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TDI Conversions Discussions on converting non TDIs into TDIS. More general items can be answered better in other sections. This is ideal for issues that don't have an overlap and are very special to swaping engines.

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Old February 13th, 2019, 08:10   #31
Join Date: Jan 2019
Location: St Louis

Right on man, thanks for the info on the alternator. I suppose I could look
Up the flow rates and pressures for VW power steering pumps and compare. Ill be tuning into the bleepin jeep for sure
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Old February 27th, 2019, 04:34   #32
Join Date: Jun 2017
Location: Pennsylvania

I went live on BleepinJeep this week! This is my priority but I promise I will complete this build thread even if slowly

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Old March 4th, 2019, 08:53   #33
Join Date: Jun 2017
Location: Pennsylvania

Ive been working on fitting up the intercooler. I got a 25x11x3 core with same side I/O which are 2.5 and I am reducing them directly off the IC to 2 and running all 2 tubes. I also had the Map sensor bung welded into the race pipe on the intake. I am going to change how the tube is routed between the intake and IC so that I have more room in front of the engine and dont have to modify the hood support at all.

I moved the radiator toward the engine 1 to make more room for this intercooler. Very minimal trimming to grille and surround.

How I have it for now:

This is more or less what Im changing it to, but with a 45 bend in the vertical tube.

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Old March 8th, 2019, 06:07   #34
Join Date: Jun 2017
Location: Pennsylvania

Because I could not find a (reasonably priced) 97+ manual pedal assembly I had to make a clutch master support bracket. No big deal.

Heres what I ended up with to mount the VW throttle pedal. Basically just an adapter to go to the stock XJ throttle pedal bolts.

Finalizing the coolant system. I kept the stock oil cooler, capped the one 5/8 tube that comes out by the thermostat. This tube is for a mustang 2.3 turbo, but in hindsight I should have just made this out of a piece of steel tube and painted it. I ended up using a black pipe elbow at the back end of it anyway and tapping a 5/16 barb fitting into it to connect in that 5/16 hose fitting that comes off the back of the head. The top radiator hose is a 2001 TDI lower radiator hose cut down a bit, it is 1.25 on both ends.

This should be a good spot for the frost heater

A little more bendy than I wanted but it works out pretty well. Napa #8698 with about 4 cut off the radiator end and maybe 3 off the thermostat end. I used one of those stainless coils inside the thermostat end to help the hose keep its shape. The thermostat end is 1.25 the radiator end is 1.5

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