New Diesel Swap

Beowulf

Expedition Leader
http://www.Jptrails.com

Quote:
"If your like me and love Jeeps but want economy your not alone. I have been searching high and low but with little support from after market companies doing your own swap could me a nightmare! Now there is a solution...HPA Motorsports. Hpa motorsports will be offering TDI conversions for the CJ/YJ/TJ in the very near future. There are many versions of the TDI and if you want simple you can convert a electronic diesel back to mechanical pump injection meaning fewer wires and no computers. The TDI typically produces 90HP/178Ft Tq which may not sound like its enough to switch to a TDI conversion. A simple turbo upgrade or intercooling can net 100-150Ft Tq so now the upgrade has your attention. I am pretty familir with the TDI motor since I owned a 2005 Jetta PD TDI which I never got below 42mpg on average, my best tank being 47 1/2mpg. Now we're talking about Jeeps and they are not designed to get into the 40's....maybe the 30's..maybe. I am sharing a company newsletter which I recently received and wanted to share. Also if your going to Sema the project YJ test Jeep will be there TBA."

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QUOTE:

"The past several weeks have been busy ones as our team has been working aggressively to finalize tooling and fitment for the Jeep TDI conversion while at the same time, augmenting our YJ’s running gear with a variety of upgraded parts.

To ensure our YJ was up to the task of transmitting the torque and HP of our TDI swap, both the Dana 30 and 35 axles have been torn out and beefed up. Precision Gear was called upon to outfit these small pumpkins with 4:10 gears and Alloy USA delivered unbelievable axles. The quality of these parts builds back our confidence in these OEM axles.

We have made some minor adjustments to our initial engine mounts to facilitate a seamless integration with the OEM rubber mounts. We have elected to supply a ready to install flywheel along with heat shields for the starter to protect it from the downpipe. Lastly, the downpipe has been re-routed to ensure it mates with off the shelf 2.5” exhaust systems. In our case, a Magnaflow has been strapped to the underside of the YJ.

Our Stage 1 Grouping is now finalized and is targeted to the “Do It Yourself” enthusiast. Take a browse through the product photo gallery to see detailed pictures of the installation. Note: Our engine mounts can either be bolted in or welded on. The installation images showcase the installation using the supplied bolts. Minor clearancing is required on the AX-5 bell housing to accommodate Bosch starter nose

The Stage 1 adapter set is as follows:

• CNC flywheel/crankshaft adapter
• CNC bell housing adapter plate
• Left and Right Male / Female engine mount set.
• (OEM jeep rubber mounts not included)
• Downpipe
• CNC machined Starter flange and heat shields
• (Bosch Starter not included)
• Flywheel and Crankshaft bolts
• Dowel pins for bell housing
• Turbo outlet adapter

Also included is a short OEM parts list to identify starters, engines etc. required for a successful conversion.
Stage 1 package $2599 USD

Our Stage 2 package’s intake track has been finalized. An air to water intercooler has been configured to optimize the space available under the hood, and sustain charge air cooling during low speed off-road applications. With off-road low gear terrain, air to air cooling intercooling as the factory TDI’s are equipped was simply not a good fit. Using a stand alone closed loop water system, our secondary radiator, cooling fan, pump and after cooler can maintain a steady state air intake charge best suited to feed our high torque output.

Our Jeep is bound for a debut at this years SEMA show. Once we return, we will develop the AX-15 adapter for late November release."
 

Snafu

Adventurer
This is a dream project of mine...but I'm wondering if the WK Mercedes diesel would fit into the JK without an extreme amount of money or work?

I know Petersen's 4 wheel and offroad stuck a 6.7L Cummins into a JK for their Ultimate Adventure truck...but that was a serious amount of fab and I'm sure money to make that happen

I love diesel but I also love Jeeps!
 

jeepdreamer

Expedition Leader
Fellow EP folks...

Snafu...
If your referring to the MB diesel found in th Grand Cherk...well, I would NOT say easy or cheap. While I think it is an out-freakin'-standing engine...they are very intense with respect to sensors, input, and interface. You may have a marginally easier time with one of these in a new JK due to some similar systems but you'd pretty much be stuck with the auto if your finding a used one to swap. I don't even want to think what not having a donor GC sitting there would entail to do the swap. LOTS of electronics....Lots of wiring etc...And the mere idea of buying one new and then trying to put it togethera part at a time...uh, not without really deep pockets! I would say that for a JK a good choice may be the Cummins 3.3? The biggest issue from the get go no matter what moter you choose is getting past the smog Nazis!
 

x32792

Adventurer
At What Cost?

Over the weekend, I attended Jeeptoberfest in Ocala, Florida where I saw Shawn Harmon drive an '01 TJ with Cummins 4BT effortlessly thru the Extreme Off Road Course which defeated many well built out gas powered rigs and even flipped one while I was there.

After his run, I introduced myself to Shawn in the parking lot and he gave me his card. He owns a small company called OFF-ROAD DIESEL located in Bradenton, FL (www.offroaddiesel.us) NO AFFILIATION

Apparently, it can be done, but as with the VW conversion...At what cost?
 
D

Deleted member 9101

Guest
I am a big fan of TDI swaps...I had one in a Jetta for a while and loved that little motor.
 

jingram

Adventurer
jingram,

I did not see your post. Thank you for providing the link.

I didn't respond to sound like an ***... sorry about that. I actually posted and asked a moderator to merge the threads, but that part didn't take and I didn't go back in and check. Oops.
 

Vizoo

Adventurer
He owns a small company called OFF-ROAD DIESEL located in Bradenton, FL (www.offroaddiesel.us) NO AFFILIATION

The link opens his page, but there is almost nothing on it... Keep getting this message on all links

.....
Cincopa user is out of traffic quota for this month.
If you are the owner you can
Go Pro Now! and get 14-day free trial
.....
 

OFF-ROAD DIESEL

New member
Cummins 4bt

Hello,

First of thank you for mentioning me on the forum. My name is Shawn and i am the owner of OFF-ROAD DIESEL in bradenton FL.

A little about my jeep it is a 2001 jeep wrangler that has gone through some big changes. It started it's life with the 2.5 power plant and 5 speed manual with 4.10 gears.
It now has a 3.9 cummins with a custom ground cam tweaked injection pump and is also front mount intercooled.
The transmission has gone through some changes as well i started off with a 700r4 automatic with a lock up torque converter this trans was great for fuel milage getting in the neighbrohood of 35 miles per gallon. i switched from the 700r4 to a turbo 400 just for the extra strength with it being a three speed trans the fuel milage is around 22-25 mpg.
The rearend has been swapped out for a ford 8.8 out of a 97 explorer and has 3.73 gears and chromoloy shafts. Still using the track lok locker with new clutch plates and a little trick i know to keep them both turning but streetable at the same time.
The suspension is being changed once again. Right now as i write this i have reconfigured the mounts for the now bullet proof dana 30.( no more lower control ar mounts below the axle).RCV axles to be installed before jeep beach this year. And all factory suspension mounts have been shaved from the frame so that the new six inch long arm can be installed tomorrow.
With all of the extra weight from the cummins i have added cross drilled rotors to the front and with the addition of the ford 8.8 i now have rear disc all with power stop ceramic pads.

With all of that being said I love the extra power that i have with the diesel swap.

If anyone has any questions about the swap or if you would like to have one done to your vehicle please feel free to e-mail me @
offroaddiesel@hardcore4x4.com
 

CharlieV

Adventurer
I swapped a 4BTAA into my Scrambler and can say that the cost was very high. The diesel conversion is well worth it for me, but given the cost they're not for entirely practical.
 

4Rescue

Expedition Leader
I swapped a 4BTAA into my Scrambler and can say that the cost was very high. The diesel conversion is well worth it for me, but given the cost they're not for entirely practical.
From yur sig, that saounds like an AWESOME truck... I'm am a HUGE fan of the LWB Jeeps (CJ6-8 and LJ's specificaly)

Drove my mom's 2010 TDI Jetta SW this weekend and man does that thing pull... I've changed my mind, I'd LOVE to have that motor in my 4Runner... I'd like more displacement, but I don't know that I'd NEED it eh ;) The TDI clearly has enough OOMPH and can be mod'd to make more fairly easily.

Cheers

Dave
 

Metcalf

Expedition Leader
There is also the 5-cyl 2.5 liter VW engine from the transporter if I remember right. The bellhousing/flywheel stuff is the same as the 1.9L stuff. They too can be converted with a TDI-M injector pump also. I think one of those would be a GREAT engine for a CJ7/TJ/YJ.

I think the 1.9 would work, but you would need to try and keep the weight down to about 4000lbs or less.

MMMMmmmmm Diesels....
 

MuleShoer

Adventurer
Off-Road Diesel

I sent Shawn, the owner of "Off-Road Diesel" , an email about a JK conversion and got no response. anybody else.
This will be the third diesel conversion small company I have contacted with no success, I guess the JK is in the to hard to convert bucket.
The hunt of a GC diesel donor continues
 

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