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.