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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 18th, 2018, 12:14   #16
1.9ZOOK
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No,everything seems to be fine,no clutch chatter or tranny input shaft bearing noise.That's the most likely places a misalignment issue will show up.
With an older vehicle like yours,you will probably be chasing body rattles.
I started with the loudest and slowly eliminated most of them.
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Old February 18th, 2018, 16:18   #17
Millennium Falcon
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Well My crank adapter is almost done. I still need to counterbore the holes for the VW crank and drill the holes for the willys flywheel. Slowly coming along. Forgot how long things take when aiming for perfection. This is my second part. I was not pleased with the first one so i started all over. This one is spot on so far... Fingers crossed I don't mess up on the last hole. Still a mile long list, but Im trying to only take it one thing at a time.



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Old February 18th, 2018, 23:41   #18
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I finished the VW side of the crank adapter. Counter bore is done. I mounted it on the crank and it actually fits! haha! I put the indicator on it and It looks like i have about .003 run-out on the side, and just a tiny bit over .001 on the face. Im pretty happy with that. there is a little surface corrosion on the cranks so I will polish that before I do the final install. That could change my reading slightly. I was just happy it fit and all the bolts lined up. Since the VW crank is an eccentric pattern I didn't use the rotary table. Tomorrow I will drill the holes for the willys flywheel and then its done! My aluminum plate for the trans adapter will be here Thursday. That should be pretty straight forward since I already have my template made. I just have to transfer it to the plate. Milling the 1.000 thick alum will be a slow process on my little machine. But I really like working with aluminum. Should be fun. Then I will set the engine in the frame and figure out all the stuff its going to run into! I know the vacuum pump will be a problem.








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1949 Willys cj3a ALH tdi swap
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Old February 19th, 2018, 11:15   #19
Millennium Falcon
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Done



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2004 passat 1.8t auto 104k

1949 Willys cj3a ALH tdi swap
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Old February 19th, 2018, 20:08   #20
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Nice. looks like a fun project. Will it even weigh more than 2800lbs?
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Old February 19th, 2018, 20:19   #21
Millennium Falcon
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The jeep supposedly has a curb weight of 2215 lbs and that is with the heavy cast iron flat head engine. Im told that weighs in around 500lbs ready to run. The ALH should shave a little weight of that number.
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1949 Willys cj3a ALH tdi swap
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Old February 19th, 2018, 20:21   #22
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Clutch and flywheel bolted up just for fun. Aluminum plate for the block should arrive tomorrow.

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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 February 20th, 2018, 09:32   #23
A-man930
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Anxious to see your diy adapter.
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Old February 20th, 2018, 10:38   #24
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Nice project!!
The bike looks interesting too, is it a Yamaha SR 500?
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Old February 20th, 2018, 16:34   #25
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It's absolutely amazing what people adapt a TDI too.
Planes, trains ???, boats, automobiles. Only thing left is in a submarine.

Nice job on the jeep, betcha Kayser/Willis never dreamt of that.
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Old February 20th, 2018, 21:49   #26
Millennium Falcon
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THanks! Im kinda at a stand still at the moment. I have several issues that i need to sort out. as small as this engine is it really doesnt want to fit in the willys. Main issue is the steering box/oil filter, firewall vacuum pump, and starter/Turbo clearance. Other than that it fit right in haha!
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1949 Willys cj3a ALH tdi swap
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Old February 20th, 2018, 22:55   #27
1.9ZOOK
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I know a lot of people move the drive train forward 2" which really helps with everything
firewall related.Then eliminating the air conditioner pump and tensioner and using a shorter belt and homemade adjustable idler wheel.And it also makes room for the exhaust to wrap over the top of the bell housing.This is what I did for the rear heater out let...

I kept the 3 coolant glow plugs.
Idler wheel tensioner

Last edited by 1.9ZOOK; February 20th, 2018 at 22:59.
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Old February 21st, 2018, 04:29   #28
bwk9087
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Quote:
Originally Posted by 1.9ZOOK View Post
I know a lot of people move the drive train forward 2" which really helps with everything
firewall related.Then eliminating the air conditioner pump and tensioner and using a shorter belt and homemade adjustable idler wheel.And it also makes room for the exhaust to wrap over the top of the bell housing.This is what I did for the rear heater out let...

I kept the 3 coolant glow plugs.
Idler wheel tensioner
Hey Zook, I went looking for your pics of the coolant plugs you kept in your conversion, but all you pics are fubar in your thread. Do you still have pics of where they are? Or are they on the other side of the rear heater outlet not show in this pic?
thanks
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Old February 21st, 2018, 05:50   #29
Millennium Falcon
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Thanks zook, I read every page of your build very cool and informative! Google chrome extension lets you still see the pictures.

I plan un running the auto transmission water neck from a 2003 alh without the glow plugs. I have a plan to run a single pully with a v-belt to the alternator. No power steering or anything. I had to delete the alternator from the stock location to clear the frame rail.
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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 February 21st, 2018, 06:20   #30
bwk9087
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Quote:
Originally Posted by Millennium Falcon View Post
Thanks zook, I read every page of your build very cool and informative! Google chrome extension lets you still see the pictures.

I plan un running the auto transmission water neck from a 2003 alh without the glow plugs. I have a plan to run a single pully with a v-belt to the alternator. No power steering or anything. I had to delete the alternator from the stock location to clear the frame rail.
Hi, what extension do you run to see them?
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