click image for larger version

Name:	image-3487240643.jpg
Views:	167
Size:	124.2 KB
ID:	282591   Click image for larger version

Name:	image-2365607840.jpg
Views:	169
Size:	104.3 KB
ID:	282592  

__________________
THE MPGp
1979WagoneerLTD is offline   Quote Quick Reply
Old 08-12-2013, 03:00 PM   #29
Jeeper
 
Join Date: Aug 2013
Location: Crestview, FL
Posts: 31
jeepnfool is offline   Quote Quick Reply
Old 08-14-2013, 08:10 PM   #30
Jeeper
 
1979WagoneerLTD's Avatar
 
Join Date: Nov 2008
Location: GA
Posts: 378
The stock KP39 (rusty) and the Garrett VNT17.
Attached Thumbnails
Click image for larger version

Name:	image-3116020607.jpg
Views:	140
Size:	128.0 KB
ID:	285899   Click image for larger version

Name:	image-3065298214.jpg
Views:	156
Size:	150.7 KB
ID:	285900  

Click image for larger version

Name:	image-3321294906.jpg
Views:	122
Size:	128.9 KB
ID:	285901   Click image for larger version

Name:	image-743706320.jpg
Views:	133
Size:	138.2 KB
ID:	285902  


__________________
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




Download our Mobile App

» Network Links
»Jeep Parts
» Featured Product

All times are GMT -5. The time now is 04:47 PM.



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