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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 April 16th, 2018, 07:31   #151
Millennium Falcon
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Thank you I will check out that data in vcds
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2003 Jetta TDI wagon, 5-speed, swap, Sprint520 nozzles 165k
2004 passat 1.8t auto 104k

1949 Willys cj3a ALH tdi swap
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Old April 17th, 2018, 05:05   #152
bwk9087
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Quote:
Originally Posted by Millennium Falcon View Post
Thanks! Maybe you guys can help me out. When I hold the throttle around 1000-1500 rpm it will return to idle without me moving the pedal. If I hold it at say 2000 rpm it will stay there. Someone suggested it may be brake input overriding the throttle....??? Any ideas what it could be and how to remedy it? Thanks!
mine does this same thing. No brake switches hooked up yet.
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Old April 18th, 2018, 08:03   #153
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Quote:
Originally Posted by bwk9087 View Post
mine does this same thing. No brake switches hooked up yet.
Unless you get "left foot braking" turned on in the ECU then you will have this issue. F | F36 | F47 must all read "0" in measuring block 006

To meet those conditions on the ALH/BEW/BHW engines it would be:

F (Brake Light) = GND
F36 (Clutch Switch) = 12V
F47 (Brake Switch) = 12V
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Old April 22nd, 2018, 05:23   #154
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I think I have it fixed. The harness was setup correctly...pedal was bad. I had a spare. Been driving around the house. seem good now. Thanks!
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2003 Jetta TDI wagon, 5-speed, swap, Sprint520 nozzles 165k
2004 passat 1.8t auto 104k

1949 Willys cj3a ALH tdi swap
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Old April 23rd, 2018, 21:30   #155
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First drive video (around the yard) no exhaust on it yet.

https://youtu.be/fft572sBB_Mhttps://youtu.be/fft572sBB_M
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2003 Jetta TDI wagon, 5-speed, swap, Sprint520 nozzles 165k
2004 passat 1.8t auto 104k

1949 Willys cj3a ALH tdi swap
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Old April 23rd, 2018, 22:35   #156
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https://www.youtube.com/watch?v=FzpPDQnN5ds
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2003 Jetta TDI wagon, 5-speed, swap, Sprint520 nozzles 165k
2004 passat 1.8t auto 104k

1949 Willys cj3a ALH tdi swap
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Old April 25th, 2018, 18:42   #157
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I added a little TDI flare to the stock willys tailgate decal design.





My exhaust parts have begun to trickle in... Muffler and SS filler rod came today.



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2003 Jetta TDI wagon, 5-speed, swap, Sprint520 nozzles 165k
2004 passat 1.8t auto 104k

1949 Willys cj3a ALH tdi swap
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Old April 25th, 2018, 18:56   #158
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That will get rid of that ear piercing whistle
(although some of the younger Gen seems to like it)
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Old April 26th, 2018, 06:33   #159
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Yeah its cute for about 10 minutes and then I just want QUIET! haha
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2003 Jetta TDI wagon, 5-speed, swap, Sprint520 nozzles 165k
2004 passat 1.8t auto 104k

1949 Willys cj3a ALH tdi swap
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Old April 26th, 2018, 18:37   #160
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Default Muffling a TDI engine in a Conversion set-up

Awesome build .. thanks for the PM. I apologize for not taking notice much sooner!

For what it is worth....
My exhaust comes off the Turbo with a 1 7/8" inside diameter 180* sweep pipe to a spring-loaded donut style joint. From the joint, it immediately goes into a 2" ID 12" long resonator, then exits into a 2" ID pipe that elbows 90 degrees with a short run to the CAT which is welded directly to a 16" long glass-pac muffler with 2" ID and 2.25" ID exit hole.

That set-up is reasonably quiet..... but, even with my bad hearing, I can hear the Turbo whistle occasionally!
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Old April 28th, 2018, 16:19   #161
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Well.... The jeep is 99% done. Just waiting on shocks. Exhaust is done and mounted. even went on a 3 mile test run! It worked surprisingly well for the first run! No shakes or shimmys. Had her up to 45mpg which was about 2500 rpm. I will post a video once I have a decent one. Here is the exhaust system. Its 2" 304ss. This setup seems very quiet! I am pleased. I can still hear a little turbo noise but not bad at all. More fender rattles and engine noise.

Let me just say this thing has some giddy-up! 13lbs of boost and a little whistle and 45mph comes quickly.













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2003 Jetta TDI wagon, 5-speed, swap, Sprint520 nozzles 165k
2004 passat 1.8t auto 104k

1949 Willys cj3a ALH tdi swap
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Old April 29th, 2018, 16:41   #162
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Beautiful welding work. Just curious, why the 90* bend at the back instead of exiting straight along the driver's side?
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Old April 29th, 2018, 17:06   #163
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Thanks! I did the exhaust that way because I was trying to recreate the factory willys setup. Also, I have had a few jeeps with rear exit exhausts and the fumes swirl up into the cab pretty bad when the top is off. Im not sure if thats why willys did it the way they did but it works to keep fumes from swirling.

Here is a picture of a factory willys setup.
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2003 Jetta TDI wagon, 5-speed, swap, Sprint520 nozzles 165k
2004 passat 1.8t auto 104k

1949 Willys cj3a ALH tdi swap
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Old April 29th, 2018, 18:47   #164
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Quote:
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Dang dude, it's pictures like this that make me wish I wouldn't have bought a MIG first... very nice.
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Old April 30th, 2018, 06:27   #165
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Thanks! I like the tig, but I couldnt survive without my MIG!


Here is a little teaser video!

https://youtu.be/iEPMmTnfLlA
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2003 Jetta TDI wagon, 5-speed, swap, Sprint520 nozzles 165k
2004 passat 1.8t auto 104k

1949 Willys cj3a ALH tdi swap
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