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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 6th, 2012, 07:30   #46
unclesfunnyonions
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Great find on the i/c, fits nice.


Alex.
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Old August 6th, 2012, 07:36   #47
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Quote:
Originally Posted by Growler View Post
man, between watching you and the guy with the BMW 2002 im really enjoying these swaps...
yeah, I'm watching his swap with great interest since it is in my top 3 for swap candidates.
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Old August 6th, 2012, 22:41   #48
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It really is a good time to be browsing the swap section isnt it
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Old August 7th, 2012, 13:42   #49
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I have a 99 Ranger with close to 200K miles on it and I would love to drop and ALH engine in it. My truck has spent it's entire life in Georgia and is rust free. The 2.5 engine is a dog compared to a tuned ALH. I will be following this thread very closely. Good luck!
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Old August 7th, 2012, 17:40   #50
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Thanks. Should have a big update in the next couple days. Little ones to come later tonight.
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Old August 7th, 2012, 20:37   #51
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Quote:
Originally Posted by greengeeker View Post
yeah, I'm watching his swap with great interest since it is in my top 3 for swap candidates.
Hilarious....I've been watching your swap too....patiently waiting to see the mythical T5 adapter plate...
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Old August 13th, 2012, 09:15   #52
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We want updates.
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Old August 13th, 2012, 21:40   #53
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We want updates.

Sorry been plugging away at the Ranger as well as other peoples' tdi's.
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Old August 13th, 2012, 22:22   #54
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Default Fuel System, Part 1

The Ranger of course was fuel injected which meant it's in-tank fuel pump was putting out around ~60psi of fuel pressure which is way more than the 4psi I need for the tdi. So I need to drop the tank to get at the fuel pressure regulator which is also mounted to the sending unit which is convenient since I also need to drain 1/2 of tank of 6 yo gasoline.

Out comes the tank, my fuel pump used to de-fuel mis-fueled tdi's and my spare battery:



Out comes the sending unit so I can get every last bit of gas out:



And here's the sending unit:





In the above pictures you can see the fuel pump, fuel pressure regulator and some sort of EVAP check valve. I'm going to remove the last two and reuse the connectors on the sending unit for return lines (more on that in Part 2).



Here are the connectors as they are installed on the Ford lines. I simply cut a slit to remove them from the lines.


And here they are on the sending unit:



I wasn't too crazy about the return lines the way they were on the top of the sending unit - I figured they would aerate the fuel when the fuel level was below 3/4 tank. To remedy this I went to the bone yard and picked up a sending unit from a diesel superduty for the stainless lines. Don't laugh, this was my first attempt at TIG welding stainless.



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Old August 13th, 2012, 22:37   #55
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Default Fuel Tank Mod

This is a pretty basic mod and the premise is almost identical to the ventectomy we have all done on our tdi's: remove the expansion space in your fuel system to increase the fuel capacity of your tank.

Here is the tank with the hump to the left of the fuel sending unit hole:



I took some measurements and calculated this volume to be worth 1.7 gallons. That plus the volume in the lines should make it at least 2 additional gallons.

In this picture I posted earlier you can see another EVAP check valve on the top of the hump that relieves any built up pressure in the tank to the EVAP charcoal canister located above the spare tire:



I'm going to use this fitting and tee into the main vent line that goes up to the fuel fill neck with some hardware store bling .



Here it is all ready to go back in the truck:

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Old August 14th, 2012, 08:44   #56
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Are you not using a 2000 TDI? On mine I just removed the fuel pump and tied right into the strainer at the bottom. No need for a fuel pump to supply the injection pump on the VW. My VW intank unit was just a float and a strainer/reservoir. I thought only the newer TDIs had a lift pump.
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Old August 14th, 2012, 14:19   #57
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Quote:
Originally Posted by Lone Ranger View Post
Are you not using a 2000 TDI? On mine I just removed the fuel pump and tied right into the strainer at the bottom. No need for a fuel pump to supply the injection pump on the VW. My VW intank unit was just a float and a strainer/reservoir. I thought only the newer TDIs had a lift pump.
Some people add a lift pump for performance purposes.
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Old August 14th, 2012, 15:18   #58
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Exactly. I'm using the stock Ranger pump as my lift pump and will add an aftermarket, adjustable fuel pressure regulator to dial the pressure down to TDI-friendly territories.
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Old August 15th, 2012, 07:53   #59
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I wasnt aware that adding a lift pump would yield better performance or you are planning to do some performance upgrades then?
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Old August 15th, 2012, 08:20   #60
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Quote:
Originally Posted by Lone Ranger View Post
I wasnt aware that adding a lift pump would yield better performance or you are planning to do some performance upgrades then?
To be fair a lift pump isn't going to do much for a stock power TDI. They do assist the IP at higher when you start pushing the limits of the 10mm in moderately modded tdi's and the 11mm in significantly modded tdi's.

At the moment I'm planning on two stages (with a possible third) of performance:

Stage 1: 2.5Lima/2.3Duratec Power Level: 119-135bhp
Stage 2: 4.0L Power Level: 160bhp
Stage 3: 4.0L HO Power Level: 207bhp
Stage 4: 5.0L Power Level+

My intercooler, charge air piping and fuel system mods I'm putting in place are prepping for all these stages of performance so I don't have to revisit later. The big test will be whether the M5OD-R1 can handle the torque (if driven sanely) of stage 3. I've received heresay info on therangerstation that it is designed for a 300ftlb torque limit. We'll find out if that is true. If it doesn't hold up I'll just throw a T5 in there and be done with it.
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Last edited by greengeeker; August 15th, 2012 at 22:14.
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