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Old 12-02-2012, 09:33 AM   #1
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My diesel TJ

I've completed the 1.9 VW diesel conversion on the 00 TJ using the HPA setup and it works well.Diesel Jeep Wrangler first run - YouTube

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Old 12-02-2012, 09:45 AM   #2
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Oh man, jealous of the diesel swap!

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Old 12-02-2012, 10:13 AM   #3
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Quote:
Originally Posted by 1979WagoneerLTD
I've completed the 1.9 VW diesel conversion on the 00 TJ using the HPA setup and it works well.Diesel Jeep Wrangler first run - YouTube
How expensive was that swap?
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Old 12-02-2012, 10:23 AM   #4
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I don't even want to think about it. However, the diesel powertrain was the main part of a complete build, including lift, brakes, tires, tummy tuck, sye, etc$ The starting point was a basic, unmodified 00 SE, so you can figure 8-10k just for basics, then 8-10 k for the HPA plus engine. I had a line on the engine plus entire harness and peripherals, which helped the cost factor. All of the design, layout, fabrication, and labor was done in-house (leterally if you count my garage!).
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Old 12-02-2012, 10:38 AM   #5
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Any mileage numbers yet?
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Old 12-02-2012, 11:19 AM   #6
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It has 10.5 miles on it so not enough info yet. Right now I'm fixing issues as they arise. The Carter low pressure fuel pump (specd from a late ISB Cummins) is leaking, as is the Raycor filter. One of the CAC tubes blew off under full boost (about the time the drive wheels broke away on rain slick pavement), etc, etc.
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Old 12-02-2012, 01:18 PM   #7
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Man that is so cool! I've been wanting to do a diesel swap in my TJ. I'm really interested to see how this does for you.
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Old 12-02-2012, 01:22 PM   #8
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ive heard of people doing this, but the guys ive heard said they missed the lower end power of the 2.5 off road. let us know how yours does.
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Old 12-02-2012, 04:16 PM   #9
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The torque is, well, very impressive. I kept the gear ratio at 4.11. The turbo spools as soon as you stab the throttle, and I mean immediately. More video as soon as I can get someone to film; the whole iPhone-while-u drive maneuver doesn't record well.
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Old 12-02-2012, 06:12 PM   #10
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what works on the gauge cluster?
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Old 12-02-2012, 06:20 PM   #11
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Subscribed let us know what MPG you get once everything is dialed in
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Old 12-02-2012, 07:48 PM   #12
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Quote:
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what works on the gauge cluster?
Good question, and an issue all later Jeep engine swappers must address.

With the VW engine management system, you essentially have to let it work as a "stand alone" network. In my case, the JTEC is left in its place and powered as if nothing had happened; the CKP is there registering engine speed HOWEVER I have not set-up a CMP/distributor reference for it. The JTEC is the hub of the CCD (Chrysler Collision Detection - a misnomer, as it is a name for muliplexed pre-CAN communication), with the instrument cluster being a recipient of data to drive the instruments. So I tee'd the oil pressure switch to pressure both the VW and CCD sensors, the VSS works as normal, the CKP triggers the fuel pump relay for the low-pressure pump, and the Coolant temp sensor is placed (tentatively) just downstream the main coolant hose "to" radiator.

I have all instruments working.

The DCL is the VW or "DDICM" interface for diagnostics, using the K line. I use PC based VAG-COM for that; the monitors run with the only codes being network CAN related, as well as one for the coolant pre-heater the Golf donor had.
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Old 12-02-2012, 08:48 PM   #13
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Originally Posted by tallzdatank View Post
ive heard of people doing this, but the guys ive heard said they missed the lower end power of the 2.5 off road. let us know how yours does.
The low end WHAT of the 2.5!?
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Old 12-02-2012, 08:52 PM   #14
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nice
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Old 12-02-2012, 09:36 PM   #15
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A few pics from the build.
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Old 12-02-2012, 10:32 PM   #16
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Old 12-02-2012, 10:36 PM   #17
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I was about to say...I saw in-progress pics on HPA's facebook page. Got some of 'em saved, too. I'm going to get in touch with you in the future. I'd LOVE to do this swap assuming there are still some good 1.9's left by the time I get around to having the funds...
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Old 12-02-2012, 11:04 PM   #18
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Nice work, the day my TJ gets an engine swap it will be tough to pick between a diesel or a Hemi.
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Old 12-02-2012, 11:15 PM   #19
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Very tough pick indeed. Both are good IMO.
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Old 12-03-2012, 04:24 AM   #20
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Well done sir
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Old 12-03-2012, 08:53 AM   #21
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Few more pics. In order to map the operating system wiring diagram, I had to blow them up on a plotter, then paste them to a science project display board from Office Depot. Makes it much easier to have it right there to quickly reference, write-on, label, etc.
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Old 12-03-2012, 08:58 AM   #22
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The aux cooling system for the intercooler and fuel cooler. With any modern CRD, EUI/in head setup, the fuel can superheat and needs to be cooled before you send it back to the tank.
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Old 12-03-2012, 10:09 AM   #23
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Quote:
Originally Posted by Sottyman
I was about to say...I saw in-progress pics on HPA's facebook page. Got some of 'em saved, too. I'm going to get in touch with you in the future. I'd LOVE to do this swap assuming there are still some good 1.9's left by the time I get around to having the funds...
Sure, I am willing to help guide anyone that has interest in doing this type of conversion. The next project I'm planning is a 2.0 TDI in the 11 unlimited rubicon. This will require a dedicated gateway for legit CAN interface. That should be a neat rig.
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Old 12-03-2012, 07:12 PM   #24
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Sure, I am willing to help guide anyone that has interest in doing this type of conversion. The next project I'm planning is a 2.0 TDI in the 11 unlimited rubicon. This will require a dedicated gateway for legit CAN interface. That should be a neat rig.

What can you tell me about the motor orientation? How much more clearance do you get over the Jeep motor?
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Old 12-03-2012, 07:53 PM   #25
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I've considered this swap myself a couple of times but I was always curious, would I be able to keep my flat to the frame tummy tuck?
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Old 12-03-2012, 08:27 PM   #26
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What can you tell me about the motor orientation? How much more clearance do you get over the Jeep motor?
It sits in approximately the same footprint as the 2.5, maybe a little closer to the firewall because the VW engine has a tandem mechanical fuel pump/vacuum pump that takes-up about 4 inches aft the trans/engine mounting surface.

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I've considered this swap myself a couple of times but I was always curious, would I be able to keep my flat to the frame tummy tuck?
Sure can. In fact, the conversion was designed around the Nth TT, including the final motor mount placement and custom rear trans mount.
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Old 12-04-2012, 08:03 AM   #27
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The 2.5 before removal, compared to present 1.9.
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Old 12-04-2012, 08:17 AM   #28
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The rig pretty-much blown apart; Dana 44 donor in the lower center. Local Craigslist for some parts, Epray for other, and a few on the forum.
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Old 12-04-2012, 08:28 AM   #29
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2000 2.5 SE, one-owner CL local deal. Interior sport decor package, sound bar/cassette deck, and full-sized spare. Total bone stock and unwheeled - paid $6500, which was a premuim however I really wanted to pay more for the virgin example. There were lots of TJ hack jobs for less, but I didn't want to end-up getting someone elses stolen parts
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Old 12-04-2012, 08:41 AM   #30
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Few other details. Powr-lock was the only mod for the 44. Some shots of the HPA components, all of which are high-quality.
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