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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 August 28th, 2017, 20:15   #61
john.jackson9213
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Join Date: Mar 2007
Location: Miramar, Ca. (Think Top Gun)
TDI(s): 1996 B4V
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Here is a Monday afternoon progress update from Matt:

Bled the clutch more, everything seemed to be fine, went out for a drive today and by the end of the drive it was mushy again and couldn't engage reverse without shutting the truck off. I'm going to replace the master and hose.

Seems that everything that's original on the truck is just worn out/leaking/tired.

Jeep temp sending unit isn't reading right either so I'm going to replace that. Grounded connection and it goes right to max so the gauge and wiring are good.

Coolant also sprayed everywhere due to a bad cap on the radiator.

The oil pan gasket is also seeping so I'm going to do without the gasket and just silicone seal it like Mk4's are, I did the same on my ahu in my rabbit truck.

The alignment is also wayyyy off, it's toe'd out in the front badly. It's twitchy and all over the road.

I don't have a single good n75 here apparently so I'm going to grab also. They all are leaking vacuum out the vent port so boost control is all over the place.

Last bit of bad news, the left rear rim is bent like all hell. It has a good 1/4"-3/8" wobble in it spinning on the hoist.


Good news, tach works and i adjusted it to read correct 900prm at idle, heater valve operation works, and it has 5 miles on it now .



Matt likely means 5 kilometers on the truck - Originally sold in Canada, so metric speedometer/odometer. JJ
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1996 B4V, Hella E-Codes, GLX leather, EuroTuning.cz 02A 6 speed conversion w/.71 5th and .588 6th gear, A4 shift linkage by Matt-98AHU. 11 mm pump by Oldpoopie. Now, GTC1549VZ turbo by Whitbread. TDtuning, 24 lbs. boost, 162 hp, 285 lb/ft tq. Smoke Free (9/18/15). Koni Yellows and Big Brake 5 lug conversion.

Last edited by john.jackson9213; August 28th, 2017 at 20:17.
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Old September 20th, 2017, 16:24   #62
All Stock
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Any Updates?
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Old September 21st, 2017, 11:46   #63
john.jackson9213
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Latest up dates:

Clutch is now working fine and holding. Salve cylinder and a hose were replaced.

New N75 installed and the tune is being dialed in.

One more oil leak still to fix. Last one fixed was a leaking intermediate shaft seal. It was new, but still leaked.

Fuel sender works fine. Truck took 21.5 gallons in a 23.5 gallon tank. So he will be able to put some more miles on the truck now.

Rear springs are getting change out today. Putting in a good, clean used set of standard Comanche springs to replace the bastard pack that is in now. Guess I cheaped out on the springs!

Asked Matt to check the rear axle gear ratio for me.

I may have a driving video tomorrow.

Still need to send Matt the EGT gauge. He has the probe installed and wire into the cab.
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JJ
1996 B4V, Hella E-Codes, GLX leather, EuroTuning.cz 02A 6 speed conversion w/.71 5th and .588 6th gear, A4 shift linkage by Matt-98AHU. 11 mm pump by Oldpoopie. Now, GTC1549VZ turbo by Whitbread. TDtuning, 24 lbs. boost, 162 hp, 285 lb/ft tq. Smoke Free (9/18/15). Koni Yellows and Big Brake 5 lug conversion.

Last edited by john.jackson9213; September 21st, 2017 at 11:49.
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Old September 24th, 2017, 13:46   #64
john.jackson9213
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TDI(s): 1996 B4V
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Short video of the Comanche TDI driving here on YouTube:



https://youtu.be/mr3ThOyOhT8
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JJ
1996 B4V, Hella E-Codes, GLX leather, EuroTuning.cz 02A 6 speed conversion w/.71 5th and .588 6th gear, A4 shift linkage by Matt-98AHU. 11 mm pump by Oldpoopie. Now, GTC1549VZ turbo by Whitbread. TDtuning, 24 lbs. boost, 162 hp, 285 lb/ft tq. Smoke Free (9/18/15). Koni Yellows and Big Brake 5 lug conversion.
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Old September 24th, 2017, 15:06   #65
turbobrick240
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Nice! Must feel good to have it running nice and smooth after all the effort. Makes me miss my old '87 MJ. If you ever need a tailgate, I have one in good shape you're welcome to have. Now I want a tdi in my XJ.
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Old September 24th, 2017, 20:16   #66
ToddA1
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Wow, this got finished quickly!

-Todd
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Old September 25th, 2017, 13:15   #67
john.jackson9213
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Not "finished" yet. Still lots to do if I am going to drive the Alaska Highway next summer.

At my age, it is better to to pay Matt than try to do everything by myself. I tend to way over think everything. That takes all kinds of wrong turns.
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JJ
1996 B4V, Hella E-Codes, GLX leather, EuroTuning.cz 02A 6 speed conversion w/.71 5th and .588 6th gear, A4 shift linkage by Matt-98AHU. 11 mm pump by Oldpoopie. Now, GTC1549VZ turbo by Whitbread. TDtuning, 24 lbs. boost, 162 hp, 285 lb/ft tq. Smoke Free (9/18/15). Koni Yellows and Big Brake 5 lug conversion.
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Old November 27th, 2017, 16:17   #68
john.jackson9213
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Just a quick update.

The Comanche is at Whitbread's for the winter...May be able to get it delivered to San Diego in early March.
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JJ
1996 B4V, Hella E-Codes, GLX leather, EuroTuning.cz 02A 6 speed conversion w/.71 5th and .588 6th gear, A4 shift linkage by Matt-98AHU. 11 mm pump by Oldpoopie. Now, GTC1549VZ turbo by Whitbread. TDtuning, 24 lbs. boost, 162 hp, 285 lb/ft tq. Smoke Free (9/18/15). Koni Yellows and Big Brake 5 lug conversion.
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Old January 24th, 2018, 19:59   #69
john.jackson9213
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One more short/quick update:

Matt got the front end aligned and changed out the rear springs.

Made arrangements to get the truck trailered out to California. Will be here about the second week in March. Thanks to another Jeep enthusiast in the mid west who is buying a Jeep in Calif and trailering it back to the mid west.

Then the truck will need to be registered in California and insured.
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JJ
1996 B4V, Hella E-Codes, GLX leather, EuroTuning.cz 02A 6 speed conversion w/.71 5th and .588 6th gear, A4 shift linkage by Matt-98AHU. 11 mm pump by Oldpoopie. Now, GTC1549VZ turbo by Whitbread. TDtuning, 24 lbs. boost, 162 hp, 285 lb/ft tq. Smoke Free (9/18/15). Koni Yellows and Big Brake 5 lug conversion.
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Old January 24th, 2018, 20:30   #70
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Looking forward to a ride next time I'm down there!
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Old January 25th, 2018, 07:01   #71
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Location: spiral arm, milky way (aka central NC)
Fuel Economy: golf=38-43mpg...tacoma tdi=29-33mpg
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very cool
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Old February 13th, 2018, 07:03   #72
john.jackson9213
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Last update before Comanche gets picked up this next weekend.

Matt says the Volvo electric power steering pump has randomly loosing assist on the road, but always checks out fine in the shop! (Love this type of problem - NOT). He suspects the pump is cavitating.

So Matt has removed the electric power steering pump and built a custom mount bracket to mount a Mark 4 TDI power steering pump on the passenger side of the motor. Working fine now. Pictures below.







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1996 B4V, Hella E-Codes, GLX leather, EuroTuning.cz 02A 6 speed conversion w/.71 5th and .588 6th gear, A4 shift linkage by Matt-98AHU. 11 mm pump by Oldpoopie. Now, GTC1549VZ turbo by Whitbread. TDtuning, 24 lbs. boost, 162 hp, 285 lb/ft tq. Smoke Free (9/18/15). Koni Yellows and Big Brake 5 lug conversion.
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Old February 13th, 2018, 13:30   #73
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I moved away from using the timing idler pulley because of its size. Being its small it will rotate much faster than originally designed. Most idlers use a larger bearing and a larger circumference for this reason as well. In addition it is now going at a faster speed because it is driven by the crank pulley which it many times larger in circumference then the small timing belt cog.

I used it to address added tension on an alternator pulley. That whole setup I had was wrong to begin with and it has now been completely changed. I now have an A/C compressor where your pump is and a larger idler in the same exact place.

I did however get about 10k miles out of it and a lot of those were highway miles from Detroit to Nashville, back, and then to San Diego and back. Having said that its possible you will be fine. Worst case when you do a timing belt just move the old timing pulley down there as you will replace the TB one and then keep one around as a spare... just incase.
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Old February 13th, 2018, 15:53   #74
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Quote:
Originally Posted by All Stock View Post
I moved away from using the timing idler pulley because of its size. Being its small it will rotate much faster than originally designed. Most idlers use a larger bearing and a larger circumference for this reason as well. In addition it is now going at a faster speed because it is driven by the crank pulley which it many times larger in circumference then the small timing belt cog.

I used it to address added tension on an alternator pulley. That whole setup I had was wrong to begin with and it has now been completely changed. I now have an A/C compressor where your pump is and a larger idler in the same exact place.

I did however get about 10k miles out of it and a lot of those were highway miles from Detroit to Nashville, back, and then to San Diego and back. Having said that its possible you will be fine. Worst case when you do a timing belt just move the old timing pulley down there as you will replace the TB one and then keep one around as a spare... just incase.
what All stock said, that idler is now spinning a bazillion rpm beyond it's normal speed... way overdriven from stock ... they barely last long enough for a timing belt when driven relatively slow compared to your current setup
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Old February 14th, 2018, 01:02   #75
john.jackson9213
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Good information on the idler. Thank you both. Just hope I remember it before the idler fails in a couple of years or more.
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JJ
1996 B4V, Hella E-Codes, GLX leather, EuroTuning.cz 02A 6 speed conversion w/.71 5th and .588 6th gear, A4 shift linkage by Matt-98AHU. 11 mm pump by Oldpoopie. Now, GTC1549VZ turbo by Whitbread. TDtuning, 24 lbs. boost, 162 hp, 285 lb/ft tq. Smoke Free (9/18/15). Koni Yellows and Big Brake 5 lug conversion.
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