TDI diesel swap process walk through TJ Jeep Wrangler
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- Опубликовано: 26 авг 2024
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TDI to Jeep Adapter kits:
tdconversions....
Going over the basics of what it takes to swap the engine and how cheap and how easy you can do it
Damn jeeps are HUGE! I swapped an ALH into my samurai, I had to move the engine back and the radiator forward to get enough clearance. The jeep on the other hand just looks like a cavernous void in front of it.
lol ya it would have been nice to move it forward some since I have the room, but it already had custom drive shafts and everything setup for the tranny to stay in the stock location.
Great tips, thanks for making this video! 👍
no problem, this swap is so awesome I want everybody to see how realistic it is to do it!
Did your computer require tuning to eliminate the immobilizer? If so who do you recommend. Also, are your gauges working off the jeep computer? I have a 2004 jeep TJ and a 2005 VW Jetta 1.9. I need to know which wires to use and which to discard. And does the jeep computer require tuning when only using the gauges? Great video!
Yes the computer will needed the immobilizer turned off, deleted and tuned. I have used Malone Tuning for both of mine. Using the Jeep ECU and engine sensors the factory Jeep gauges will work, I made a video on that specifically. I made a video on cutting out the wiring harness on my 03 as well, your 05 should be very similar.
What dimensions are the intercooler you used?
The one in this video is about stock ALH size, 12x10x4 core, much too small once I bumped the power up years later
Considering a TDI Wrangler swap as well but before getting too excited... how much of a PIA is registration & insurance(?)
Unfortunately I can't help you there, this is still registered as a gas vehicle with just liability insurance. Wyoming doesn't care at all what engine is in it.
Could a TDI swap work with an automatic transmission? I haven't been able to find a forum with an automatic write up. Thanks
TDI swapped trucks Facebook group has the most info you will find. There are quite a few automatic options depending on the vehicle, but most need to be able to run without a computer so older pre-2000 or even 1994 are the best. Getting the transmission computer to communicate with the TDI is usually complicated, and can be very expensive.
I have a 2000 TJ that would like to swap an ALH due to their reliability and strength. I found a 2000 Jetta TDI. Guys is asking $1,000 whole car but the timing belt broke he said not starting. Would it be too costly to rebuild ?
Well usually it bends valves/lifters/sometimes the cam is damaged, new heads are about $1000-1500, as long as it didn't damage pistons it's not terrible, but that's pretty high for a basically junk engine, if it's manual you can make some back selling the transmission/manual swap kit. But it's a pretty expensive start if you can't do the work yourself, most engine rebuilds are pretty costly these days.
My Monday question on my jeep TJ, what all needs vacuum other than the brake booster, heater controls and turbo actuator. I am not using the EGR system. Thanks.
That's it, brakes, turbo, and heater!
@@TDISwaps Thanks, that is the answer I was hoping for.
I have a 03 Jeep tj and was planning on doing a alh swap I was wondering what exactly do I need to do for the wiring do they make a plug and play wire harness kit? Do I need to re wire everything myself? Also do I have to run both the Volkswagen and Jeep ecu?
It's usually easiest to run separate wiring for the engine and the jeep. I have other videos going over all that as well as using the jeep wiring to make the gauges work. I can also build standalone harnesses for just the engine.
I would definitely be interested in buying a stand alone harness I just gotta find a donor car and get everything for the swap together
@johnpalmer415 check out the playlist on all my jeep videos that will help a lot, as well as my recent wiring videos on my dodge Dakota, very similar setup. But you can find me on Facebook facebook.com/profile.php?id=100014261163897&mibextid=ZbWKwL
where did you get the universal premade engine mounts? And how did you align the motor. I am having difficulty determining if my engine is perfectly aligned? Thanks
So the engine side of my mounts are from TD conversions website, and the frame side are just universal v8 motor mounts, to be honest having it perfected aligned is not that critical, I think mine ended up about 1/4-1/2" off of centered.
@@TDISwaps Thanks for the reply. Since I am keeping the compressor I had a devil of a time making something work on the driverside. I got it in just behind and below the compressor. On the passenger side I mounted it closer to the front of the engine. Hope that it will not matter if they aren't both mounted across from each other. Got my computer and wiring harness back from Canada today so I about ready to get this show on the road--I hope.
@@herseyjake1 nice! Sounds like you got it under control. Yes the driver's side is a pain there is like 1 place it fits with the a/c compressor there. And no the location on each side won't matter at all, if you check out my Toyota it's passenger side mount is clear in front of the engine! Ha ha. Anyways, good work!
Kinda unrelated, but what long arm kit is that? I like how the uppers mount and the belly pan all go together. Been on the hunt for a good kit and this one caught my eye. Thanks🥃
No problem ha ha, it's the Rubicon express 5.5" full kit, pretty pricey at over 3k, I redid the rear and made a weld on truss, their "bolt on" setup isn't that great, other than that it's awesome, flexes like no other!
Looks like a LOT of room in the front of the engine bay for a big turbo🤔😏
Ha ha compounds are in the making!
how did/do you decide to weld in the new motor mounts
Well I started with some universal premade mounts and then cut and welded them to work in my situation, but having the engine in place held up by straps right where you want it makes it easier to see where you can put the mounts and what will work.
What year is the engine?
The jeeps engine is a 2001
Video on how you fabbed up the powersterring and ac?
No ac, I will make one on the power steering though
Got that video posted you asked about
Hey I noticed your reply to comments! Was just wondering which year VW did you use? Which engines are the easiest/cheap swap if that's possible Haha. I want to swap my TJ for mpg but have never done a swap before...thanks!
Haha yeah I'm glad to help out, I just go for whatever TDI I can get a good deal on that's what I search for on marketplace and Craigslist, usually the 2000 to 2003 ALH is the cheapest that's what both my swaps are
@@TDISwaps Does it matter if the donor car is an automatic or manual? The trickiest part for me would be the wiring. Is EVERYTHING from the donor just swapped over? Or are some of the JEEP computers and wiring used? Is there step by step instructions anywhere? Thank you for responding!
@@nathanp5507 Your welcome, and the donor car doesn't matter, you will get the computer tuned to stand alone from whatever it is. I go over the wiring and keeping the Jeep ECU for the gauges in another video.
Actually drove mine 3 quarters of a mile this afternoon. First time to check the transmission and it feels good. Will my stock jeep tj radiator be sufficient to keep her cool? Installed a cheap $25.00 pressure regulator but I am not impressed. Gauge works around 25-30 lbs but drop to zero when backing off with the adjustment. Still might go to the H setup now that I have another metal fuel line going to the tank for a return .
I used a stock radiator for awhile but the mountain passes heated me up more than I liked so I did a $120 ebay 3 core and that really helped, although it barely gets to temp around town lol. Guess it depends on your conditions. Ya guys have run as much as 25-30 PSI to the ALH pump without issue, but it's asking for leaks if you ask me.
@@TDISwaps probably put about 5 miles on her today just driving a half mile on my county road back and forth. A few minutes ago I just determined that my brake booster is bad and that is why the vacuum is so weak. I used a vacuum hand pump to the actuator earlier today before I discovered the booster problem. When I applied vacuum to the actuator the lever moved but nothing changed with the idle or when I was driving.Your thoughts...
@@herseyjake1 the actuator is moved by the ECU as the boost comes in and goes away, it's pretty hard to recreate. I would just cap off the brake booster until it's fixed and make sure your n75 valve is getting full vacuum and then it should work correctly
@@TDISwaps I have capped off the brake boost until I can go and pick up one. How does the ECU control the actuator since there isn't a electrical plug connected to the actuator? The EXPENSIVE harness I had made didn't include one because they said it is basically useless and didn't work most of the time. Also, the harness did not provide for a electrical connector to the n75 valve. I can't see how the ECU can communicate with either of the 2. I haven't ridden in anything powered by a tdi 11.9 so I don't know what kind of power to expect. Currently there isn't much but I suspect I haven't experienced any boost yet. And I haven't test driven it since discovering the bad brake booster. Thanks.
@@herseyjake1 you must be missing some stuff that's needed for the turbo to work, I can't send pictures here but you can contact me on Facebook so I can sent you diagrams. m.facebook.com/profile.php?id=100014261163897&ref=content_filter
Are you using the stock jeep fuel pump? I understand the 1.9 only needs 8-10 fuel pressure whereas the stock jeep pump is considerably higher. And what did you look for when ordering water hose pipes off of ebay? Thanks.
So you don't actually need a fuel pump for the older 99-03 1.9s, but you can also do an H setup in the send and return lines using 2 tees and then run the factory fuel pump just sending most of the fuel back to the tank. I go over that in my Toyota setup. My intercooler hoses are off eBay just a universal kit but my water hoses are from the parts store. I put the part number to a few of those in my Toyota video as well.
Mine 1.9 is out of a 2005 Jetta. I will check your Toyota videos. Thanks.
@@herseyjake1 oh ok yes on an 05 TDI it does need a pump, but I have still seen guys use the factory pump with the H setup, either that or an inline pressure regulator to drop it to the 10 PSI.
@@TDISwaps ok, I am finally at the fuel supply point.
@@herseyjake1 ya I have seen multiple ways of making it work with the PD TDI engines, but the H setup and/or a pressure regulator are definitely the easiest options and you don't even need to mess with the fuel tank at all! I never even dropped mine.
What tune are you using stage 3 or 4 ?
I have all custom tunes from TekMekTronics, over stage 5 if you are looking at numbers, 200 HP/350 TQ
@@TDISwaps- Geez - that beats my stock 4.0 torque by a longshot and is a little better on HP. This swap is looking better and better to me.
@wes11bravo yes it definitely rips compared to the 4.0, and with a 5k rev limit it really feels like the 4.0 power band still. That and over 20 MPG makes it pretty hard to beat. If you can do it cheap the fuel savings pays for the swap in less than 50k miles.
What turbo did you get on here? I love the placement👌
that turbo is a gt2056v with a t25 flange, then I have a universal vw 8v t25 manifold to the engine. It comes straight out and then the turbo curls up which makes for a ton of room below by the motor mounts and starter.
Okay thanks👍🏻 Where did you get that t25 flange for the gt2056v? I’ve got a 1.6td out of a mechanical pump jetta mf engine code going to go in a Nissan hardbody, so I’m thinking a gt1544v might be better for me and the smaller engine, but maybe where you got the t25 housing/flange you say might have a t25 flange for a gt1544v too..?
Otherwise I think my only option is to make some flanges and make my own adapter to go from my stock k14 turbo manifold to the gt1544v flange type.
@@mattheripper well what flange does that 1544 come with? The t25 is a square flange like the bigger t3/t4 turbos. Your old turbo should be a 3 bolt triangle flange I think
Yeah both are fairly oddball flanges. The old school turbo is a four bolt but a trapezoid layout. The gt1544v is similarish to a t25 but rotated 90°, I’m sure it’s smaller than the t25 bolt pattern though it is square layout bolt wise, the turbine inlet isn’t oval like a t25 flange, it’s actually just a circular port for the turbine inlet on the gt1544v. The goal for the hardbody is to have a new age vnt turbo that’s size for fuel mileage over power. That being said though if you look at the listing on eBay for the gt1544v it says the Ford and Peugeot 1.6 hdi diesels it came off was making 110hp, so I’d assume it has some potential to get me over the stock 68hp the vw mechanical 1.6td’s made. What do you think? Where did you get the t25 housing for the gt2056v? That would be nice and easy if they did have a solution for a gt1544v housing going t25 too
Good job.. . The cluster is matching the tdi harness or you did some mods?
I left the jeep harness in there and screwed the Jeep gauge sensors into the VW block, then the VW harness just runs the engine and the gas pedal
TDI Swaps thank you very much. I’m considering a YJ/tdi . Which tdi engine do you recommend? Hp/work hours.
I always say find the best deal, all TDIs are good TDIs ha ha, some are a little better and some are a little easier to swap, but they are all good. newer is generally more complicated but makes bigger power easier. I spend a few weeks off and on pulling the engine and harness and getting it cleaned up and ready and measuring how it will fit, then at least for my jeep I swapped the engine in and had it driving in a weekend, with lots of loose ends of course.
TDI Swaps thx . Can you send me a link with a full tdi conversion kit/prices? If there is other company except coty.
oh ya Koty is the most expensive. look up whitebread performance and also td conversions, whitebread is the cheapest at about $900
How are you liking it so far? And is worth it?
I live in the mountains with headwinds in every direction it seems, and 30-50 miles to get anywhere. I could hardly justify driving the Jeep before at 10 MPG and downshifting every hill. Now I am getting 21-23 MPG and more power than I ever need. Of course there have been issues along the way, but it's also never left me stranded in 17k miles.
A diesel swap is the only swap I've seen capable of paying for itself in fuel savings
This is very true. I've been thinking about doing it to my YJ 2.5.
@@pabloaguirre6259 Ya the power the TDI has over the 2.5l is almost unbelievable, not to mention 2x the fuel mileage. It's hard to go wrong.
It truly sounds amazing. I'll have to make it happen.
I have a 63 Jeep Gladiator. What transmission did you use in this swap.
ax15 is the easiest, multiple choices for adapters so the price isn't through the roof
TDI Swaps
Thank you sir! 👍🇺🇸🙏
no problem, I'm going to try make more videos of the engine and wiring removal for my next swap, I'm doing a Toyota pickup
TDI Swaps
Sweet! 👍