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Old 04-01-2011, 12:49 AM   #1
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YJ 4.2 to DIESEL conversion - 'Preciate any insight

OK, I know I'm new to WF, and Jeeps (bought my first 3 weeks ago for $2000), but am not new to the offroad realm.

SO here's the run down, It's was a bone stock 87 YJ in great shape (no rust, dents dings, etc.. garage kept by previous owner, and is with me too), 86K miles (original), 4.2, manual.

Mods I have done so far....OME suspension, Kuhmo 31x10.50x15 AT tires (good all round tire) Kargo Master roof rack with Rigid Industries LEDs, scanner with custom dash fabbed mount (looks OEM - I like everything on the dash to look clean and blend in), underhood air compressor (still have to run plumbing to front and rear bumper), and in two weeks a HAM radio with Tuffy radio center console.

Primary use is daily driver, and 4x4 - specifically expedition/overland type of 4x4ing - forest roads, beach, mountains, just general all over type travel. Minimal to none on the rock crawling (I used to be stationed out west and now live back east, IMO nothing in the east will ever amount to the greatness of MOAB or the west off roading in general)

So now that you have a good background/use this is what I am currently pondering and researching/consumed with:

swap in the following

VW 1.9 4cyl diesel (the VW rabbit motors) with a turbo - On the cheaper side and parts are readily available. Later on adding a bio/oil conversion kit with a 5 micron filter (basically allows you to pour straight used motor oil in to use as fuel). I would add an oil bypass, and coolant bypass/filter to help reduce the effects of electrolysis.

M22 Rock Crusher - It speaks for itself...greatest ever made - downside is not in production anymore, and I have to give my left cojone` for one.

NP205 - Thought about an NP207 but the 205 is the same thing with an aluminum housing insted of cast iron which means more efficient cooling and less weight. Might have a hard time finding an adaptor plate for this setup, if so I'll machine one up.

I'm guesstimating it'll be about $5K to do it all myself and should get 27+ mpg. I'm keeping this forever, so I'd like to build it up the way I'd like it. I want to avoid any newer diesel motors because of all the electronics and higher price tags.

So that is the pending future swap. Sorry for all the additional info, but I figure the more you know the easier it would be for you to formulate suggestions, etc.. Thanks for all the feedback in advance. I'll post some picks of it when I get back in town.

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Old 04-01-2011, 12:58 AM   #2
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I have an np207 I'm getting rid of lol. Sounds like it'll be a nice setup though get some pics of it! And usually diesel swaps are either 4bt or 6bt so this will be interesting to see

And welcome to the forum

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Old 04-01-2011, 01:44 AM   #3
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Quote:
Originally Posted by Dursky View Post
OK, I know I'm new to WF, and Jeeps (bought my first 3 weeks ago for $2000), but am not new to the offroad realm.

SO here's the run down, It's was a bone stock 87 YJ in great shape (no rust, dents dings, etc.. garage kept by previous owner, and is with me too), 86K miles (original), 4.2, manual.

Mods I have done so far....OME suspension, Kuhmo 31x10.50x15 AT tires (good all round tire) Kargo Master roof rack with Rigid Industries LEDs, scanner with custom dash fabbed mount (looks OEM - I like everything on the dash to look clean and blend in), underhood air compressor (still have to run plumbing to front and rear bumper), and in two weeks a HAM radio with Tuffy radio center console.

Primary use is daily driver, and 4x4 - specifically expedition/overland type of 4x4ing - forest roads, beach, mountains, just general all over type travel. Minimal to none on the rock crawling (I used to be stationed out west and now live back east, IMO nothing in the east will ever amount to the greatness of MOAB or the west off roading in general)

So now that you have a good background/use this is what I am currently pondering and researching/consumed with:

swap in the following

VW 1.9 4cyl diesel (the VW rabbit motors) with a turbo - On the cheaper side and parts are readily available. Later on adding a bio/oil conversion kit with a 5 micron filter (basically allows you to pour straight used motor oil in to use as fuel). I would add an oil bypass, and coolant bypass/filter to help reduce the effects of electrolysis.

M22 Rock Crusher - It speaks for itself...greatest ever made - downside is not in production anymore, and I have to give my left cojone` for one.

NP205 - Thought about an NP207 but the 205 is the same thing with an aluminum housing insted of cast iron which means more efficient cooling and less weight. Might have a hard time finding an adaptor plate for this setup, if so I'll machine one up.

I'm guesstimating it'll be about $5K to do it all myself and should get 27+ mpg. I'm keeping this forever, so I'd like to build it up the way I'd like it. I want to avoid any newer diesel motors because of all the electronics and higher price tags.

So that is the pending future swap. Sorry for all the additional info, but I figure the more you know the easier it would be for you to formulate suggestions, etc.. Thanks for all the feedback in advance. I'll post some picks of it when I get back in town.
Sounds like a good plan. And like tang said, most diesel swaps into Jeeps are with a Cummins 4BT(3.9L turbo) with a very rare 6BT(5.9L turbo) swap here and there. As soon as I get the funds I'll be swapping in a Cummins 6BT into my TJ(already got the engine and axles). It would cost you a bit more because the engines are more expensive but you'd have a lot more power with either of the Cummins engines and there is no electrical to worry about. Just a couple of wires here and there and your good to go.

There was a guy here a while ago who was running the 4BT in his jeep and he was getting around 27-30mpg(if I remember right).

Anyways good luck with the build and welcome to the forum. We'll be here if you need some advice or an answer to a question.
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Old 04-01-2011, 03:43 AM   #4
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Yeah I would be curious if the little Volkswagen motor will be enough for you. The 258 has I think 190 ft lbs of torque and that little motor has 175 or so...but either way it's your jeep don't let me deter you if that's what you wanna do
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Old 04-01-2011, 09:50 AM   #5
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Thanks so far

Tang87, Intersting point about the ftlbs. This is a conceptual idea still in the early stages, so I had not considered the ftlbs. I did read the thread about the fellow who swapped in the Cummings. Very doable and it looked sharp. I would go with the 4bt.

I'll do some research into that motor and see. I really want to run the M22 Rock Crusher, but if I can't find one I'll consider an M20, or 21. I'll have to see if there is an adaptor plate for the bbl-M22 setup.

Does anyone have any first hand knowledge on the NP205, or know any pros/cons to them?

Thanks to all who have responded!
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Old 04-01-2011, 10:11 AM   #6
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Looks like the np205 is gear driven with a 30 spline input. They were also with the Muncie tranny so it would work out just make sure the spline count on the 4bt is the same. http://www.high-impact.net/transmiss...case_NP205.htm there is a link
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Old 04-01-2011, 04:46 PM   #7
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Sounds like a interesting swap. It has been done to trackers and sami's. I know you can build them to perform well but there is no replacement for displacement. I'm doing a diesel swap too but I'm using a Mercedes 3.0L 5 cyl turbo diesel.
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Old 04-03-2011, 10:55 AM   #8
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Foud A Company

Ok, so I found a company through JPmags blog called HPA Motors. They specialize in VW/Audi, etc... motors for upgrades, tricking out. They happened to do a 1.9TDi YJ conversion, utilizing the existing transmission in the Jeep. It's a good read, and the HPA is now making/selling the kits for the swap.

I was originally going to go with the 1.9 TD but the TDi may be the better option. With the kit they are pulling 280ftlbs of torgue, a big jump from the stock 177. Kit is a little pricey ($3200 - for everything minus the motor) so I have begun calling junk yards, and crash yard to see if they have one laying around, otherwise the bare motor itself brand new is about $7000. They do have complete install packages available (brand new motor included) but they want $15,999. Too rich for my blood. Besides DIY is half the fun.

Here is the link to HPA's VW YJ, HPA Motorsports Inc. - Jeep TDI Conversion Packages

They are getting 40+ mpg with this!!!
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Old 04-03-2011, 11:05 AM   #9
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Quote:
Originally Posted by Dursky
Ok, so I found a company through JPmags blog called HPA Motors. They specialize in VW/Audi, etc... motors for upgrades, tricking out. They happened to do a 1.9TDi YJ conversion, utilizing the existing transmission in the Jeep. It's a good read, and the HPA is now making/selling the kits for the swap.

I was originally going to go with the 1.9 TD but the TDi may be the better option. With the kit they are pulling 280ftlbs of torgue, a big jump from the stock 177. Kit is a little pricey ($3200 - for everything minus the motor) so I have begun calling junk yards, and crash yard to see if they have one laying around, otherwise the bare motor itself brand new is about $7000. They do have complete install packages available (brand new motor included) but they want $15,999. Too rich for my blood. Besides DIY is half the fun.

Here is the link to HPA's VW YJ, HPA Motorsports Inc. - Jeep TDI Conversion Packages

They are getting 40+ mpg with this!!!
For that price a 6bt is what I would go with lol but that is sweet to get 40mpg lol.
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Old 04-03-2011, 11:08 AM   #10
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Quote:
Originally Posted by Dursky View Post
Ok, so I found a company through JPmags blog called HPA Motors. They specialize in VW/Audi, etc... motors for upgrades, tricking out. They happened to do a 1.9TDi YJ conversion, utilizing the existing transmission in the Jeep. It's a good read, and the HPA is now making/selling the kits for the swap.

I was originally going to go with the 1.9 TD but the TDi may be the better option. With the kit they are pulling 280ftlbs of torgue, a big jump from the stock 177. Kit is a little pricey ($3200 - for everything minus the motor) so I have begun calling junk yards, and crash yard to see if they have one laying around, otherwise the bare motor itself brand new is about $7000. They do have complete install packages available (brand new motor included) but they want $15,999. Too rich for my blood. Besides DIY is half the fun.

Here is the link to HPA's VW YJ, HPA Motorsports Inc. - Jeep TDI Conversion Packages

They are getting 40+ mpg with this!!!
their kit will not work with your jeep unless you also plan to swap in an AX15. the AX15 was not put in wranglers till the 1989 model year.
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Old 04-03-2011, 11:22 AM   #11
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Correct

Yes, now that you mention it I do remember reading something about the 15.

At the end of the day I am in no rush to complete this. I plan on laying this out and having all my ducks in a row over the next year or two (need to finish college and get BACK into the work force (Mechanical Engineering major, prior Air Force).

Thanks to everyone for the insight/comments. As time goes on and I think of something else, I'll post it back in this thread.
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Old 04-03-2011, 11:25 AM   #12
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Quote:
Originally Posted by Dursky
Yes, now that you mention it I do remember reading something about the 15.

At the end of the day I am in no rush to complete this. I plan on laying this out and having all my ducks in a row over the next year or two (need to finish college and get BACK into the work force (Mechanical Engineering major, prior Air Force).

Thanks to everyone for the insight/comments. As time goes on and I think of something else, I'll post it back in this thread.
Awesome and don't forget how the weight will affect the ride and springs If you go heavier. also did you do your OME lift?
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Old 04-03-2011, 11:45 AM   #13
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Oh what fun

Yes I did install the OME suspension. I try to do as much as I can on my own. Not too bad to install when using an impact gun and pb blaster. took me about 4.5 hours doing it by myself. Now that the springs have settled I love it! The ride quality ifawesome, even my wife noticed how much better it rode. I know they have a higher price tag, but after using several other lifts on other vehicles I have now think OME is THE BEST. Worth every penny.

As far as the swap, I am planning on putting the heavy springs on the front. I have heavy in the rear, and med up front, currently.
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Old 04-03-2011, 06:33 PM   #14
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Quote:
Originally Posted by Dursky
Yes I did install the OME suspension. I try to do as much as I can on my own. Not too bad to install when using an impact gun and pb blaster. took me about 4.5 hours doing it by myself. Now that the springs have settled I love it! The ride quality ifawesome, even my wife noticed how much better it rode. I know they have a higher price tag, but after using several other lifts on other vehicles I have now think OME is THE BEST. Worth every penny.

As far as the swap, I am planning on putting the heavy springs on the front. I have heavy in the rear, and med up front, currently.
I see. Did you need any extras with the suspension lift? I plan on doing OME later need to get prices lined up for it when I get my jeep back
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Old 04-03-2011, 09:22 PM   #15
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I see. Did you need any extras with the suspension lift? I plan on doing OME later need to get prices lined up for it when I get my jeep back
No extras needed. The only thing that the OME doesn't come with is aftermarket U-Bolts for the leaves. Contacted OME/ARB about it and they recommend using the stock ones. I did and no complaints. I'll post some pics in the suspension thread and talk more about it. Don't want to get off topic here.
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Old 04-03-2011, 11:15 PM   #16
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Originally Posted by Dursky

No extras needed. The only thing that the OME doesn't come with is aftermarket U-Bolts for the leaves. Contacted OME/ARB about it and they recommend using the stock ones. I did and no complaints. I'll post some pics in the suspension thread and talk more about it. Don't want to get off topic here.
That's fine I just thought I'd ask while we are waiting for the diesel decision lol.
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Old 11-18-2011, 03:12 AM   #17
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Hi everyone, I have 2 Wranglers 95 4cyl Auto and just bought a 91 inline 6 with stick yesterday for parts(now thinkin bout fixing it tho). Don't know if 91 runs yet bought it at car auction for 650 bucks but if it doesnt run i was thinkin bout putting in vw diesel. FYI theres a guy in Montclair or Claremount CA brings in VW diesels from Germany nme of place is Quality German Parts and if I remmber correctly hes on Brooks street. Hope this helps and I look forward to learning from u guys n helping out where I can.
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Old 11-18-2011, 06:09 AM   #18
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Lots of money
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Old 11-21-2011, 11:27 AM   #19
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I've looked at the HPA kit too but thought it was more than I could afford. They do offer a high quality and complete kit for the money, it's just out of my budget. I was considering a kit for a Toyota from Acme and then mixing & matching parts from the AX-5 and a Toyota G52, W58, or R151 to mate up with my NP231. The AX-5 has the same front bolt pattern and input shafts can be swapped between the two makes. If you wanted to swap axles, you could consider just using a Toyota T-case and all it's gearing options.

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