CJ5 1977 1.9D (1Y) "Eisengelb"

[LeonardoL]

Hello, guys.

I am starting this topic as some users might be interested in my current setup, and some ideas could be reused in other projects.

I registered at this forum looking for some info about the IDI VW engines. In Brazil, we have no ordinary passenger cars powered by diesel engines - as law allows just trucks (>=1 ton load capacity) and 4x4 offroad vehicles to be powered with diesel - so information about these engines is very scarce here.

My vehicle in a CJ-5 Jeep, which nicely fits in the "4x4" category, and thus can have a diesel motor. It has some differences from the US version, specially in the chassis dimensions, but essentially is the same thing.

Summarizing the most important changes by now, the current setup is the following:

- CJ-5 Willys Jeep (1977 BR model);
- VW 1.9D (1Y) diesel engine, adapted in 2001 using a fresh engine;
- Bosch VE injection pump and VW stock injectors;
- Eaton M24 supercharger (from brazillian Ford Fiesta), with 0.6kg/cm2 max pressure (currently);
- Snorkel and off-road air filter, both using 3" pipes, exaust using 2.5" pipes;
- Clark 260F transmission (used by some Ford Maverick models and light trucks) with original transfer case;
- Hydraulic VW steering (temporary, to be replaced by a Ford Galaxie one);
- Brake discs in all wheels, with 2 calipers for each front wheel (and a double-crossed piping system);
- Full floating rear axle, using reinforced axle (made from Cr-Mo steel) and reinforced hubs;
- Parking brake activated by pedal - the rear drive shaft is held with a separate disk brake;
- BF Goodrich tires (33");

I have a lot of pictures from the ongoing renovation/remaking process, which includes some of the described items here (and more) in the following address: http://leonardol.fotopic.net

There, you will find pictures about the axle exchange, the new brakes and brake pipes, the parking brake, some cleaning procedures, oil exchanges, and also future changes. Unfortunatelly, the captions are in portuguese only, and there are few pictures from the Jeep itself.

However, if you are interested in something, just ask me, and I will do my best to reply. I am also attaching some photos from the Jeep itself, below:





The last one is very outdated: I still need to get new pictures under the hood to reflect a lot of changes that have been made since I got the Jeep. But for now, I think it might give a clue about the setup. 

BTW, "Eisengelb" is the Jeep's name, meaning "yellow iron" in german.

Cheers,
Leonardo

[Syncroincity]

 :)Wow, very nice work, and a beauty of a Jeep!
Is the transmission stock, or another brand? Did you use an adaptor plate?

Keep posting with updates, welcome to the forum!

[LeonardoL]

Syncroincity,

Thank you!

The transmission have been changed - as our original Willys transmission is known for not standing even the original engine... And yes, I used an adaptor from Deeptec, which make adaptors ready for several engines and transmissions setups.

The only original parts of the rear powertrain are between the transfer case and the differential (including these). Everything else - engine, transmission, brakes, rear axle, rear hubs - have been replaced by modified parts.

I am finishing the new radiator and radiator fan adjustments (including new water hoses for it). Soon as I finish this, I pretend to add some pictures about the current setup here (engine, transmission, and such).

Leonardo

[OM617]

Very interesting, definitely more pictures!

Do you still use the turbo or just the supercharger?

[LeonardoL]

OM617,

This in a N/A engine, originally without turbo.

I already considered turboing, but I think the supercharger setup can be a little bit enhanced so it overcomes the current limitations - allowing the engine to run totally N/A or with full pressure at any RPM. For now, it works as any ordinary supercharger.

Leonardo

[burn_your_money]

Hello Leonardo,

I would like to see some more pictures of your supercharger setup if you could

Thanks

[LeonardoL]

burn_your_money,

Now, the SC and the old IC (picture above) are out of the Jeep.

As soon as I get a new IC the SC will be back in place, and I will take new pictures. For now, I am running totally N/A.

I'm attaching updated pictures from the engine, showing the new radiator and everything else (still a bit messy, after the SC comes back some things will be cleaned up).




Cheers,
Leonardo