Parts list for a TDI swap

[Halbarad]

Salutations all, I am collecting information on swapping a 1.9 TDI ALH or similar small diesel engine into my TJ. I have intentions of crossing the country (multiple times) and venturing down to the states and exploring and this would be my ride of choice. The milage/range I currently get from my 4.0L will not cut it to do that. 13-15 MPG is terrible for road tripping. I do NOT want a V8, so please kindly keep your opinions about that to yourself. Currently the Jeep only has 108,000 ish km, still young. Though the 4.0 has started the lifter tick

I am keeping the 4.0 after I pull it for potential future use. I am going to keep this Jeep till either it or I dies. So I am going to do it the right way.

I have read up on many of the TDI build threads on this forum and will continue to do so, but I would like to know what I will all need for parts to make this happen. I can source a non running 1.9 TDI ALH still in the car locally for $800. There are running ones local as well, but I imagine it would be smart to rebuild the engine anyway. I've done 90% of the work that has been done on my Jeep and while I am no mechanic, my brother is and I have family that can weld, an uncle in metal fabrication and a cousin who is a semi mechanic. I have my bases covered for sourcing help and parts for the most part. I just want suggestions of engines or to know which parts I am missing from my list.


Engine (have a source for a TDI)
Adapter for NV3550 (is the Cody built one worth it for the price?)
Wiring harness and ECU (I am assuming standalone would be ideal, would like to retain original gauges however)
Motor mounts (can be fabricated)
Rad and cooling (pull it from the car?)
Exhaust (local shop that does fantastic work, plus the Jeep's is still in good condition, small cat leak, may just pull it or something while I am at it)


I know for a fact that there is a ton I am still missing. Any good advice is appreciated. I am not married to the idea of the TDI, but I would love a diesel TJ. As far as I know the TDIs are the better engines for reliability and decent power. Note, I am not looking to make 1000hp and 1000ft-lbs. The power of the 4.0 is perfectly fine for me, maybe a tad more would be nice. If there are better engines one can source (not V8s unless its somehow getting like 30mpg) I would love to know. I live in a very agricultural based area, so Kubota, John Deere etc are all brands I can easily get parts from if they make a decent engine I overlooked. Unfortunately the R2.8 is beyond what I want to afford, otherwise I would do that (where are they available used?).

It is long but there it is. Thanks Evan.

 

[GregBelleville]

I don't have any help to offer, but I happen to own a 2015 Golf TDI with the 2.0 and I think it would be a ton of fun in a TJ. It averages about 40 mpg in my Golf it would be interesting to see what the mileage would be like in a TJ.

 

[Halbarad]

I don't have any help to offer, but I happen to own a 2015 Golf TDI with the 2.0 and I think it would be a ton of fun in a TJ. It averages about 40 mpg in my Golf it would be interesting to see what the mileage would be like in a TJ.

The numbers I am striving for lol. Cody built advertises 35 mpg, which seems overstated. I imagine a healthy 25+ mpg from the "Brick on Wheels" that is a TJ would be reasonable. Really, I have the time to do it, not driving the Jeep for winter currently so I am looking for things to do to it. I did a center console delete just after Christmas.

 

[GregBelleville]

The numbers I am striving for lol. Cody built advertises 35 mpg, which seems overstated. I imagine a healthy 25+ mpg from the "Brick on Wheels" that is a TJ would be reasonable. Really, I have the time to do it, not driving the Jeep for winter currently so I am looking for things to do to it. I did a center console delete just after Christmas.

A 25 mpg TJ would honestly be pretty awesome. It would be interesting to see how that motor does 4 wheeling if properly geared. They make good low end torque.

Please share a pic of the center console delete you have me curious.

 

[Halbarad]

A 25 mpg TJ would honestly be pretty awesome. It would be interesting to see how that motor does 4 wheeling if properly geared. They make good low end torque.

Please share a pic of the center console delete you have me curious.

Here ya go! I found that I got very little use from the center console, so after removal I put carpet down and will soon be 3D printing a couple cup holder, a tray for miscellaneous items and my sister-in-law is willing to sew some custom covers for the t-case and hand brake for me. Feels WAY roomier in the front now. Not finished yet, but I like it!

 

[lBasket]

Here ya go! I found that I got very little use from the center console, so after removal I put carpet down and will soon be 3D printing a couple cup holder, a tray for miscellaneous items and my sister-in-law is willing to sew some custom covers for the t-case and hand brake for me. Feels WAY roomier in the front now. Not finished yet, but I like it!
View attachment 664208View attachment 664207View attachment 664206

Where elbow go??

 

[Halbarad]

Where elbow go??

Not on the center console anymore! I usually rest my right arm, when not shifting, on my lap or its helping keep the wheel straight (yay for the prairies and the endless wind) anyway. I hardly used the console to rest my arm on.

 

[TJuser]

Salutations all, I am collecting information on swapping a 1.9 TDI ALH or similar small diesel engine into my TJ. I have intentions of crossing the country (multiple times) and venturing down to the states and exploring and this would be my ride of choice. The milage/range I currently get from my 4.0L will not cut it to do that. 13-15 MPG is terrible for road tripping. I do NOT want a V8, so please kindly keep your opinions about that to yourself. Currently the Jeep only has 108,000 ish km, still young. Though the 4.0 has started the lifter tick

I am keeping the 4.0 after I pull it for potential future use. I am going to keep this Jeep till either it or I dies. So I am going to do it the right way.

I have read up on many of the TDI build threads on this forum and will continue to do so, but I would like to know what I will all need for parts to make this happen. I can source a non running 1.9 TDI ALH still in the car locally for $800. There are running ones local as well, but I imagine it would be smart to rebuild the engine anyway. I've done 90% of the work that has been done on my Jeep and while I am no mechanic, my brother is and I have family that can weld, an uncle in metal fabrication and a cousin who is a semi mechanic. I have my bases covered for sourcing help and parts for the most part. I just want suggestions of engines or to know which parts I am missing from my list.


Engine (have a source for a TDI)
Adapter for NV3550 (is the Cody built one worth it for the price?)
Wiring harness and ECU (I am assuming standalone would be ideal, would like to retain original gauges however)
Motor mounts (can be fabricated)
Rad and cooling (pull it from the car?)
Exhaust (local shop that does fantastic work, plus the Jeep's is still in good condition, small cat leak, may just pull it or something while I am at it)


I know for a fact that there is a ton I am still missing. Any good advice is appreciated. I am not married to the idea of the TDI, but I would love a diesel TJ. As far as I know the TDIs are the better engines for reliability and decent power. Note, I am not looking to make 1000hp and 1000ft-lbs. The power of the 4.0 is perfectly fine for me, maybe a tad more would be nice. If there are better engines one can source (not V8s unless its somehow getting like 30mpg) I would love to know. I live in a very agricultural based area, so Kubota, John Deere etc are all brands I can easily get parts from if they make a decent engine I overlooked. Unfortunately the R2.8 is beyond what I want to afford, otherwise I would do that (where are they available used?).

It is long but there it is. Thanks Evan.

I think the TDI's are probably the best supported at a lower price point as far as diesels go in a TJ.

You should be able to get all the parts you need from Cotybuilt, and if you make the ALH a standalone harness, you can retain the jeep gauge cluster and readings, although you'll probably need to get rid of the CEL. They've got everything to pretty much make the engine a drop-in, and watching some videos, it seems that if you prep properly, you can have the engine swapped in on a weekend.

Adapter - Cotybuilt is best, tdi conversions makes one but it's pricey
Wiring harness - Can make it standalone, and DIY the wiring to have the stock gauge cluster working. You could purchase the wiring harness adapters from Cotybuilt, but they are pretty pricey. If you have extra money at a later date, you could swap the wiring later on.
Motor mounts - Could DIY, but its time vs money. Cotybuilt is probably the best route here.
Cooling system - Stock tj system should be adequate, just need to do custom plumbing, electric fan conversion might be good.
Exhaust - Cotybuilt makes a downpipe, or you can leave it up to a local shop
Fueling - Stock fuel pressure on a TJ is too high for the TDI. Probably make a regulated return would be best

Other things to think about are tuning and turbo for a little bump in power. Cotybuilt makes everything for a BHW, BEW and BRM engine to be easily swapped as possible. With the ALH, you'll still likely need to figure out the power steering, AC (if you have it) and anything else mounted on the accessory drive. If money is a large concern, the best bet is to do the bare minimum to have an ALH in the TJ, and then worry about the small luxuries, tuning and other things to make it a complete build.

The Youtube channels BleepinJeep, Dirt Lifestyle and TDI swaps have some good videos on them.

IMO it makes a lot of sense. 100+lbs lighter than the 4l, more torque, revs up to 5k rpm, sips fuel and is a very reliable engine. Depending on what you build vs buy, it can be done around $3000. Fuel savings don't take long to offset the cost of the swap.

 

[Halbarad]

I think the TDI's are probably the best supported at a lower price point as far as diesels go in a TJ.

You should be able to get all the parts you need from Cotybuilt, and if you make the ALH a standalone harness, you can retain the jeep gauge cluster and readings, although you'll probably need to get rid of the CEL. They've got everything to pretty much make the engine a drop-in, and watching some videos, it seems that if you prep properly, you can have the engine swapped in on a weekend.

Adapter - Cotybuilt is best, tdi conversions makes one but it's pricey
Wiring harness - Can make it standalone, and DIY the wiring to have the stock gauge cluster working. You could purchase the wiring harness adapters from Cotybuilt, but they are pretty pricey. If you have extra money at a later date, you could swap the wiring later on.
Motor mounts - Could DIY, but its time vs money. Cotybuilt is probably the best route here.
Cooling system - Stock tj system should be adequate, just need to do custom plumbing, electric fan conversion might be good.
Exhaust - Cotybuilt makes a downpipe, or you can leave it up to a local shop
Fueling - Stock fuel pressure on a TJ is too high for the TDI. Probably make a regulated return would be best

Other things to think about are tuning and turbo for a little bump in power. Cotybuilt makes everything for a BHW, BEW and BRM engine to be easily swapped as possible. With the ALH, you'll still likely need to figure out the power steering, AC (if you have it) and anything else mounted on the accessory drive. If money is a large concern, the best bet is to do the bare minimum to have an ALH in the TJ, and then worry about the small luxuries, tuning and other things to make it a complete build.

The Youtube channels BleepinJeep, Dirt Lifestyle and TDI swaps have some good videos on them.

IMO it makes a lot of sense. 100+lbs lighter than the 4l, more torque, revs up to 5k rpm, sips fuel and is a very reliable engine. Depending on what you build vs buy, it can be done around $3000. Fuel savings don't take long to offset the cost of the swap.

I am thinking I may get the adapters from Codybuilt, but the rest is to expensive. I can source a whole Jetta TDI locally for less than $1,000 CAD. I have full intentions of rebuilding the engine (and strengthening weak points while its apart) and then building it up with injectors, turbo etc. before dropping it in.

Yeah retaining the OEM gauges and such would be ideal for me, but yeah certain parts would have to go. Good point on the fan conversion though. And I would probably add an intercooler to the TJs setup for the new TDI turbo.

Thanks for the advice, more to add to my list now.

 

[Wildman]

@RustyAutoholicGuy has done a few diesel swaps.

 

[k1n3k]

I've done an ALH swap into a Samurai in the last few years and was looking to do it in my Jeep next.

First off, I'd go with a CJAA or BEW over the ALH in a Jeep. reason being is the commonrail engines are a bit easier to get some power out of them and tend to have lower EGT when doing it. Parts are more common for them and you're also not messing with getting the IQ and crap right with the VE pump. Commonrail just works. Don't waste your time with mTDI on the ALH either. been there, done that and don't recommend it.

However, if you're going to do an ALH, you're going to need the full engine harness, dash harness, ECU and accelerator pedal. The ECU will need to have the anti-theft stuff turned off. In the great white north, I think Cascade German can handle those services for you. There are a few places that can carve down your factory VW wiring harness and make a standalone harness from it.

As for the cotybuilt kit, that really is going to be your best bet. I'd buy everything they have for it too. They have done the work to figure out how to make it fit and get the stuff to cooperate with the Jeep. You can do it too, but it will take some trial and error and quite a bit of time and money. Last 2 swaps I did were both in Suzuki Samurais. One was an ALH and the other an AAZ. for the ALH, I only bought the adapter plate and flywheel. on the AAZ, I bought every single part available for the swap. The ALH swap took twice the money and twice the time. Trust me when I tell you you're better off buying the parts, or you better be a damn good fabricator and have time to spare.

Now, as for mileage... if you're doing this to save money then you really should consider a different vehicle or just rebuild your 4.0. My samurai went from 17mpg to 32mpg. I'll have to drive it 176,000 miles before the cost of the swap is made up by the fuel. its probably not worth it.

 

[Wildman]

I've done an ALH swap into a Samurai in the last few years and was looking to do it in my Jeep next.

First off, I'd go with a CJAA or BEW over the ALH in a Jeep. reason being is the commonrail engines are a bit easier to get some power out of them and tend to have lower EGT when doing it. Parts are more common for them and you're also not messing with getting the IQ and crap right with the VE pump. Commonrail just works. Don't waste your time with mTDI on the ALH either. been there, done that and don't recommend it.

However, if you're going to do an ALH, you're going to need the full engine harness, dash harness, ECU and accelerator pedal. The ECU will need to have the anti-theft stuff turned off. In the great white north, I think Cascade German can handle those services for you. There are a few places that can carve down your factory VW wiring harness and make a standalone harness from it.

As for the cotybuilt kit, that really is going to be your best bet. I'd buy everything they have for it too. They have done the work to figure out how to make it fit and get the stuff to cooperate with the Jeep. You can do it too, but it will take some trial and error and quite a bit of time and money. Last 2 swaps I did were both in Suzuki Samurais. One was an ALH and the other an AAZ. for the ALH, I only bought the adapter plate and flywheel. on the AAZ, I bought every single part available for the swap. The ALH swap took twice the money and twice the time. Trust me when I tell you you're better off buying the parts, or you better be a damn good fabricator and have time to spare.

Now, as for mileage... if you're doing this to save money then you really should consider a different vehicle or just rebuild your 4.0. My samurai went from 17mpg to 32mpg. I'll have to drive it 176,000 miles before the cost of the swap is made up by the fuel. its probably not worth it.

Sounds like a Magnum V-8 or Hemi swap... it's not something you do to save money...

I wonder about the performance of a TDI compared to a V-8?

 

[Halbarad]

I've done an ALH swap into a Samurai in the last few years and was looking to do it in my Jeep next.

First off, I'd go with a CJAA or BEW over the ALH in a Jeep. reason being is the commonrail engines are a bit easier to get some power out of them and tend to have lower EGT when doing it. Parts are more common for them and you're also not messing with getting the IQ and crap right with the VE pump. Commonrail just works. Don't waste your time with mTDI on the ALH either. been there, done that and don't recommend it.

However, if you're going to do an ALH, you're going to need the full engine harness, dash harness, ECU and accelerator pedal. The ECU will need to have the anti-theft stuff turned off. In the great white north, I think Cascade German can handle those services for you. There are a few places that can carve down your factory VW wiring harness and make a standalone harness from it.

As for the cotybuilt kit, that really is going to be your best bet. I'd buy everything they have for it too. They have done the work to figure out how to make it fit and get the stuff to cooperate with the Jeep. You can do it too, but it will take some trial and error and quite a bit of time and money. Last 2 swaps I did were both in Suzuki Samurais. One was an ALH and the other an AAZ. for the ALH, I only bought the adapter plate and flywheel. on the AAZ, I bought every single part available for the swap. The ALH swap took twice the money and twice the time. Trust me when I tell you you're better off buying the parts, or you better be a damn good fabricator and have time to spare.

Now, as for mileage... if you're doing this to save money then you really should consider a different vehicle or just rebuild your 4.0. My samurai went from 17mpg to 32mpg. I'll have to drive it 176,000 miles before the cost of the swap is made up by the fuel. its probably not worth it.

The point isn't milage, its range. Are they the same thing yes, but also no. I can go 400km on a single tank right now, with a diesel I could go upwards of 550-600km on one tank. Where I intend to go, gas stations are relatively few and far between. Range matters, that is why I want a diesel. They make good power on decent range vs a gas engine. MPG is not the concern, how far I can go is.

I will take a look into the BEW engine as well then, the ALH is just one that is commonly available in my area. A few complete Jetta TDIs for under $800 CAD around me. Time and fabrication are not huge concerns, I have family that do metal fab and welding so I got decent connections for when I need help.

 

[TJuser]

I am thinking I may get the adapters from Codybuilt, but the rest is to expensive. I can source a whole Jetta TDI locally for less than $1,000 CAD. I have full intentions of rebuilding the engine (and strengthening weak points while its apart) and then building it up with injectors, turbo etc. before dropping it in.

Yeah retaining the OEM gauges and such would be ideal for me, but yeah certain parts would have to go. Good point on the fan conversion though. And I would probably add an intercooler to the TJs setup for the new TDI turbo.

Thanks for the advice, more to add to my list now.

I've done an ALH swap into a Samurai in the last few years and was looking to do it in my Jeep next.

First off, I'd go with a CJAA or BEW over the ALH in a Jeep. reason being is the commonrail engines are a bit easier to get some power out of them and tend to have lower EGT when doing it. Parts are more common for them and you're also not messing with getting the IQ and crap right with the VE pump. Commonrail just works. Don't waste your time with mTDI on the ALH either. been there, done that and don't recommend it.

However, if you're going to do an ALH, you're going to need the full engine harness, dash harness, ECU and accelerator pedal. The ECU will need to have the anti-theft stuff turned off. In the great white north, I think Cascade German can handle those services for you. There are a few places that can carve down your factory VW wiring harness and make a standalone harness from it.

As for the cotybuilt kit, that really is going to be your best bet. I'd buy everything they have for it too. They have done the work to figure out how to make it fit and get the stuff to cooperate with the Jeep. You can do it too, but it will take some trial and error and quite a bit of time and money. Last 2 swaps I did were both in Suzuki Samurais. One was an ALH and the other an AAZ. for the ALH, I only bought the adapter plate and flywheel. on the AAZ, I bought every single part available for the swap. The ALH swap took twice the money and twice the time. Trust me when I tell you you're better off buying the parts, or you better be a damn good fabricator and have time to spare.

Now, as for mileage... if you're doing this to save money then you really should consider a different vehicle or just rebuild your 4.0. My samurai went from 17mpg to 32mpg. I'll have to drive it 176,000 miles before the cost of the swap is made up by the fuel. its probably not worth it.

Interesting to hear from someone that's done these swaps. I'm not surprised if it would be cheaper to buy everything from Cotybuilt. You save the time, and it's easy to forget about small things that add up. I have to tell myself this plenty. Buy once, cry once. I agree with K1n3k about the CR engines as well. You'll be buying more from Cotybuilt on it, and upfront it'll be more costly. But you can start adding power a lot easier, and with the wiring adapters, it ties in very nicely with the rest of the tj.

As far as intercoolers, an air-to-water intercooler may be best, as you probably won't have the airflow effective enough.

Sounds like a Magnum V-8 or Hemi swap... it's not something you do to save money...

I wonder about the performance of a TDI compared to a V-8?

Honestly I imagine it'd be a lot nicer on a smaller rig. v8s are great on a stretched tj running tons an fodeez, but the small, lightweight torquey nature of the TDI's really appeal to me. Especially with the peak torque being right down low in the rpm range. Maybe I'm biased as I'm a bit of a diesel nut, but TJ's should've come with a small diesel from factory IMO

 

[Halbarad]

Sounds like a Magnum V-8 or Hemi swap... it's not something you do to save money...

I wonder about the performance of a TDI compared to a V-8?

I wonder that as well, a V8 would definitely move a TJ waaay easier. But how would it do for range? I have yet to see a V8 that isn't a full blown fuel addict. Even the newer ones, though they are much better than say a 360 or 318 that I have access to.

 

[Halbarad]

Interesting to hear from someone that's done these swaps. I'm not surprised if it would be cheaper to buy everything from Cotybuilt. You save the time, and it's easy to forget about small things that add up. I have to tell myself this plenty. Buy once, cry once. I agree with K1n3k about the CR engines as well. You'll be buying more from Cotybuilt on it, and upfront it'll be more costly. But you can start adding power a lot easier, and with the wiring adapters, it ties in very nicely with the rest of the tj.

As far as intercoolers, an air-to-water intercooler may be best, as you probably won't have the airflow effective enough.


Honestly I imagine it'd be a lot nicer on a smaller rig. v8s are great on a stretched tj running tons an fodeez, but the small, lightweight torquey nature of the TDI's really appeal to me. Especially with the peak torque being right down low in the rpm range. Maybe I'm biased as I'm a bit of a diesel nut, but TJ's should've come with a small diesel from factory IMO

Things to consider I suppose

That's why I am also diesel biased, a Jeep will never be a race car, so why do race car things to it? We need torque and horsepower, not a screaming V8. Though they do look like fun, must admit.

 

[Halbarad]

The point isn't milage, its range. Are they the same thing yes, but also no. I can go 400km on a single tank right now, with a diesel I could go upwards of 550-600km on one tank. Where I intend to go, gas stations are relatively few and far between. Range matters, that is why I want a diesel. They make good power on decent range vs a gas engine. MPG is not the concern, how far I can go is.

I will take a look into the BEW engine as well then, the ALH is just one that is commonly available in my area. A few complete Jetta TDIs for under $800 CAD around me. Time and fabrication are not huge concerns, I have family that do metal fab and welding so I got decent connections for when I need help.

To add onto my own comment, another route I thought of but have laid aside was a range extension fuel tank and a turbo kit. I have talked to Jezza a bit about this (very helpful answered a bunch of questions) and while it may still be an option, I do like the idea of a diesel TJ. I also cannot find a range extension tank anywhere, so It would have to be custom made and it would add more weight, so why not go fully custom? Depending on what a swap would take, I may yet return to a turbo, we shall see.

 

[Wildman]

GenRight makes a 24 gallon tank for a TJ if you're not trying to stretch the WB.
23 gallon if you want to stretch the WB but have to outbound the shocks or coilovers.

 

[Halbarad]

GenRight makes a 24 gallon tank for a TJ if you're not trying to stretch the WB.
23 gallon if you want to stretch the WB but have to outbound the shocks or coilovers.

I have seen that yep, I was thinking more along the lines of an additional tank. There is a company that made a range extension tank for the TJ. It bolted up beneath the driver seat on the frame. Though I can no longer find it

Long Range America I believe it was. Current site does not have it listed tho...

 

[Wildman]

I have seen that yep, I was thinking more along the lines of an additional tank. There is a company that made a range extension tank for the TJ. It bolted up beneath the driver seat on the frame. Though I can no longer find it

Long Range America I believe it was. Current site does not have it listed tho...

There was a thread about that tank a few months ago. Or one like it.

Thread 'Long Ranger auxiliary fuel tank'

Sep 12, 2025

Has anyone here installed or seen installed one of these 17 gal aux tanks?
http://thelongranger.com.au/jeep/wrangler/tj/

I had a LRA tank on my Gladiator and it worked amazingly well. Although refitting the exhaust was a major pita. I live in an area where I'm always carrying jerry cans but lifting them is getting harder and harder. Pushing a button for an onboard aux tank would be nice. I DO NOT HARD CORE OFF ROAD - just to clarify, so hanging up on rocks is not a concern. Longer distance between filling up is definitely a concern though.

Genright does have a 24 gal tank for...

• ChadH
• Replies: 10
• Forum: TJ General Discussion