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Engine Specific Info and Questions => Diesel Swaps => Topic started by: theman53 on June 12, 2012, 07:22:04 pm

Title: 1.9aaz moded to TDI in a Jeep.
Post by: theman53 on June 12, 2012, 07:22:04 pm
1.9aaz moded to TDI in a Jeep Wrangler CJ...

This will be my next project I think. I will get my jetta done first, but after and possilbly during I want to build a jeep for the wife. I have never been a jeep guy ever since my first car which was a CJ5 underneath welded onto a 74 super beetle up top. The 258 straight 6 was horrible.

At any rate, if any of you guys are jeep guys too, what jeeps should I start to look for? Probably will be a mall crawler as it is for the wife so it won't have huge tires on it, 33" at best. Ideally I want to find one that is rolling, blown up, and cheap. I just don't know about Jeeps other than I never liked them when I wheeled a lot. Seemed like driveshaft eating things. The axles weren't up to par either, but as stated this will be a female driven unit. Let me know what you guys that wheel jeeps prefer as what years, what to avoid, etc. I do have a set of puny dana 44s from a bronco that I could sub for the 35s or whatever those jeeps have. My 44 have 4.56 gears in them so I would need to know what trans ratios the jeeps have that would be desirable. I think acme makes adaptors, but I will make one if I cannot buy one. I will start searching soon for this info myself...it isn't like I cannot find the info, but I figured I would ask here first to get a head start and let you guys share knowledge if you have it.

Plan for the engine is MTDI AHU style with my AAZ bottom end. Huge nozzles and either my VNT 15 or the bigger VNT 2256 if it doesn't make it onto the 1.6 someday.
Title: Re: 1.9aaz moded to TDI in a Jeep.
Post by: 745 turbogreasel on June 13, 2012, 12:24:45 am
CJ5 or earlier will be way lighter and less complicated to convert.
Title: Re: 1.9aaz moded to TDI in a Jeep.
Post by: bajacalal on June 13, 2012, 01:26:09 am
If you hate Jeeps so much, why don't you just put the VW engine in a Samurai like everybody does?

I've probably owned a dozen different 4x4s. The Wrangler TJ Jeeps with coil springs are much more comfortable than the CJ series, followed by the Wrangler YJ (the square headlight ones). A CJ is probably one of the least comfortable vehicles out there and they aren't all that easy to drive if you aren't used to that kind of vehicle. They look so cool though. The fuel injection on a Wrangler would make the electronics something to contend with (get rid of) but the earlier ones, before 1991 I think, were carbureted and had things like a mechanical speedometer and gauges so those would be more suitable for a diesel swap.

Here's what I would do. Mercedes Benz. OM617. NV3500 or AX15 trans (that's the 5 speed that came in a Cherokee). I really, really want to put this combination in a CJ. I don't think it would be too challenging. An adapter exists to couple these together. I think that engine would be much more suited to this kind of vehicle.

Title: Re: 1.9aaz moded to TDI in a Jeep.
Post by: billybobf on June 13, 2012, 02:01:59 am
I am considering putting an eco 1.6 in my toyota 4runner, but I daily drive it and Im not sure I will be ok with the lost power, but i also have 20 forward gears and 4 reverse gears, so Im sure I can HANDLE the lack of power in exchange for some good mileage burning whatever waste oil I can find

I think the jeep will be cool with a 1.9tdi
Title: Re: 1.9aaz moded to TDI in a Jeep.
Post by: theman53 on June 13, 2012, 09:50:27 am
Main reason I wouldn't do the sami is the wife doesn't like sami's she likes jeeps. She used to have a wrangler back in the day is why. That and I know even less about the sami platform.

I do not know anything about mercedes OM617 or how to mod them. I just did a quick search on ebay and the only one I found was 1,200 dollars plus freight, so I think I will stick to the M TDI plan. If one could be had cheaper I would go that route as the extra displacement would be nice. I would still have to learn, but for 1,000 dollars or more I can build a great running TDI out of what I have.

She won't mind the comfort deal as we have newer cars for that. She loves my old Bronco and it is 100% off road with 38.5x16.5 R15 and it doesn't ride well. But the big thing here is it will be a fun toy that she drives once in a while. If it is worthy maybe it would see the mud, but I doubt it.
Title: Re: 1.9aaz moded to TDI in a Jeep.
Post by: R.O.R-2.0 on June 13, 2012, 12:34:36 pm
im gonna go with OM617 power in my Toy 4runner..

you can get a WHOLE OM617 for ~$1000 on this side of the country..

i like the OM engine better in a big vehicle.. i think the 1.6 or 1.9 would be a bit of a stretch in a big (jeep sized) vehicle..

ive thought about using VW power, even bought a 2.0L I5 TD engine, but i feel even IT is too small for a 4000# vehicle..

an OM engine would feel right at home in a 4000#+ vehicle..
Title: Re: 1.9aaz moded to TDI in a Jeep.
Post by: theman53 on June 13, 2012, 04:55:02 pm
Those jeeps *IMHO* were gutless from stock with whatever 4 banger they had in there. The older ones were better. Still the only jeep I was ever impressed with that had a AMC/jeep powerplant was the 360 in a fiberglass tub my friend had. It was built very well, would pull the front tires off the ground 8 inches when he had 33" on it. Many friends have done the SBC in one that ran good, and one pal had a built 460, but it wasn't as impressive as the SBC or the 360.

That said, the TDI I am building should have plenty of oomph and weigh 1/2 as much as the OM617. Plus I don't have to learn another engine platform and get the engine and parts. I have to buy a head, pistons, and that is it. I have injectors and a turbo or 2 currently for the TDI. I am just looking for jeep info as to which years rust more, wheel bearing issues, axle/transfer case issues, electronic activated stuff to deal with etc.
Title: Re: 1.9aaz moded to TDI in a Jeep.
Post by: R.O.R-2.0 on June 13, 2012, 05:13:20 pm
Those jeeps *IMHO* were gutless from stock with whatever 4 banger they had in there. The older ones were better. Still the only jeep I was ever impressed with that had a AMC/jeep powerplant was the 360 in a fiberglass tub my friend had. It was built very well, would pull the front tires off the ground 8 inches when he had 33" on it. Many friends have done the SBC in one that ran good, and one pal had a built 460, but it wasn't as impressive as the SBC or the 360.

That said, the TDI I am building should have plenty of oomph and weigh 1/2 as much as the OM617. Plus I don't have to learn another engine platform and get the engine and parts. I have to buy a head, pistons, and that is it. I have injectors and a turbo or 2 currently for the TDI. I am just looking for jeep info as to which years rust more, wheel bearing issues, axle/transfer case issues, electronic activated stuff to deal with etc.

start off with a CJ if you want something thats gonna be cool, and last..

what are you going to do for a trans? the Jeep Peugeot 5 speeds are junk. the AX-10/15 trannies werent much better..

please tell me you are NOT considering using a stock Jeep slush-o-matic?
Title: Re: 1.9aaz moded to TDI in a Jeep.
Post by: theman53 on June 13, 2012, 05:19:20 pm
I figured whatever I had that was decent...T18 4 speed if it would work.
Title: Re: 1.9aaz moded to TDI in a Jeep.
Post by: R.O.R-2.0 on June 13, 2012, 05:22:56 pm
I figured whatever I had that was decent...T18 4 speed if it would work.

OH!

so, you are planning on using an older setup?

i guess i should have clarified that all the trannies i was talking about, are 80s and newer trannies..

should be a pretty cool setup when its done..

only reason i want an OM powerplant in mine, is because its appropriate size to the vehicle, and the ability to make 300hp somewhat easily..
Title: Re: 1.9aaz moded to TDI in a Jeep.
Post by: theman53 on June 13, 2012, 08:16:56 pm
I really don't know. As far as that goes as long as I could adapt the transfer case and bell housing ends to it I "could" run anything. I really like the trans in the 94 chevy I have *NV4500* but I have no clue on dimentions of the jeep or how long that trans would be, or if there would be any driveshaft/diff problems of being on the opposite sides or not. IIRC jeeps and the new chevy are all driver side pumpkin...I am not even on stage 1 of the build, so don't flame too hard just yet LOL
Title: Re: 1.9aaz moded to TDI in a Jeep.
Post by: 8v-of-fury on June 13, 2012, 09:46:13 pm
So with most basics covered, what are you going to do about the Injection Pump? It will not be a bolt on and go operation to make an M-tdi as I'm sure you know already through my trail and errors eh Lucas?

I would talk to Andrew about the killer pumps he is hoping to be popping out in the next little while. 20mm shaft, 12mm head.. proper fueling and advance for our engines to redline.. and capable of fully fueling a 3.9L Chummings 4BT ;)
Title: Re: 1.9aaz moded to TDI in a Jeep.
Post by: theman53 on June 13, 2012, 10:59:31 pm
I currently have a cummins 4b 12mm pump that will be modded
Title: Re: 1.9aaz moded to TDI in a Jeep.
Post by: bajacalal on June 14, 2012, 12:41:15 am
I do not know anything about mercedes OM617 or how to mod them. I just did a quick search on ebay and the only one I found was 1,200 dollars plus freight, so I think I will stick to the M TDI plan. If one could be had cheaper I would go that route as the extra displacement would be nice. I would still have to learn, but for 1,000 dollars or more I can build a great running TDI out of what I have.

Are you serious? Around here, the 300d is the cheapest and most common diesel vehicle. Go anywhere in California and you will still see them on the roads. You can still find them in any junkyard. I have seen people sell them (the whole car) for under $500 not running or running with no papers, etc...
 
Come on, move out of your comfort zone a little. Learn something new. I'm thinking about getting a Honda CRX just because I have never owned a Japanese car and I want to explore something new. The Mercedes engines are very different from anything else on the road but they are still diesels just like ours... with an inline pump, cast iron head (on the OM617) and no timing belt. As far as power/weight you are looking at about the same as a stock Jeep inline 6 but with better fuel consumption.
Title: Re: 1.9aaz moded to TDI in a Jeep.
Post by: theman53 on June 14, 2012, 08:46:06 am
I think Californians may have had more money than the people in the farming community around here. I can count on one hand the Mercedes Diesel or not of that vintage I have ever seen on the road in Holmes county, my cousin owns one of them.
Like I said, IF I could find one rather cheap, as in 300.00 for a running engine, I would do it. I know to mod them wouldn't be that big of a deal. I know diesels, so the more air and fuel you dump to them the better they run, but I am thinking a 200hp TDI is just cheaper and easier for me. I also forgot to mention I have a new set of head studs made for our engines, rod, mains, oil pump...basically I only have to buy a gasket set, head, pistons, and injection lines and I am ready to go as I do have everything else. That and I really want to build a TDI. In your situation I would probably do the OM617, the biggest thing I would have to overcome is the lack of ability to mess with the IP. When I drove my cousins I looked into that IP he had to see what I could do and it just isn't as simple as the VE pumps.
Title: Re: 1.9aaz moded to TDI in a Jeep.
Post by: bajacalal on June 14, 2012, 12:42:22 pm
I suppose so, or maybe it's just a cultural thing. I read somewhere that southern California, specifically LA, Orange and San Diego counties, have more Mercedes and BMW sales than the rest of the United States combined. Maybe the guy here who buys the black Mercedes S-class drives the fully loaded full size pickup there.

Oddly enough, my friend from Germany told me that the 300D wagons were really popular in Germany with the farm families there who use them as their all purpose/go to town vehicle.

Title: Re: 1.9aaz moded to TDI in a Jeep.
Post by: 745 turbogreasel on June 14, 2012, 04:04:36 pm
Anyone selling a MBZ under $500 in CA is a sucker, because PnP will pay that to crush them.  There are still a lot of them here.

IMO while the NV4500 has been used in many Jeeps, it is overweight and overkill for 200 HP  the 3500 came behind many a small block, an are dirt cheap and easy to find.
Title: Re: 1.9aaz moded to TDI in a Jeep.
Post by: theman53 on June 14, 2012, 06:42:37 pm
I think you are about right. I could not even tell you where a Mercedes dealer is in Ohio. Like most things the cities like Cleveland, Columbus, and Cincinnatti probably have one, but I am 100% sure there is not one in Holmes county Ohio.

I haven't had experience with the NV3500 as my truck is the HD 3/4 ton and came with the truck. I just know I really like it. I have driven some 1/2 tons that probably had the 3500 and they would probably work for a jeep, I just like the granny gear.
Title: Re: 1.9aaz moded to TDI in a Jeep.
Post by: bajacalal on June 16, 2012, 12:25:09 am
I want an NV4500... for my 1st Gen Dodge.

I don't think one ever came in a Jeep. That is way too heavy duty for an OEM to consider it. They used the NV3500 though which is similar and smaller. I know someone who has a NV4500 which behind a 4BT Cummins in a Wrangler so I is definitely doable (this is what you should be putting in there btw) but way overkill and the granny 1st is not necessary for a light vehicle, not really suited for towing, unless you want to plow a field with it or do some hardcore rock crawling, I dunno... but then there's always the low range.

Title: Re: 1.9aaz moded to TDI in a Jeep.
Post by: theman53 on June 16, 2012, 01:00:36 am
I cannot locate a Jeep anywhere close with a blown engine. I am not in a hurry, but this has opened up my eyes to another possibility of buying a running one and waiting for it to blow up...So many different obsticles. I also haven't found a VW to X trans bellhousing kit other than the acme VW to Sami. I am sure they are out there but I haven't found them yet.

I was just thinking how much I like my NV4500 in the 3/4 truck. After thinking more in a Heep either of the trans I am familiar with *T18 or NV4500* are TOO much trans. If a sami trans can handle the load most times an NV3500 would for sure. And probably most out there. Whatever you guys said that came in the jeep would probably hold up better than the sami/tracker trans do.
Title: Re: 1.9aaz moded to TDI in a Jeep.
Post by: 81 vw pu on June 16, 2012, 02:51:46 am
I also haven't found a VW to X trans bellhousing kit other than the acme VW to Sami. I am sure they are out there but I haven't found them yet.

Have you checked out this site yet?

http://www.hpamotorsport.com/TDI-YJ-AX5.htm
Title: Re: 1.9aaz moded to TDI in a Jeep.
Post by: billybobf on June 16, 2012, 03:55:17 am
acme used to sell toyota conversions,

this said, the jeep ax5 and ax15 are ACTUALLY TOYOTA transmissions, one is a more common one then the other, one is a v-6/turbo tranny, which if using a jeep tranny but a toyota adapter, you would need the turbo bellhousing, this is hard to come by, good luck, but I think the ax5 can be used with any OTHER 4cyl bellhousing

so, tdi, to toyota, toyota bellhousing to ax5 should get you where you need to be, then ax5 to dana300, lol jk

you would almost be doing opposite of this guy, lol, putting toyota input and bellhousing on jeep ax5 trans. lol

http://www.jeepforum.com/forum/f19/replacing-ax-5-g54-toyota-transmission-615231/
Title: Re: 1.9aaz moded to TDI in a Jeep.
Post by: theman53 on June 16, 2012, 09:18:06 am
81...thanks, but that is a little more pricey than I want. I didn't find that one searching.

billybobf-Thanks, so for a VW you don't really need the jeep shaft, right? I will look into this. I could see paying a few hundred for an adapter, but over 1,000 isn't going to happen.
Title: Re: 1.9aaz moded to TDI in a Jeep.
Post by: R.O.R-2.0 on June 16, 2012, 10:04:36 am
acme used to sell toyota conversions,

this said, the jeep ax5 and ax15 are ACTUALLY TOYOTA transmissions, one is a more common one then the other, one is a v-6/turbo tranny, which if using a jeep tranny but a toyota adapter, you would need the turbo bellhousing, this is hard to come by, good luck, but I think the ax5 can be used with any OTHER 4cyl bellhousing

so, tdi, to toyota, toyota bellhousing to ax5 should get you where you need to be, then ax5 to dana300, lol jk

you would almost be doing opposite of this guy, lol, putting toyota input and bellhousing on jeep ax5 trans. lol

http://www.jeepforum.com/forum/f19/replacing-ax-5-g54-toyota-transmission-615231/

SORRY dude, but the AX5, and 15, are NOT toyota trannies.. i know that for positive.. they are AISIN-Warner trannies tho. thats not toyota. AISIN-warner makes trannies for EVERYONE.. GM/ISUZU, Jeep, Toyota, and a few others use it.

they are VERY close to a toyota trans tho, so if you go that route, get the AX15. the AX5 is basically the 4 cylinder/ W52/G56 (weak model, toothpick internals) they are not interchangable with toy trannies tho, afaik.. some parts may interchange, but not all..

Lucas, if it were me, i would buy adapters to go from VW, to toyota R150/R151 trans.. that is the bigger V6 trans with HEAVY DUTY input shaft and internals..

R150 is the turbo 4 banger trans. its more hard to come by. uses a gear drive 23 spline top shift transfer case. lower first gear to lite the turbo.

R151 is the V6 trans. WAY easier to come by, cheaper, nice gear lay out, nice overdrive, chain driven top shift 23 spline t-case..

everyone says the V6 transfer cases are weak, and i have yet to blow one up. ive blown up every piece of the drivetrain atleast once, but the trans/t-case.. the chain drive cases are fine.
Title: Re: 1.9aaz moded to TDI in a Jeep.
Post by: 81 vw pu on June 16, 2012, 11:33:34 am
If you do decide to go toyota trans, here's where a guy built his own adapter.
http://www.yotatech.com/f162/vw-diesel-build-up-135203/
Title: Re: 1.9aaz moded to TDI in a Jeep.
Post by: bajacalal on June 16, 2012, 12:53:12 pm
I cannot locate a Jeep anywhere close with a blown engine. I am not in a hurry, but this has opened up my eyes to another possibility of buying a running one and waiting for it to blow up...So many different obsticles. I also haven't found a VW to X trans bellhousing kit other than the acme VW to Sami. I am sure they are out there but I haven't found them yet.

I was just thinking how much I like my NV4500 in the 3/4 truck. After thinking more in a Heep either of the trans I am familiar with *T18 or NV4500* are TOO much trans. If a sami trans can handle the load most times an NV3500 would for sure. And probably most out there. Whatever you guys said that came in the jeep would probably hold up better than the sami/tracker trans do.

The reason that Acme makes the Toyota adapters is because the Toyota transmissions are considered an upgrade over the stock Samurai units which apparently don't hold up as well.

I would say strength wise for stock transmissions the NV3500 followed by the AX-15. I only threw those out there because I found a company that makes adapters for the Mercedes engine. The 4 speeds are pretty strong too and some of the older Jeeps had the Saturn overdrive unit on the transfer case or had that option. I don't think those really suit your purposes unless you are making the adapter stuff yourself in which case, the NV3500 came in the later (99 and up, I think) Cherokee and Wrangler. Prior to that the Ax-15 (6 cylinder) and AX-5 (4 cylinder) and some early ones had Peugeot units (not desirable).

I'm not aware of any company making any adapters for other applications than Suzuki/Toyota but the Toyota one, allows you to put the VW engine in basically any RWD application, the adapter+flywheel looks like it's $600.
Title: Re: 1.9aaz moded to TDI in a Jeep.
Post by: R.O.R-2.0 on June 16, 2012, 01:37:09 pm
I cannot locate a Jeep anywhere close with a blown engine. I am not in a hurry, but this has opened up my eyes to another possibility of buying a running one and waiting for it to blow up...So many different obsticles. I also haven't found a VW to X trans bellhousing kit other than the acme VW to Sami. I am sure they are out there but I haven't found them yet.

I was just thinking how much I like my NV4500 in the 3/4 truck. After thinking more in a Heep either of the trans I am familiar with *T18 or NV4500* are TOO much trans. If a sami trans can handle the load most times an NV3500 would for sure. And probably most out there. Whatever you guys said that came in the jeep would probably hold up better than the sami/tracker trans do.

The reason that Acme makes the Toyota adapters is because the Toyota transmissions are considered an upgrade over the stock Samurai units which apparently don't hold up as well.

I would say strength wise for stock transmissions the NV3500 followed by the AX-15. I only threw those out there because I found a company that makes adapters for the Mercedes engine. I don't think those really suit your purposes unless you are making the adapter stuff yourself in which case, the NV3500 came in the later (99 and up, I think) Cherokee and Wrangler. Prior to that the Ax-15 (6 cylinder) and AX-5 (4 cylinder) and some early ones had Peugeot units (not desirable).

I'm not aware of any company making any adapters for other applications than Suzuki/Toyota but the Toyota one, allows you to put the VW engine in basically any RWD application, the adapter+flywheel looks like it's $600.

ever seen a sammi tranny? they look FRAGILE at best.. 100ft lbs of torque is all they are rated to hold.. the transfer case is only good for about 120 ft lbs.

toyota trannies, even the 4 cyl unit, are leaps and bounds tougher than the sammi/tracker trans.. the toyota trans looks like a SEMI trans, compared to the sammi unit..

the NV3500/3550 isnt that tough either.. i dont really care for them. so far, from my experiences, the R151 is the toughest trans of the ones we are talking about..

NV4500.. those are HUGE.. i wouldnt even consider that an option. they arent even that tough.. idk how many ive seen die behind STOCK 5.9 cummins engines..

ever wonder why they only offered the Duramax as a manual for 6 months? its because the NV4500/5600 trannies werent tough enough to deal with the duramax, long term..
Title: Re: 1.9aaz moded to TDI in a Jeep.
Post by: theman53 on June 16, 2012, 05:25:04 pm
I will see what is in the jeep I get. Now the first problem is finding a jeep. I figured as many as were around here they would be easy to come by. All that I see is fully restored 30,000.00 types or complete junk. Hardly anything in between. Glad there is no rush on this, as I truely believe it will take a while to find what I want.
Title: Re: 1.9aaz moded to TDI in a Jeep.
Post by: billybobf on June 17, 2012, 01:59:28 am
by the way, I didnt mean they were built buy toyota, but that they are 90% interchangeable with the toyota units which have the adapters available.

never heard of a w52,   or a g56, I know there is a w56, w58, and a g54.

from what I know the ax15 is interchangeable with the r151 and r150, with respects to the matching transfer cases and the bellhousings required to make them run
Title: Re: 1.9aaz moded to TDI in a Jeep.
Post by: theman53 on June 17, 2012, 12:38:54 pm
OK,
What years Heep had the NV3500 and or the AX15? I think I will start there and work towards what ROR is saying about the Toyota deal. If the r151 is mostly the same as the AX15 it should be easier to find a bellhousing to mate up. The electronics I will all worry about later. We have no such thing as smog/e-check so lights that are on won't bother me too much if I cannot get it sorted.
Title: Re: 1.9aaz moded to TDI in a Jeep.
Post by: bajacalal on June 17, 2012, 06:42:50 pm
I'm not certain of exact cut-off years but it (AX-15) was the 5 speed used for most of the 1990s in 6 cylinder Jeep applications (4 cylinder ones used the AX-5). It has an aluminum end loading case. It looks like a Toyota trans honestly. The NV3500 looks similar. The earlier Peugeot transmission splits down the middle like a suitcase.

Another thing to consider is that they aren't all the same. Some years had an external slave cylinder and some years had an internal slave cylinder (integral to the throwout bearing). I guess what you end up using depends on the Toyota bellhousing.

Also, put RedLine gear fluid in it and not normal gear oil or it won't shift right.
Title: Re: 1.9aaz moded to TDI in a Jeep.
Post by: R.O.R-2.0 on June 18, 2012, 02:45:18 pm
OK,
What years Heep had the NV3500 and or the AX15? I think I will start there and work towards what ROR is saying about the Toyota deal. If the r151 is mostly the same as the AX15 it should be easier to find a bellhousing to mate up. The electronics I will all worry about later. We have no such thing as smog/e-check so lights that are on won't bother me too much if I cannot get it sorted.

R151 is COMMON.. super common. and i know for fact that they are tough. i abused (and cared for) one every day for 75k miles.. only time it ever let me down, was when i power shifted 2nd gear one day, and the shift fork retaining bolt broke, leaving me stuck in second gear. only time ive ever heard of it happening tho, and it was a simple $5 fix, and a couple of hours labor to pull and split the trans.

they made MILLIONS of R151 toyota V6 trannies.

im NOT impressed with NV3500/3550 trannies either. they have WEAK syncros.. my cousin has one behind a STOCK 4.3 v6, and even it has syncro issues.
Title: Re: 1.9aaz moded to TDI in a Jeep.
Post by: theman53 on June 18, 2012, 05:36:03 pm
I have a guy that has 2 jeeps for a package price. One needs a rad but other than that both run...and both have autos.

I may buy them. One black and one grey. I would keep the black one and sell the grey. I just need to decide to pull the trigger or not. 93 and a 91 both with 4.0L in them. Both have hard tops and full doors.
Title: Re: 1.9aaz moded to TDI in a Jeep.
Post by: R.O.R-2.0 on June 18, 2012, 05:55:52 pm
I have a guy that has 2 jeeps for a package price. One needs a rad but other than that both run...and both have autos.

I may buy them. One black and one grey. I would keep the black one and sell the grey. I just need to decide to pull the trigger or not. 93 and a 91 both with 4.0L in them. Both have hard tops and full doors.

damn.. i would jump on that. hardtop/full door models are more rare, from what ive seen.
Title: Re: 1.9aaz moded to TDI in a Jeep.
Post by: theman53 on June 18, 2012, 09:37:09 pm
You want the 91? LOL
Title: Re: 1.9aaz moded to TDI in a Jeep.
Post by: R.O.R-2.0 on June 18, 2012, 09:47:37 pm
im not interested at all. just that those models are fairly rare from my experiences..
Title: Re: 1.9aaz moded to TDI in a Jeep.
Post by: billybobf on June 19, 2012, 12:04:38 am
how much? lol

I could build me a little eco box 4x4, but would rather a sammi, lol
Title: Re: 1.9aaz moded to TDI in a Jeep.
Post by: theman53 on June 19, 2012, 08:53:16 am
If anyone wants it I would get rid of it for 1700.00 for sure. I would need to see it to make sure it was worth it, but it needs that rad and has rusted front fenders from what I can tell.
Title: Re: 1.9aaz moded to TDI in a Jeep.
Post by: R.O.R-2.0 on June 19, 2012, 03:19:35 pm
how much? lol

I could build me a little eco box 4x4, but would rather a sammi, lol

Sami/Trackers are where its at.. anything any bigger, and the 1.6/1.9 engine starts to show its small displacement..

thats why my Toyota doesnt have a VW in it yet. i know i wouldnt be satisfied with the performance.. i doubt even an AAZ would be as good as the V6 in there now. sure, the AAZ would be better than the 22r/e...
Title: Re: 1.9aaz moded to TDI in a Jeep.
Post by: 8v-of-fury on July 11, 2012, 08:49:07 pm
Whats the v6 have for torque?
Title: Re: 1.9aaz moded to TDI in a Jeep.
Post by: theman53 on July 12, 2012, 10:01:11 am
4.0 in the jeeps didn't make quite 200ft/lbs from what I have found.
Title: Re: 1.9aaz moded to TDI in a Jeep.
Post by: 8v-of-fury on July 12, 2012, 10:21:43 am
4.0 is an inline 6 though, goods for torque
Title: Re: 1.9aaz moded to TDI in a Jeep.
Post by: R.O.R-2.0 on July 12, 2012, 03:25:42 pm
Whats the v6 have for torque?

toyota V6 has 150hp, and 190 ft #s

my toyota has always been more powerful than a Jeep 4.0L
Title: Re: 1.9aaz moded to TDI in a Jeep.
Post by: 8v-of-fury on July 12, 2012, 06:48:37 pm
190? That is a disgustingly low number for a 6 cylinder. ;).

You could easily out do that with a slightly modded TDI or slightly more modded AAZ.
Title: Re: 1.9aaz moded to TDI in a Jeep.
Post by: theman53 on July 12, 2012, 06:59:02 pm
:evil grin smiley: My point exactly :evil grin smiley:
Title: Re: 1.9aaz moded to TDI in a Jeep.
Post by: 8v-of-fury on July 12, 2012, 07:03:12 pm
Andrew has said on many occasions an AAZ will produce the same power as the TDI's with the same modifications. Just consume 15% more fuel doing so, because of efficiency.

So a compound k03 and k24 setup with all the room in the jeep/4runner... and some mad pump modifications (like 11mm head and big huge dirty injectors) were cookin BACON>
Title: Re: 1.9aaz moded to TDI in a Jeep.
Post by: theman53 on July 12, 2012, 07:10:32 pm
What about a VNT 2256 and a 12mm pump....that is what I have. I also have the hybrid that we just made of the T3 vw hot side and the T3 mercedes cold side and that same 12mm pump. I plan on making an MTDI out of my AAZ with it, as I think I wrote early on in this thread. Also, I have 80% of the parts and even if I don't make the OM617 power, I bet I will be darn close and 1/2 the weight.
Even at an AAZ I think I could push 200HP and hopefully closer to the high 200's *wishful 280ft/lbs* if the turbo and 12mm pump will suffice.
Title: Re: 1.9aaz moded to TDI in a Jeep.
Post by: 8v-of-fury on July 12, 2012, 08:35:03 pm
If your only looking for 200hp an 11mm would do that with no problem. A 10mm will do 150hp. There wont be many advantages to the 12mm head unfortunately, disadvantages really being that you will be limited to like 3700-4000 rpms. HOWEVER! If that massive turbo will spool like a mother before 4000 (like 2500) then you have a good candidate for some mad power.

I feel that the 300ft.lbs would be achievable at that point. It may require some knowledgeable pump tweaking, to do with advance curves though.
Title: Re: 1.9aaz moded to TDI in a Jeep.
Post by: theman53 on July 12, 2012, 09:26:49 pm
I had the 12mm pump on my 1.6 for a few days. It was leaking out the screws up top, so I had air. But with its current Gov spring setup it would go 72mph in 3rd gear, probably more but it sounded too violent for me and I would shift. With my AGS and 3.67 R&P that is approx 4,800.
For the most part when done it "should" be the wife's unit, so I am not too bent out of shape if it doesn't rev to the moon for her.
Title: Re: 1.9aaz moded to TDI in a Jeep.
Post by: 8v-of-fury on July 12, 2012, 09:30:42 pm
Well if it sounded bad at 4800.. LOL thats like taking the 9mm pumps to 5800.

Its just that the plunger is physically bigger, and is harder to get the mass moving back an forth as fast eh?
Title: Re: 1.9aaz moded to TDI in a Jeep.
Post by: theman53 on July 12, 2012, 09:56:10 pm
FWIW it ran about as good as my Giles pump. It had more bottom end snap, but after that it kind of pulled like the Giles rig. It definately had more get and go than a stock VW pump.
BTW GILES pump would make that noise around the 79 mph mark in 3rd. If I was driving spirited I would usually still shift at 70mph.
Title: Re: 1.9aaz moded to TDI in a Jeep.
Post by: R.O.R-2.0 on July 13, 2012, 11:55:43 am
190? That is a disgustingly low number for a 6 cylinder. ;).

You could easily out do that with a slightly modded TDI or slightly more modded AAZ.

usually a gasser makes 1:1 power:torque ratio..

i thought 190 ft lbs was GOOD for a 180 cubic inch engine that spins 8000 revs..
Title: Re: 1.9aaz moded to TDI in a Jeep.
Post by: 8v-of-fury on July 13, 2012, 09:53:01 pm
still disgusto for a jeep/runner.. considering most mk3/4 jettas had near that.
Title: Re: 1.9aaz moded to TDI in a Jeep.
Post by: theman53 on July 15, 2012, 12:19:24 pm
Well if it sounded bad at 4800.. LOL thats like taking the 9mm pumps to 5800.

Its just that the plunger is physically bigger, and is harder to get the mass moving back an forth as fast eh?

I think with me that fine line between want and need is somewhere around 5,000 RPM  : D
Title: Re: 1.9aaz moded to TDI in a Jeep.
Post by: RabbitJockey on July 24, 2012, 11:51:42 am
If your only looking for 200hp an 11mm would do that with no problem. A 10mm will do 150hp. There wont be many advantages to the 12mm head unfortunately, disadvantages really being that you will be limited to like 3700-4000 rpms. HOWEVER! If that massive turbo will spool like a mother before 4000 (like 2500) then you have a good candidate for some mad power.

I feel that the 300ft.lbs would be achievable at that point. It may require some knowledgeable pump tweaking, to do with advance curves though.

i bet with a proper turbo a 10mm can do more than 150hp, lets not forget daves 1.6 that did 195whp with a 9mm pump.  or joshs car even, he did well over 200hp with a 10mm pump on his 1.6.  i guess the difference is much larger turbos than people usually use on a tdi and also perhaps revving higher since ve pumps can only move so much fuel per stroke so the higher u rev the more fuel u can move, tho u still can move put so much in per combustion.  but also just to be contradictory, i have heard(note that means this is hearsay) that 12mm pumps can be revved higher but you need to have high flowing injectors, which makes sense to me, but i'm not about to go try and break a 12mm pump haha.

yesterday i was driving home from getting supper with my lovely lady when i got behind a jeep the bumper said "Yes it's supposed to smell like that" and the license was "DSL-JEEP".  when the light turned green it was obvious he was running bio or wvo haha.  so the next light i blew a bunch of black smoke while we were sitting there, and at the next light i was able to get next to him(york, pa has alot of redundant traffic lights) i said hey is that a 617 and he says yep (light turns green pull to the next one) and i asked "hey do they make an adapter for that or did u have to do it your self?", he said "i made it, and i sell them mercedesdiesel4x4.com (http://mercedesdiesel4x4.com)"  cool right? haha  anyways that light turned green, and the turbo on it sounded great.  those mercedes have a lot of power potential, but i don't think they had much power stock haha.
Title: Re: 1.9aaz moded to TDI in a Jeep.
Post by: theman53 on July 25, 2012, 08:26:23 am
I passed on a 400.00 jeep...it was a cherokee and I need the wrangler for the woman. Cool site and I looked they do much more bellhousings than for a jeep, but sadly all are for the MB engine.
Title: Re: 1.9aaz moded to TDI in a Jeep.
Post by: RabbitJockey on July 25, 2012, 11:42:21 am
yeah good prices too i thought especially for the little father son business that it appears to be.  i can't imagine that they are moving thousands of these things.  maybe they'd make a vw adaptor.
Title: Re: 1.9aaz moded to TDI in a Jeep.
Post by: theman53 on September 20, 2012, 10:13:11 pm
Well, if all goes well I pick up a 2002 Jeep Wrangler Monday. All he has to do is clean it out and take my money. It has a blown engine, 4 cylinder with a manual trans. It is in excellent shape and I got it for a ton less than blue book...I would almost say for my looks and a song, but it took some $$$ too. I only saw 2 small, very small rust issues and it looks very, very good for a 2002 Ohio Heep. I will build a TDI out of an AAZ block and drop it in next year. 12mm cummins pump and a 2256vk probably if not that then the VNT 15 I have.

I will post pics as soon as it happens.
Title: Re: 1.9aaz moded to TDI in a Jeep.
Post by: R.O.R-2.0 on September 21, 2012, 05:15:43 pm
Well, if all goes well I pick up a 2002 Jeep Wrangler Monday. All he has to do is clean it out and take my money. It has a blown engine, 4 cylinder with a manual trans. It is in excellent shape and I got it for a ton less than blue book...I would almost say for my looks and a song, but it took some $$$ too. I only saw 2 small, very small rust issues and it looks very, very good for a 2002 Ohio Heep. I will build a TDI out of an AAZ block and drop it in next year. 12mm cummins pump and a 2256vk probably if not that then the VNT 15 I have.

I will post pics as soon as it happens.


i would honestly consider the VNT15 as the best option.. instaboost!
Title: Re: 1.9aaz moded to TDI in a Jeep.
Post by: 8v-of-fury on September 21, 2012, 09:50:37 pm
Well, if all goes well I pick up a 2002 Jeep Wrangler Monday. All he has to do is clean it out and take my money. It has a blown engine, 4 cylinder with a manual trans. It is in excellent shape and I got it for a ton less than blue book...I would almost say for my looks and a song, but it took some $$$ too. I only saw 2 small, very small rust issues and it looks very, very good for a 2002 Ohio Heep. I will build a TDI out of an AAZ block and drop it in next year. 12mm cummins pump and a 2256vk probably if not that then the VNT 15 I have.

I will post pics as soon as it happens.


i would honestly consider the VNT15 as the best option.. instaboost!

Every turbo you've ever had on your rig has had "Instaboost"... ;) No matter what the size of it, the condition or the engine its on this is Kevin's reaction to it;

"Yeah that Holset HX-50 over there on my 1.6? HOLY *** DOES IT SPOOL FAST"

"I have a K03 on my 1.5, it doesn't spool anywhere near as fast as my HX-50 did... BUT DAMN ITS PRETTY FAST SPOOLING!"

LMFAO.  :-*

It all depends on what transmission you are using and what gears its got in it as to what turbo you choose.
Title: Re: 1.9aaz moded to TDI in a Jeep.
Post by: theman53 on September 21, 2012, 10:02:31 pm
In what I think is if I have a 1.9 I will definately spool the 2256 just fine. I don't know yet as I haven't done it, but from what I gather on libbydiesel's setup it will be all in how the vanes are adjusted. Right now it has a 4 cylinder engine and manual trans, so I don't know if I am going to go with the bigger trans or just see if this one will like it. It will come down to the cost of another trans and if the adapter plate will work with both or not. If it will not I may try real hard to find the bigger trans for it.
Title: Re: 1.9aaz moded to TDI in a Jeep.
Post by: R.O.R-2.0 on September 22, 2012, 03:23:47 pm
Well, if all goes well I pick up a 2002 Jeep Wrangler Monday. All he has to do is clean it out and take my money. It has a blown engine, 4 cylinder with a manual trans. It is in excellent shape and I got it for a ton less than blue book...I would almost say for my looks and a song, but it took some $$$ too. I only saw 2 small, very small rust issues and it looks very, very good for a 2002 Ohio Heep. I will build a TDI out of an AAZ block and drop it in next year. 12mm cummins pump and a 2256vk probably if not that then the VNT 15 I have.

I will post pics as soon as it happens.


i would honestly consider the VNT15 as the best option.. instaboost!

Every turbo you've ever had on your rig has had "Instaboost"... ;) No matter what the size of it, the condition or the engine its on this is Kevin's reaction to it;

"Yeah that Holset HX-50 over there on my 1.6? HOLY *** DOES IT SPOOL FAST"

"I have a K03 on my 1.5, it doesn't spool anywhere near as fast as my HX-50 did... BUT DAMN ITS PRETTY FAST SPOOLING!"

LMFAO.  :-*

It all depends on what transmission you are using and what gears its got in it as to what turbo you choose.

my VNT20 is NOT instaboost!

nowheres close to it.

neither was my K24..

but the VNT15, even with the vanes open, was instaboost..

how can you claim that a VNT15 is NOT instaboost?

the second you throw any amount of heat to a VNT15, it spools..

an HX50.. that may never spool on a 1.6D.. we would have to figure out how to turn 10k rpms to spool something that HUGE..

if ive claimed any of my other turbos are instaboost, im comparing them to a similarly sized turbo.. my VNT20 spools MUCH QUICKER than a T3 or K24 does.. the VNT20 is a variable nozzle turbo, of course it spools quickly..

after it exploded, i kinda hatd it, and thought they were junk, but honestly, out of all the turbos ive run on my car, the VNT15 is my favorite, hands down! it spooled quick, and pulled hard right until the rollers started skipping..

Title: Re: 1.9aaz moded to TDI in a Jeep.
Post by: theman53 on September 24, 2012, 09:42:39 pm
Well here it is. It will start the slow process now. 2002 jeep wrangler 2.5 4 cylinder manual trans shale green metallic.
(https://sphotos-a.xx.fbcdn.net/hphotos-ash4/3115_10151262088006057_1120798070_n.jpg)
(https://sphotos-a.xx.fbcdn.net/hphotos-prn1/s720x720/148800_10151262086541057_1812585950_n.jpg)
(https://sphotos-b.xx.fbcdn.net/hphotos-ash3/s480x480/577131_3933837619500_1236521079_n.jpg)

It has new tires on the front, pass front fender is rusty and there is a small rust spot under the driver door. It made it on its own power to the house but has a BAD engine knock *guessing piston skirt broke off* but it misses and sounds like it is going to explode at any second. Everything works that I played with except the Odometer, but I think that is part of that "jeep thing" they brag about, which means all Chrystler products electrical systems and all things associated with them are junk. Brakes feel new. Overall, I am pleased with this purchase...and the wife is too. Amazing considering it is another non running vehicle. I could make serious money on it if I dropped in another jeep gas engine and sold it, but I believe this diesel will be most fun.




Title: Re: 1.9aaz moded to TDI in a Jeep.
Post by: theman53 on September 24, 2012, 09:45:55 pm
Next question is the 4 cyl and 6 cyl have different manual trans. I have to make all the adapter stuff either way. Should I roll the dice to see if the 4 banger trans is up to the task or just get the nv 3550 right now. Also, I have no idea if the transfer is the same between the 2 trans, I think it is, but these jeep sites are nothing compared to our GTD. As long as it is taking my machinist on the 1.6 TD head, I may take him my TDI head soon so it will be ready next year.
Title: Re: 1.9aaz moded to TDI in a Jeep.
Post by: RabbitJockey on September 24, 2012, 10:14:58 pm
ok justin
Title: Re: 1.9aaz moded to TDI in a Jeep.
Post by: 8v-of-fury on September 24, 2012, 10:15:49 pm
What a sexy girl that Justine is.
Title: Re: 1.9aaz moded to TDI in a Jeep.
Post by: theman53 on September 24, 2012, 10:30:37 pm
http://www.jeepwranglertech.com/jeep-wrangler-transmission.html
So I don't lose it and maybe someone else can use at a later date. Looks like the NV3550 can be used in all jeep 4.0 from 1997-2006

http://www.jeep4x4center.com/knowledge-base/jeep-wrangler-fluid-capacities.htm
Also looks like all heeps had NV 231 transfer case except Rubicons. So I can mix and match trans.

http://www.novak-adapt.com/knowledge/ax5.htm
That site tells me the ax 5 has only 21 spline transfer, the bigger trans had the 23...I don't want to spend too much on finding another trans and T case combo.
EDIT: I wish I had JB's money, but that is about it
Title: Re: 1.9aaz moded to TDI in a Jeep.
Post by: R.O.R-2.0 on September 25, 2012, 02:02:27 pm
http://www.jeepwranglertech.com/jeep-wrangler-transmission.html
So I don't lose it and maybe someone else can use at a later date. Looks like the NV3550 can be used in all jeep 4.0 from 1997-2006

http://www.jeep4x4center.com/knowledge-base/jeep-wrangler-fluid-capacities.htm
Also looks like all heeps had NV 231 transfer case except Rubicons. So I can mix and match trans.

http://www.novak-adapt.com/knowledge/ax5.htm
That site tells me the ax 5 has only 21 spline transfer, the bigger trans had the 23...I don't want to spend too much on finding another trans and T case combo.
EDIT: I wish I had JB's money, but that is about it

get an AX15/R150

in the Jeep, they were called AX15..

in the toyota V6 trucks, they were called R150..

they are just an aisin-warner trans..

very tough tho.. ive seen lots of 350 chevys mated to R150 toyota trannies, and live lots of miles as well..

im not very impressed with the NV3500/3550 trannies.. they have weak syncros, and 5th gear often times goes out..

the Aisin-warner trannies are BULLET PROOF from my experiences.. ive personally wheeled the hell out of one for like 50k miles..
Title: Re: 1.9aaz moded to TDI in a Jeep.
Post by: theman53 on September 25, 2012, 05:37:09 pm
Cool, the ax 15 are cheaper. The syncros in all my GM stuff always go out on 2nd, but they are tough as hell. Since this is for the woman mainly I would rather go with a smoother feeling trans. The ax 15 I didn't think had as good of gear ratios as the NV but it really wasn't that big of a difference. I just have to find someone looking for the ax5 and the transfer to go to buying mt stuff.


...also looked at the 6 speed NSG370, but many have said it won't handle anything for power.
Title: Re: 1.9aaz moded to TDI in a Jeep.
Post by: theman53 on September 25, 2012, 10:14:13 pm
I found an ax-15 with a transfer case, but it has the internal slave cylinder bellhousing for 300.00. I may get it, but with everything I have to buy lately I don't have the coin. Someone needs to buy my MK1 stuff I have for sale for the last 4 months.
Title: Re: 1.9aaz moded to TDI in a Jeep.
Post by: R.O.R-2.0 on September 26, 2012, 02:42:33 pm
I wish I had JB's money..

dont we all?!?!

think of the COOL one of a kind VWs we could build with JBs money?!
Title: Re: 1.9aaz moded to TDI in a Jeep.
Post by: R.O.R-2.0 on September 26, 2012, 02:43:40 pm
I found an ax-15 with a transfer case, but it has the internal slave cylinder bellhousing for 300.00. I may get it, but with everything I have to buy lately I don't have the coin. Someone needs to buy my MK1 stuff I have for sale for the last 4 months.

the Toyota R150f bell housing has an external slave..

and you can buy adapters to go from VW to Yota..
Title: Re: 1.9aaz moded to TDI in a Jeep.
Post by: theman53 on September 26, 2012, 06:32:35 pm
I found a deal on a nv3550 I may go that route. It is almost new out of a wreck. Time will tell if I get it, but I will have almost 600.00 less than if I bought an AX 15 and had it rebuilt *I called my friend Matt who has a trans shop*. I am not in a huge hurry as I still have the 1.6L TD project to do... once I get the pieces back.
Title: Re: 1.9aaz moded to TDI in a Jeep.
Post by: theman53 on September 29, 2012, 02:52:59 pm
This is the complete junk crank out of my 1.6TD. I figured it wouldn't be too hard to cut up to use the end of it for making a flywheel spacer. This is a job for someone with a lot of time. Took about 15 minutes to get all the way through.
(http://a1.ec-images.myspacecdn.com/images02/150/61c7686e88a64b6987482a2a2fc9f259/l.jpg)
(http://a4.ec-images.myspacecdn.com/images02/151/2b019bb4a4164afb94bf65ef0394445b/l.jpg)

The idea is that I can make the spacer off of the actual crank hub. Instead of making tons of measurements I will be able to mark it through the back side and then bolt it to the crank. Then mark and drill the rest.
Title: Re: 1.9aaz moded to TDI in a Jeep.
Post by: theman53 on October 02, 2012, 09:34:09 am
Ok, I have asked this on several different jeep forums with no answer. Here is the deal:
I have a 2002 NV231 transfer case in this wrangler with a 21 spline input shaft. This 23 spline input is for sale http://www.ebay.com/itm/180984577476?ssPageName=STRK:MEWAX:IT&_trksid=p3984.m1423.l2649
I will be mating the transfer to a NV3550 trans with a 23 spline output shaft. There are 4 different 23 spline input shafts for this transfer case, 2 different lengths and 2 different bearings...........What I need to know is if any of you know which input that is 23 spline will work with my parts? If any could help that would be great. I have local yards with jeep stuff so I think I could find one cheap and easy, or go with the ebay one that is pulled, but I just need to know what will work or not.


EDIT: Just found this, still am unsure of what I could get, but at least I have the differences laid out plainly. I should be able to do it once I pull the unit from the jeep now...at least. From what I gather it will be a late 23 spline with the narrow bearing and long input. Still if anyone knows what is up and could tell me I would take that.

http://www.novak-adapt.com/knowledge/np_nvg_input_gears.htm
Title: Re: 1.9aaz moded to TDI in a Jeep.
Post by: R.O.R-2.0 on October 02, 2012, 01:02:43 pm
Ok, I have asked this on several different jeep forums with no answer. Here is the deal:
I have a 2002 NV231 transfer case in this wrangler with a 21 spline input shaft. This 23 spline input is for sale http://www.ebay.com/itm/180984577476?ssPageName=STRK:MEWAX:IT&_trksid=p3984.m1423.l2649
I will be mating the transfer to a NV3550 trans with a 23 spline output shaft. There are 4 different 23 spline input shafts for this transfer case, 2 different lengths and 2 different bearings...........What I need to know is if any of you know which input that is 23 spline will work with my parts? If any could help that would be great. I have local yards with jeep stuff so I think I could find one cheap and easy, or go with the ebay one that is pulled, but I just need to know what will work or not.


EDIT: Just found this, still am unsure of what I could get, but at least I have the differences laid out plainly. I should be able to do it once I pull the unit from the jeep now...at least. From what I gather it will be a late 23 spline with the narrow bearing and long input. Still if anyone knows what is up and could tell me I would take that.

http://www.novak-adapt.com/knowledge/np_nvg_input_gears.htm

if nothing else, use the GM output shaft.. its 23 spline, and made to work with the NV231..

my cousins 94 Chevy has a NV3550 and NV231 tc
Title: Re: 1.9aaz moded to TDI in a Jeep.
Post by: theman53 on October 02, 2012, 05:49:39 pm
I think I can, but the deal with the Jeep thing is there are different lengths. I figured you can run any of them, but to get it to match the trans without adding another seal is key. Plus mine takes a small bearing from what I have read...they couldn't make it easy. They should have had it to where all were the same length, same bearing, and all you had to worry was spline count. I will check into the chevy one, according to that site it maybe the same one as the jeep, as they used the same inputs in many different NV transfer cases.
See:
We've decoded most of the Jeep input gears and many are available for sale. The Jeep 231 transfer case is the main focus of our information here, but these gears interchanges can apply to:

NP231
NP233
NP241 (Chevy, Dodge, Jeep JK)
NP242
NP243
NP246
NP247 (always has 23 splines)
NP249 (always has 23 splines)
Title: Re: 1.9aaz moded to TDI in a Jeep.
Post by: theman53 on October 24, 2012, 10:44:02 am
Found it without a doubt I know what is needed for my trans/transfer to work.

I need a 23 spline long input shaft with a 16mm bearing and the later style gear cut. Then I can put that in place of what my 4 cylinder trans ax5 21 spline input and it will work with the new 3550 trans.

So I don't forget again, http://www.novak-adapt.com/catalog/231_parts/np_231_parts.htm

This page is more about me not forgetting as it is helping someone else to search it LOL
Title: Re: 1.9aaz moded to TDI in a Jeep.
Post by: theman53 on January 13, 2013, 08:51:15 am
K&N filter for this will be this one. I thought I had posted it earlier. I am using this thread for my parts list and a central place so I don't lose all my research.
http://www.knfilters.com/search/product.aspx?prod=RC-5182XD
Title: Re: 1.9aaz moded to TDI in a Jeep.
Post by: theman53 on January 16, 2013, 04:36:25 pm
I've been doing a lot of research, and this is what I've come up with:

1.) The Jeep Liberties came with NV1500 (between 2003 and 2004 with the 2.4L motors).

2.) The NV1500 shares the same case pattern as the NV3500/NV3550.

3.) The NV3500 shares the same case pattern as the Toyota R-series transmissions.

4.) The Toyota R151F bellhousing has the 22RE pattern on the front with NV3500 pattern on rear.

5.) Volkswagen TDI/TD to 22RE style transmissions adapters are common and relatively cheap (Rocky-Road, ACME Adapters).

Result: The ability to bolt on a Volksagen TDI/TD into a Jeep Liberty using:

TDI/TD engine | Common Adapter | R151F bellhousing | NV1500 trans

Anyone see any fault in my logic?

*********************
I ripped that off another forum and it was interesting to find. This is helping me as I have the NV3550 and now know that the Acme cheap adapter will work for what I need if I don't want to build it myself.



http://www.acmeadapters.com/store_engine.php
Title: Re: 1.9aaz moded to TDI in a Jeep.
Post by: R.O.R-2.0 on January 16, 2013, 06:33:30 pm
I've been doing a lot of research, and this is what I've come up with:

1.) The Jeep Liberties came with NV1500 (between 2003 and 2004 with the 2.4L motors).

2.) The NV1500 shares the same case pattern as the NV3500/NV3550.

3.) The NV3500 shares the same case pattern as the Toyota R-series transmissions.

4.) The Toyota R151F bellhousing has the 22RE pattern on the front with NV3500 pattern on rear.

5.) Volkswagen TDI/TD to 22RE style transmissions adapters are common and relatively cheap (Rocky-Road, ACME Adapters).

Result: The ability to bolt on a Volksagen TDI/TD into a Jeep Liberty using:

TDI/TD engine | Common Adapter | R151F bellhousing | NV1500 trans

Anyone see any fault in my logic?

*********************
I ripped that off another forum and it was interesting to find. This is helping me as I have the NV3550 and now know that the Acme cheap adapter will work for what I need if I don't want to build it myself.



http://www.acmeadapters.com/store_engine.php

NV3500 and Toyota R150/151 trannies have ZERO in common..

ive worked on alot of both..

the NV3500 in my cousins truck, and the R150 in my truck are 100% different in every aspect..

the jeep AX15 is IDENTICAL in every way to an R150/151 tho..
Title: Re: 1.9aaz moded to TDI in a Jeep.
Post by: theman53 on January 16, 2013, 10:03:15 pm
On the outside the nv3550 is identical to the ax15. I am just looking at getting this mess bolted together.

And you are comparing the NV 3500 to the NV 3550. The 3500 came in trucks, the 3550 was something weird that jeep did.
Title: Re: 1.9aaz moded to TDI in a Jeep.
Post by: R.O.R-2.0 on January 17, 2013, 02:21:52 am
On the outside the nv3550 is identical to the ax15. I am just looking at getting this mess bolted together.

And you are comparing the NV 3500 to the NV 3550. The 3500 came in trucks, the 3550 was something weird that jeep did.

dude, the AX15/R150/R151 are made by Aisin-Warner.. the NV3500/3550 are both made by New Venture Gear..

totally different trannies, from totally different companies..
Title: Re: 1.9aaz moded to TDI in a Jeep.
Post by: theman53 on January 17, 2013, 09:08:13 am
I know...The outside ex: bolt pattern, case shape, is the same. You couldn't interchange gears and shafts. I could care less. But if you wanted to physically bolt one onto the same engine I am saying it is possible, I am not saying that they are the same trans. 

I have done tons of research and it all ends up the same. The Jeep that has an AX 15 you can bolt an NV3550 to with no mods. So if it is like you say an AX15 is identical to a 151 then I will be able to use the acme 151 adapter for the NV3550.
Title: Re: 1.9aaz moded to TDI in a Jeep.
Post by: R.O.R-2.0 on January 17, 2013, 09:00:59 pm
I know...The outside ex: bolt pattern, case shape, is the same. You couldn't interchange gears and shafts. I could care less. But if you wanted to physically bolt one onto the same engine I am saying it is possible, I am not saying that they are the same trans. 

I have done tons of research and it all ends up the same. The Jeep that has an AX 15 you can bolt an NV3550 to with no mods. So if it is like you say an AX15 is identical to a 151 then I will be able to use the acme 151 adapter for the NV3550.


151 has different gear split.. has a lower first gear, and a MUCH higher price tag..

ok, i buy that the bell housing bolt pattern may very well be the same..
Title: Re: 1.9aaz moded to TDI in a Jeep.
Post by: theman53 on January 31, 2013, 08:37:52 am
(http://img.photobucket.com/albums/v509/flash319/AdapterMedium-1.jpg)

THIS is what I have needed. Our own 410 here is in this thread and in all honesty I am copying his design. I thought this is what I needed to get going on the adaptor. Turns out this was for the wrong Toyota. It was for a W56 trans and not the AX 15. Live and learn set back # 53...
http://forums.tdiclub.com/showthread.php?t=294454


All one ever needed to know about what swaps fit what... http://www.jeeps-offroad.com/showthread.php?t=4740
Title: Re: 1.9aaz moded to TDI in a Jeep.
Post by: theman53 on January 31, 2013, 09:00:28 am
http://www.advanceadapters.com/pdf/nv_ebook.pdf

Page 54 reading for me about the ax15 to nv3550

also what I needed to find, Pre 1995 R150\R151 = 6.5"
1996 up Toyota R series = 7.5"
AX15 = 7.875"
87-92 Turbo Supra R154 = 7.25"
AR5 = 8.2"
MA5 = 8.2"
NV3550 = 7.875"
NV1500 = 8.6"
AX5 = 7.5"
Toyota W series = 6.5"
Toyota G series = 6.5"
Suzuki AG5 = ?

Title: Re: 1.9aaz moded to TDI in a Jeep.
Post by: theman53 on March 09, 2013, 11:34:48 am
The NV3550 is a pretty robust gearbox.It shares all of its mounting points with the AX15 but, as far as I'm aware, shares no parts with it. So, any application that has an AX15, can take an NV3550 with no problems. Although the front case bolt pattern is identical between all of them (Toyota R, AX15, MA5, AR5, NV3550), the NV3550 has a unique front bearing retainer and shape. It may not be capatable with some aftermarket adapter plates.

More stuff I am trying to figure it out still...

Title: Re: 1.9aaz moded to TDI in a Jeep.
Post by: theman53 on March 10, 2013, 07:11:31 pm
Quote
I have a 92 xj as well and have a 1.9 TDI that's almost ready to bolt in.

There is many companies out there that are making TDI swaps a lot more easy and cost efficient.

I was able to get my ECU Flashed HP Boost/security eliminated along with a engine management harness that's down to 5 wires to hook up and the motor is running.

As far as mating the engine to the trans this wasn't that hard. 1/2" Alum. adaptor plate bolted to the engine with the bell housing pattern on the plate.

I'm using an AX15 5speed along with the stock clutch and flywheel. The flywheel is machined to the TDI offset crank bolt pattern. Along with the 4.0 starter.

I haven't figured out What I'm going to do about the drive by wire for the throttle or the motor mounts, and of course cooling

I found this info, so that tells me that I can make the crank spacer 1/2" under the Transmission spacer. Still tons of work to do, but I will get it eventually.

I will post specifics on this as it seems everyone that has done this before says they will sell a kit when done, but NONE do. HPA motorsports is apparently but not for the AX 15 and NV3550 yet, so it is pointless.
Title: Re: 1.9aaz moded to TDI in a Jeep.
Post by: theman53 on April 02, 2013, 10:06:08 am
http://www.vwdiesel.net/forum/index.php?topic=30436.msg273237#msg273237

I may have to use this later, if I do I want to be able to find it.
Title: Re: 1.9aaz moded to TDI in a Jeep.
Post by: theman53 on April 28, 2013, 11:43:27 pm
I need the distance measured from the block to bellhousing mating surface to the flywheel clutch surface on a 4.0L Jeep engine with an AX-15 or NV3550 trans/flywheel in it.

If anyone has it that would be great. I have posted on about every forum I can think of with nothing back yet.
Title: Re: 1.9aaz moded to TDI in a Jeep.
Post by: theman53 on May 04, 2013, 10:22:27 am
I got this from a guy online. I am going with it and if needed I will make adjustments. For me and all those who want to know

The overall thickness of the adapter is 1-9/16 with a cutout for the starter. The thickness at the cutout is 5/16. The flywheel spacer appears to be ~1-3/8 thick. I couldn't really get into the bellhousing to get a good measurement. When I pull it all back out I'll check with ya and see if you still need the measurement. I'm not sure when that will be as I'm waiting on some parts again.
Title: Re: 1.9aaz moded to TDI in a Jeep.
Post by: theman53 on May 07, 2013, 09:12:55 am
With the gas to diesel conversions you guys are doing I have a question. What do you do with the fuel pump that is in the tank? It looks to be part of the sending unit. Also, how do you route the return? I have 0 experience with newer jeeps and want some info on the best way to do it. LMK
Title: Re: 1.9aaz moded to TDI in a Jeep.
Post by: R.O.R-2.0 on May 07, 2013, 02:21:29 pm
With the gas to diesel conversions you guys are doing I have a question. What do you do with the fuel pump that is in the tank? It looks to be part of the sending unit. Also, how do you route the return? I have 0 experience with newer jeeps and want some info on the best way to do it. LMK

you should be able to either fit a regulator, and turn the pressure down, or remove the pump, and fab up a new pickup tube to go in its place..

use the gasser fuel return line as your return line from the pump..
Title: Re: 1.9aaz moded to TDI in a Jeep.
Post by: theman53 on May 07, 2013, 06:45:52 pm
Cool, that is what I will try. Using a regulator and turning it down maybe just what I want. Constant pressure feed @ 7 psi or so should do the TDI just fine.
Title: Re: 1.9aaz moded to TDI in a Jeep.
Post by: R.O.R-2.0 on May 08, 2013, 12:30:49 am
Cool, that is what I will try. Using a regulator and turning it down maybe just what I want. Constant pressure feed @ 7 psi or so should do the TDI just fine.

FWIW, you might want to use a regulator with a return built into it as well.. idk if the fuel pump will like being chiked down to 7 psi..
Title: Re: 1.9aaz moded to TDI in a Jeep.
Post by: theman53 on June 04, 2013, 10:10:21 am
Thinking on this more, what about the gas cap? some are vented some are not. What do I do about that?
Title: Re: 1.9aaz moded to TDI in a Jeep.
Post by: vanbcguy on June 04, 2013, 06:18:28 pm
Diesels generally are always vented - diesel doesn't evaporate like gas does.
Title: Re: 1.9aaz moded to TDI in a Jeep.
Post by: theman53 on June 09, 2013, 10:00:57 pm
Needed this for the revisions.
Title: Re: 1.9aaz moded to TDI in a Jeep.
Post by: theman53 on June 11, 2013, 11:10:17 am
http://www.factorychryslerparts.com/products/BRACKET-Transmission-Mount-ER0--Trans-Support/4465077/52058546AB.html

This site just tells me that the cross members are the same in the ax 5 and Ax 15 and NV3550. If I forget or someone searches this now we know.
Title: Re: 1.9aaz moded to TDI in a Jeep.
Post by: theman53 on June 12, 2013, 04:05:10 pm
(http://i1290.photobucket.com/albums/b531/the_man_53/Jeep%20to%20diesel/IMG_20130610_122420_647_zps7d624129.jpg) (http://s1290.photobucket.com/user/the_man_53/media/Jeep%20to%20diesel/IMG_20130610_122420_647_zps7d624129.jpg.html)

One huge step towards getting the trans to work in the Jeep TJ.   ;D
Title: Re: 1.9aaz moded to TDI in a Jeep.
Post by: CRSMP5 on June 15, 2013, 05:05:45 pm
will look perty in ohio patena.. :D
Title: Re: 1.9aaz moded to TDI in a Jeep.
Post by: theman53 on July 04, 2013, 10:21:27 pm
(http://i1290.photobucket.com/albums/b531/the_man_53/Jeep%20to%20diesel/DSC05695_zps3ee23ee1.jpg) (http://s1290.photobucket.com/user/the_man_53/media/Jeep%20to%20diesel/DSC05695_zps3ee23ee1.jpg.html)


crank spacer bolted on and the Jeep flywheel bolted onto it as well. Fit is fine, but my 40mm crank bolts are 2.4mm too long. I have to cut or grind them down so they don't stick through the crank. If I am lucky I will find the exact space for the bell housing tomorrow.
Title: Re: 1.9aaz moded to TDI in a Jeep.
Post by: theman53 on July 07, 2013, 02:25:28 pm
(http://i1290.photobucket.com/albums/b531/the_man_53/Jeep%20to%20diesel/DSC05700_zpsfb96df2d.jpg) (http://s1290.photobucket.com/user/the_man_53/media/Jeep%20to%20diesel/DSC05700_zpsfb96df2d.jpg.html)

This is the template. I have to drill the second set of holes but it is measured and done.
Title: Re: 1.9aaz moded to TDI in a Jeep.
Post by: theman53 on July 20, 2013, 08:25:45 pm
(http://i1290.photobucket.com/albums/b531/the_man_53/Jeep%20to%20diesel/DSC05711_zps83c9dcb3.jpg) (http://s1290.photobucket.com/user/the_man_53/media/Jeep%20to%20diesel/DSC05711_zps83c9dcb3.jpg.html)

(http://i1290.photobucket.com/albums/b531/the_man_53/Jeep%20to%20diesel/DSC05710_zps3c17aa7b.jpg) (http://s1290.photobucket.com/user/the_man_53/media/Jeep%20to%20diesel/DSC05710_zps3c17aa7b.jpg.html)

(http://i1290.photobucket.com/albums/b531/the_man_53/Jeep%20to%20diesel/DSC05709_zpsc22ffece.jpg) (http://s1290.photobucket.com/user/the_man_53/media/Jeep%20to%20diesel/DSC05709_zpsc22ffece.jpg.html)

(http://i1290.photobucket.com/albums/b531/the_man_53/Jeep%20to%20diesel/DSC05708_zps6170af15.jpg) (http://s1290.photobucket.com/user/the_man_53/media/Jeep%20to%20diesel/DSC05708_zps6170af15.jpg.html)

(http://i1290.photobucket.com/albums/b531/the_man_53/Jeep%20to%20diesel/DSC05707_zps5bc202ff.jpg) (http://s1290.photobucket.com/user/the_man_53/media/Jeep%20to%20diesel/DSC05707_zps5bc202ff.jpg.html)

(http://i1290.photobucket.com/albums/b531/the_man_53/Jeep%20to%20diesel/DSC05706_zps3efcb3af.jpg) (http://s1290.photobucket.com/user/the_man_53/media/Jeep%20to%20diesel/DSC05706_zps3efcb3af.jpg.html)

(http://i1290.photobucket.com/albums/b531/the_man_53/Jeep%20to%20diesel/DSC05705_zpsbfdd5408.jpg) (http://s1290.photobucket.com/user/the_man_53/media/Jeep%20to%20diesel/DSC05705_zpsbfdd5408.jpg.html)
Title: Re: 1.9aaz moded to TDI in a Jeep.
Post by: theman53 on August 03, 2013, 08:44:52 am
http://blog.driiive.com/the-car-of-the-week-4-july-2013/


Car of the week, and it doesn't even run good LOL.
Title: Re: 1.9aaz moded to TDI in a Jeep.
Post by: theman53 on August 03, 2013, 08:45:55 am
Project standstill as I have turbo issues with the other car and I need 340.00 just to buy the aluminum plate so I can then poke holes into it. That will wait a few weeks...
Title: Re: 1.9aaz moded to TDI in a Jeep.
Post by: theman53 on September 03, 2013, 08:43:32 pm
Aluminum is bought and I pulled the engine in the jeep over the labor day weekend. I am far from mounting anything into it, but progress none the less.
Title: Re: 1.9aaz moded to TDI in a Jeep.
Post by: theman53 on September 07, 2013, 09:40:31 pm
Pauter Rods TDI-260-506-1440F VW 1.9L TDI

Looking at these for the jeep...realizing that money doesn't grow on trees. Anyone know where the cheapest spot these can be found?
Title: Re: 1.9aaz moded to TDI in a Jeep.
Post by: theman53 on September 22, 2013, 10:40:09 am
K&N RC-5182XD

Filter I got, but may need to use it for the Jetta and want a part # to find later
Title: Re: 1.9aaz moded to TDI in a Jeep.
Post by: theman53 on October 02, 2013, 08:47:07 pm
http://www.vwdiesel.net/forum/index.php?topic=406.0
Title: Re: 1.9aaz moded to TDI in a Jeep.
Post by: RabbitJockey on October 07, 2013, 11:34:29 am
http://www.vwdiesel.net/forum/index.php?topic=406.0

(http://i0.kym-cdn.com/photos/images/newsfeed/000/003/364/I_m12YearsOld.jpg)
Title: Re: Re: 1.9aaz moded to TDI in a Jeep.
Post by: theman53 on October 07, 2013, 04:26:16 pm
I posted it as a place to find it later and no one would question it. I think you are the only one to read this thread since RoR quit talking about the trans with me.
It was good info
Title: Re: 1.9aaz moded to TDI in a Jeep.
Post by: billybobf on October 09, 2013, 01:16:30 am
ok, so I jumped pages since we were last talking, wheres this build at.

I still have my toyota, no diesel yet, and just picked up an 89 jetta diesel with the aneroid altitude compensating injection pump. would still love to find a diesel for the toyota, but im fine just driving the jetta when I need the eco
Title: Re: 1.9aaz moded to TDI in a Jeep.
Post by: RabbitJockey on October 13, 2013, 05:38:29 pm
if i found a nice 2wd single cab manual tacoma i'd buy it, u no once i sell 2 or 3 cars haha
Title: Re: 1.9aaz moded to TDI in a Jeep.
Post by: theman53 on October 29, 2013, 09:59:23 pm
http://www.wranglerforum.com/f118/tj-diesel-tdi-conversion-mk-2-a-254279.html

This guy has the spacer I would try to copy and measured in mm. You use the Passat starter and you don't need to clock it as 35 degrees like I am doing...if you can get the page to load without all the virus spam ad crap.
Title: Re: 1.9aaz moded to TDI in a Jeep.
Post by: jimfoo on March 12, 2014, 09:16:19 pm
Better get working on that Jeep of yours. How is it coming along? I have finally started putting my engine together after all these years. Hope I remember where I put all the parts!!!
Title: Re: 1.9aaz moded to TDI in a Jeep.
Post by: theman53 on March 12, 2014, 09:46:57 pm
I don't work on stuff when it is cold unless I have to. I haven't touched it since October or there about. I will start working on it soon. Still snowboarding now, so when that is done and I have some firewood cut, I will look into it again. IF I am still employed...I kind of cannot stand my work situation presently.
Title: Re: 1.9aaz moded to TDI in a Jeep.
Post by: jimfoo on March 12, 2014, 11:20:53 pm
I understand the cold part, kind of why I had parts early this winter, but am just starting to work on mine now. Dislike my job as well, but I will probably be moving at some point, so having a drivable car is a lot easier than having to tow it and carry lots of parts. Good luck on yours and keep me/us informed!
Title: Re: 1.9aaz moded to TDI in a Jeep.
Post by: DogDiesel on April 24, 2014, 10:02:39 am
I may have exactly what you want.  I have a 1987 YJ, with a 4 speed toploader ford tranny.  I have a good Mercedes 240 diesel.  Mounts are complete, engine has been fitted, and it ran and drove.  Currently the engine is pulled, and I am refabricating the bell-housing to accept a hydraulic lever clutch.  All parts are on hand.
Additionally, I have used a 5-cylinder manifold, blocked off one exhaust port, and fitted the turbo, so I was going to turbo-interecool it.
The RPM band of the 240 diesel perfectly mates with the gearing of the jeep with stock tire (30") or could work with a little bigger.
Body is southern totally rust-free and everything works.
It originally used the factory center mounted hydraulic clutch, which is prone to failure (did).
It is powder blue with factory paint, which looks good.  It is in my shop taking up one bay, a space I could use.

The real issue is I just don't have the spare time to do the project.  Even if I complete it, I really have no use for it when it is running.  I already have a 4BT project, which I have ran for years in my 68 Bronco, and now pull to convert to 5 speed from automatic.  That is a priority project.

$3000, and all you need to do is put the parts together and enjoy the fun.

Wayne

OM616.912
Title: Re: 1.9aaz moded to TDI in a Jeep.
Post by: theman53 on April 24, 2014, 11:53:55 pm
I just need to get back to work on it and on my new job. I have what I need now.
Title: Re: 1.9aaz moded to TDI in a Jeep.
Post by: theman53 on June 29, 2014, 09:16:08 pm
Tore the old trans and transfer out. I am currently rebuilding the transfer case and putting the 23 spline input gear on. Case is split waiting on more tools.

On a side note, this transfer is so cool, it has an oil pump.
Title: Re: 1.9aaz moded to TDI in a Jeep.
Post by: DogDiesel on July 17, 2014, 12:00:22 pm
On a side note about AAZ / TDI in a Jeep.  I have a project putting a Mercedes 240D engine in a YJ, and another 4BT already in a 68 Bronco, but I have always wanted a diesel in a CJ2 or CJ3. For sure the YJ would go bye-bye if I could put a diesel in a CJ2.  8)

Think the AAZ / TDI would be perfect for the Small CJs, but there are no T90 adapters out there, and the 134s are actually putting out near the same torque as the AAZ without mods.  I know an AAZ or TDI would be perfect for those little jeeps especially with the Transfer overdrive.  Not much room for a longer transmission than the T90 or T96, so options are limited.

Anyone know of a T90 adapter?   ???

Wayne
Title: Re: 1.9aaz moded to TDI in a Jeep.
Post by: theman53 on July 17, 2014, 04:26:13 pm
Like me you probably need to make it.
Title: Re: 1.9aaz moded to TDI in a Jeep.
Post by: theman53 on August 04, 2014, 11:52:23 pm
Haven't updated this in a long time.

I acquired a 1.6 engine for putting this together as soon as I can. By this time next year I will have the mTDI in it...if it all goes to plan. Right now the jeep engine is out, trans, transfer, driveshafts, gas filler, and center console are out of it. Since the TJ are so bad to frame rot and I am most of the way there, I am going to pull the tub off, sandblast the frame and bottom of the tub, then rust bullet it and put it back together. If all goes well I will have it by this fall.
Title: Re: 1.9aaz moded to TDI in a Jeep.
Post by: theman53 on August 11, 2014, 10:16:50 am
Gas tank is out...busted the fitting on the output of the tank. I found out it has 4.11 gears and the dana 35 axle setup. I wished it had the low gears but I didn't want the weakest drivetrain they put in them. I am hoping that it holds up, if not it will get big axles in the future.
Title: Re: 1.9aaz moded to TDI in a Jeep.
Post by: theman53 on August 17, 2014, 03:02:14 pm
I decided that now is the time to rust bullet the tub and frame. Next time I pull the engine I don't plan on pulling the entire drivetrain and to pull the tub off to rust proof and that is what is needed to be done. Here is what it looks like:
(http://i1290.photobucket.com/albums/b531/the_man_53/Jeep%20to%20diesel/DSC08147_zpscebc34ae.jpg) (http://s1290.photobucket.com/user/the_man_53/media/Jeep%20to%20diesel/DSC08147_zpscebc34ae.jpg.html)

(http://i1290.photobucket.com/albums/b531/the_man_53/Jeep%20to%20diesel/DSC08148_zpse77bf639.jpg) (http://s1290.photobucket.com/user/the_man_53/media/Jeep%20to%20diesel/DSC08148_zpse77bf639.jpg.html)

(http://i1290.photobucket.com/albums/b531/the_man_53/Jeep%20to%20diesel/DSC08149_zps7735294e.jpg) (http://s1290.photobucket.com/user/the_man_53/media/Jeep%20to%20diesel/DSC08149_zps7735294e.jpg.html)

(http://i1290.photobucket.com/albums/b531/the_man_53/Jeep%20to%20diesel/DSC08150_zpsb5b59a99.jpg) (http://s1290.photobucket.com/user/the_man_53/media/Jeep%20to%20diesel/DSC08150_zpsb5b59a99.jpg.html)

(http://i1290.photobucket.com/albums/b531/the_man_53/Jeep%20to%20diesel/DSC08154_zpsf7b3c5af.jpg) (http://s1290.photobucket.com/user/the_man_53/media/Jeep%20to%20diesel/DSC08154_zpsf7b3c5af.jpg.html)

(http://i1290.photobucket.com/albums/b531/the_man_53/Jeep%20to%20diesel/DSC08155_zps221e8b67.jpg) (http://s1290.photobucket.com/user/the_man_53/media/Jeep%20to%20diesel/DSC08155_zps221e8b67.jpg.html)


After looking at the pics and verifying outside, the sway bar links are trash. Completely torn in two. I am looking into building my own that I can disconnect with the pull of a pin. Will probably use this site for bearings I can hopefully weld on, see if the high temp really means it.
http://www.vxb.com/
Title: Re: 1.9aaz moded to TDI in a Jeep.
Post by: theman53 on August 25, 2014, 11:28:46 am
http://www.roughcountry.com/install/1157.pdf

body mount locations
Title: Re: 1.9aaz moded to TDI in a Jeep.
Post by: theman53 on September 02, 2014, 08:14:23 pm
I have huge updates, but not any pics yet. I worked on the Jeep instead of taking pics...I sandblasted for about 7 hours and Rust Bulleted the frame. The body and frame are separated and almost ready to be put back together. I want to fix the body bolts I broke off and then lift it back on. I haven't looked at what a Jeep weighs but the frame and axles are very light compared to what I thought they would be. I would guess the body is heavier than the frame and stuff. Furthermore I think it probably weighs less than the MKIV Jetta, but I didn't have seats or anything in it, so maybe not.
I was one tired guy after this weekend getting all of that done. I will take some pics when I go and put it back together, you just won't see any before and after shots
Title: Re: 1.9aaz moded to TDI in a Jeep.
Post by: jimfoo on September 28, 2014, 10:56:37 pm
Good to see things moving along. You might also look into Waxoylhttp://www.waxoyl-usa.com/Products.aspx?code=WAX-001&key=cat (http://www.waxoyl-usa.com/Products.aspx?code=WAX-001&key=cat) for inside the frame if it is a box frame.
Title: Re: 1.9aaz moded to TDI in a Jeep.
Post by: theman53 on September 29, 2014, 08:12:45 am
It is definitely a box frame, and I like the idea of that. Trick would be getting it in there. I put a 1" body lift on it so that I can access the frame better to wash it out, so maybe I will do this.
Title: Re: 1.9aaz moded to TDI in a Jeep.
Post by: jimfoo on September 29, 2014, 08:41:36 pm
A lot of people use a garden sprayer, the type you pump up, and a long wand to get inside holes of the frame. Some people also make their own solution from wax, oil and white gas.
Title: Re: 1.9aaz moded to TDI in a Jeep.
Post by: theman53 on September 30, 2014, 10:21:03 am
Anyone have ideas on how to hack the fuel sender up and make it suction only? I busted mine trying to figure out how it works. I also busted the regulator when I dropped the tank. I haven't found a Jeep TJ to carb SBC thread anywhere, but you would think there are people out there doing it???
Title: Re: 1.9aaz moded to TDI in a Jeep.
Post by: kriesel on November 04, 2014, 11:46:26 am
Anyone have ideas on how to hack the fuel sender up and make it suction only? I busted mine trying to figure out how it works. I also busted the regulator when I dropped the tank. I haven't found a Jeep TJ to carb SBC thread anywhere, but you would think there are people out there doing it???
My jeep diesel swap, I left the in-tank pump alone, put a fuel pressure regulator on the supply line, and regulated fuel down to what's needed for the diesel. Then needed to run a second return line back to the tank from the regulator (meant for the excess fuel to go straight to tank, and not backfeed into the oem return line).

I used an edelbrock fuel regulator to get from 60-80 psi coming out of the wrangler's tank down to my desired 5-10 psi at the engine.
Title: Re: 1.9aaz moded to TDI in a Jeep.
Post by: theman53 on November 04, 2014, 05:53:06 pm
I figured there was no way the stock fuel pump would last cut to less than 10%. I have a solution now, so all is good, but let me know how yours does as if it lasts I would much rather leave the pump alone.
Title: Re: 1.9aaz moded to TDI in a Jeep.
Post by: vanbcguy on November 04, 2014, 10:34:39 pm
As long as you use a return regulator rather than a deadheading regulator the pump will be fine. How it will react to diesel rather than gas is a whole other story though.
Title: Re: 1.9aaz moded to TDI in a Jeep.
Post by: kriesel on November 05, 2014, 08:59:53 am
Yeah, I used a return regulator on mine, and haven't had any issues with it.
Title: Re: 1.9aaz moded to TDI in a Jeep.
Post by: theman53 on January 14, 2015, 10:26:52 pm
.010 TDI pistons are at the machinists getting coated. 2 weeks or so and the block is going up. Get the machining done when it is cold and when spring comes it will be on.
Title: Re: 1.9aaz moded to TDI in a Jeep.
Post by: theman53 on February 26, 2015, 11:19:53 am
question:
         Is it a problem to use the newer tapered style small end connecting rod with the older style piston that can take a straight connecting rod?
Title: Re: 1.9aaz moded to TDI in a Jeep.
Post by: theman53 on July 16, 2015, 09:45:17 am
engine still at the machine shop
Title: Re: 1.9aaz moded to TDI in a Jeep.
Post by: libbydiesel on July 16, 2015, 09:58:13 am
The shop I use usually has my things back in less than a week.  Never more than two.  Why the 5+ months?
Title: Re: 1.9aaz moded to TDI in a Jeep.
Post by: theman53 on July 17, 2015, 08:01:26 am
He is good and lazy. Everyone brings stuff to him and he gets done what he feels he can make the most money on usually *my opinion* It is race season and those guys get the nod, and I bet he charges them quite well when they bring him something on Monday and want it by Wednesday. I called and he said it is in the plans, whatever that means.
Title: Re: 1.9aaz moded to TDI in a Jeep.
Post by: theman53 on April 22, 2017, 10:18:53 am
So I brought my stuff back from this guy. Over 2 years and nothing is done. I have another guy a little closer and he will be getting the stuff. Bad news, he honed my block and coated the pistons *which I didn't have to pay for since it took so long* but he found what looks to be a wrist pin scratch in #3. So I will have to use my other block and find some bigger pistons for this one.