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-   -   TJ Diesel TDI conversion MK 2 (http://www.wranglerforum.com/f118/tj-diesel-tdi-conversion-mk-2-a-254279.html)

1979WagoneerLTD 07-07-2013 08:57 PM

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.

1979WagoneerLTD 07-09-2013 06:17 AM

1 Attachment(s)
Both TDI Jeeps, the green is my completed unit MK l, with the white Rubi subject of this build thread.

gixxerphil 07-09-2013 06:23 AM

:popcorn:

I would love to throw a diesel in my 79 Wagoneer :drool:

1979WagoneerLTD 07-11-2013 06:02 AM

1 Attachment(s)
The front sheetmetal removed, the job becomes very manageable.

1979WagoneerLTD 07-11-2013 10:22 AM

1 Attachment(s)
Attachment 271377

Engine is removed, transmission will drop with skid.

1979WagoneerLTD 07-11-2013 10:24 AM

1 Attachment(s)
Attachment 271378

1.9 BEW TDI standing-by for adapters and other modifications that will accommodate a longitudinal installation into Jeep.

1979WagoneerLTD 07-11-2013 10:25 AM

1 Attachment(s)
Attachment 271379

This is an example of an unsatisfactory weld. Do not do this.

NCJeepin 07-11-2013 10:27 AM

Sub'd. I want to do a diesel swap sometime in the future!:)

ipboxman 07-12-2013 04:27 PM

Thanks for taking the time to do this :appl:

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 :thumb:

Zombiekiller 07-12-2013 05:05 PM

sub'd

Wondertwin1 07-12-2013 05:14 PM

I want to put a TDI in my jeep so bad. Please please please make this almost dummy proof.

RevCo666 07-12-2013 05:33 PM

Sub'd AGAIN!! last thread was awesome!!

1979WagoneerLTD 07-12-2013 09:32 PM

1 Attachment(s)
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.

1979WagoneerLTD 07-12-2013 09:37 PM

1 Attachment(s)
Clutch, pressure plate, flywheel are basic Jeep parts found on the original truck. LUK clutch and PP, Chinese flywheel from auto parts store.

1979WagoneerLTD 07-12-2013 09:51 PM

Quote:

Originally Posted by ipboxman (Post 3955442)
Thanks for taking the time to do this :appl:

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 :thumb:

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

1979WagoneerLTD 07-12-2013 09:56 PM

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.

dukes-o-hazard 07-15-2013 12:32 AM

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...

1979WagoneerLTD 07-15-2013 04:31 AM

Quote:

Originally Posted by dukes-o-hazard (Post 3963161)
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.

GoldenSahara00 07-15-2013 04:44 AM

Following along. :thumb:

dukes-o-hazard 07-16-2013 02:27 AM

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!

1979WagoneerLTD 07-16-2013 05:04 AM

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.

1979WagoneerLTD 07-16-2013 02:35 PM

2 Attachment(s)
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.

jmcc75 07-18-2013 11:54 AM

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:)

RevCo666 07-18-2013 12:00 PM

All I know is this: If I win some extra money, I'm hiring someone to make this conversion for me. :)

1979WagoneerLTD 07-19-2013 02:02 PM

Quote:

Originally Posted by jmcc75 (Post 3976203)
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.

jmcc75 07-26-2013 10:14 PM

I need more build!!! lol

1979WagoneerLTD 07-27-2013 12:11 PM

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.

1979WagoneerLTD 08-06-2013 08:41 PM

2 Attachment(s)
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.

jeepnfool 08-12-2013 02:00 PM

:punk:

1979WagoneerLTD 08-14-2013 07:10 PM

4 Attachment(s)
The stock KP39 (rusty) and the Garrett VNT17.


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