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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 July 23rd, 2016, 20:28   #1
xjjeeper
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Default ALH Jeep XJ Swap

Hey guys. My name is David. Living in Chilliwack BC. I've been into jeeps for about 5 years now. I have always dreamt of a diesel jeep. My dreams have started to come true I have a 1999 jeep xj with the 4.0 and auto (will be 5 speed swapped). Back in February I picked up a 1999.5 golf tdi with a "blown transmission" (5 speed) for super cheap. Plastic shift linkage was just broken. 30$ piece later I'm driving it for 20k kms.

I've spoke a bit with Randy (evguy) and Matt Whitbread with the direction of the build.

I've been following many other builds like Reddok's

Today I spent a few hours stripping the harness out..
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Old July 23rd, 2016, 20:32   #2
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Not sure how to upload pictures from my phone....
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Old July 23rd, 2016, 21:15   #3
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Good luck with your build. I had a '97 XJ 4.0 with a 5 speed. I had a LOT of fun with it. I used to take it off-roading (had a Rubicon Express 3.5" lift). I managed to tear one of the mirrors off on a tree one time. The BANG sure woke me up, lol.
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Old July 23rd, 2016, 21:24   #4
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Thanks! They are great all round camping, daily driving, offroading vehicles. I've got the same lift too!
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Old December 27th, 2018, 18:05   #5
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BIG UPDATE!
I kinda forgot I had this going. Anyways.. engine is in with with td conversions adapter and mounts. Center force high inertia flywheel.
Arp head studs
.260 nozzles
Gtb1756vk on passat manifold.
Fast forward harness with Malone stage 5 tune. And cruise.

Still being built. Been posting more to Tdi Swapped Trucks on Facebook
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Old December 27th, 2018, 18:20   #6
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I'll be taking more pictures as the build progresses

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Old January 19th, 2019, 12:29   #7
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Like update. Put an advance adapters slip yoke eliminator in the transfer case the other evening. Hope to have the engine in for good soon!

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Old March 11th, 2019, 22:29   #8
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Been slowly picking away at the wiring harness and modifying the coolant hard pipe. Picked up a brm coolant flange and flipped it for a coolant pipe to run above the exhaust manifold.

Also found a $89 intercooler that Jeddadeezl used in his xj build. Will fit perfectly behind the xj grille.

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Old March 11th, 2019, 22:34   #9
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Next up is intercooler piping.
http://www.siliconeintakes.com has awesome quality parts with good prices. I've ordered stuff from them before. Very quick shipping to Canada too

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Old March 11th, 2019, 22:36   #10
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Wired up the cruise control buttons.

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Old April 6th, 2019, 09:59   #11
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Due to clearance issues with the track bar, the ac compressor had to be removed and mount ground down. A Subaru belt tensioner with a dodge 2.4 idler pulley works really well.

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Old April 6th, 2019, 10:10   #12
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Pretty much plumbed up the intercooler and pipes. Radiator moved back about an inch. $6 harbor freight wire crimpers make good bead rolling pliers

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Old April 9th, 2019, 10:57   #13
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I'm beginning to dread struggling with the track bar... I REALLLLY don't want to fuss with it
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Old April 11th, 2019, 19:39   #14
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Quote:
Originally Posted by A-man930 View Post
I'm beginning to dread struggling with the track bar... I REALLLLY don't want to fuss with it
That's not really an issue. Get an adjustable one with a drop bracket

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Old April 12th, 2019, 22:01   #15
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Friend of mine welded up my custom manifold the other day. Basically an alh manifold with a 2" 1/8" wall aluminum tube welded to it. Along with a map sensor flange.
Also made a steel coolant pipe for the flange at the back of the head to reach the rad. Welded a 3/8" npt bung in for the Jeep coolant temp sensor.

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