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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 May 24th, 2014, 22:22   #1
TDIsyncro
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Default 2007 GMC Canyon TDI Project

I have been working on this a little bit at a time for about 1 year now. Mainly just collecting some parts and developing the complete picture of how everything will work. I am getting close now so thought I would start to share some pictures.

Concept was originally a 2008 Ranger, but I like the canyon better and came with a 5000 lbs towing capacity and limited slip differential so I traded the Ranger straight across for the Canyon. Lot more parts available on the market for drop kits and accessories too. I intend to install a cab controlled air ride after the engine is in place. I want to be able to drop it 5/4 for high way driving, and lift when on short back road drives. I will also be able to level it when pulling trailers.








This one came with a 5cyl I5 and 4L65E auto transmission. It turns at around 2200 RPM at 110 kph. Very good gearing in place for TDI. I wanted to do the build first with the factory transmission. If I am happy with automatic, I have a 6L80E to swap in. If I am not happy with the Auto, I will go to a T56.





My transplant engine is a 2011 CJAA CR 2.0 TDI with 3000km on it. Yes, it is squeaky clean and just like new!

This is a picture of an engine being floor tested with the harness and ECU that was made up for my CR engine by Johan @ Van Vaught.







Video of run:

https://www.youtube.com/watch?v=TUsCY69oUv0




.
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Last edited by TDIsyncro; May 24th, 2014 at 22:28.
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Old May 24th, 2014, 22:26   #2
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I have already been running one of these things to asses the problems and opportunities there are in the project.

http://www.usshift.com/

I ordered it with the harness and was a fairly easy installation. Shift points are a lot more firm and it locks the torque converter at as low as 1400 RPM as far as I can tell. Comes with laptop software to custom create shift points.

I discovered the down side is that I am using a TPS, and this does not work with the cruise control system. The controller will drop line pressure off as soon as TPS position drops off with removal of ones foot from pedal. The only solution around that is to tag team it with a aftermarket cruise control system.

http://www.rostra.com/universal-afte...-by-rostra.php

Best idea I could come up with was a cable link to the TDI pedal, or one other idea I am working on in my mind...not sure about it yet.
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http://forums.tdiclub.com/showthread.php?t=270527
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http://forums.tdiclub.com/showthread.php?t=415533

Last edited by TDIsyncro; May 24th, 2014 at 22:55.
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Old May 24th, 2014, 22:26   #3
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future2
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http://forums.tdiclub.com/showthread.php?t=270527
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Old May 24th, 2014, 22:26   #4
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Neat!
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Old May 26th, 2014, 18:14   #5
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First step is prepping the engine.
The OEM accessory bracket holds A/C and alternator only. I will replace this bracket from a 2010 Audi A4 2.0TDI. To do this I have to remove the high pressure fuel pump, timing belt, alternator, etc.

The CJAA OEM bracket also covers one of the bolt holes for the driver side engine mount.

New bracket installed.

Bolt hole is clear to install motor mount. motor mount from 2004/5 Passat TDI.

Installation of wire harness.

A bit of a problem. North American engines have pressure sensor GP. Apparently many European CR engines have only GP. The connectors do not fit. Rather than snipping the connectors off and replacing them, Johan has some European GP on way to me. I hope!

Harness connector for crank position sensor went missing. Had to splice a new one on.

Making boss for factor EGT using coupling nut and bolt.

Boss installed. Oh yeah..that is the custom log manifold I built in the fall. The paint is good for around 1800F.
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2001 Audi A4 - New Project - 2.0TDI CR 450HP All Turbo
http://forums.tdiclub.com/showthread.php?t=270527
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http://forums.tdiclub.com/showthread.php?t=415533

Last edited by TDIsyncro; May 26th, 2014 at 18:18.
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Old May 26th, 2014, 18:26   #6
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I will be using this O2 sensor. I will mount a bung on the turbo down pipe after the engine is installed as I am not sure what my down pipe will look like yet.


Recirculating heater to be installed.


This is the thermostat octopus assembly on the CJAA. I don't like it. Too many hoses to plug off when not using EGR system.



The new thermostat system has a different fitment than the old style. Note length and oring.



The block is also machined differently to accept this new design.



Old style thermostat housing. I will be using one from a BHW TDI with a bit of a trick.



This is how the block is machined for the old style.



I will make an adapter that will fit old thermostat housing to new block opening.
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http://forums.tdiclub.com/showthread.php?t=270527
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Old May 26th, 2014, 18:33   #7
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Custom actuator mounting bracket on turbo.




The turbo is a custom built unit. It was designed to be a HP turbo in a compound setup. I do plan to turn this project into a compound turbo next year.

Turbo is mounted. Need a new oil feed line and oil return line. Buying a feed line and a few other bits from Ryan@Darkside.

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http://forums.tdiclub.com/showthread.php?t=270527
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http://forums.tdiclub.com/showthread.php?t=415533
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Old May 26th, 2014, 18:48   #8
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Transmission, torque converter, flex plate and starter all bolt up nicely. Had one small problem to resolve with crank adapter so sent it back for an adjustment.






There is a little snout on the crank that has to be removed.



No need to be fancy about it. Used the angle grinder.

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http://forums.tdiclub.com/showthread.php?t=270527
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Old May 26th, 2014, 18:52   #9
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Note the water outlet on the back of the head. Extra hoses for EGR system. It is bulky and not clean. I am going to replace this with a custom machined aluminum fitting. I will also include 3 GP in the new part for added heat in winter driving conditions.






I hope to really clean up the final look of the CR engine.
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Last edited by TDIsyncro; May 26th, 2014 at 19:01.
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Old May 26th, 2014, 20:17   #10
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very nice project ... good info on the audi a4 tdi bracket that has power steering ... looks like it's coming together ... BTW its spelled "assess" the way you have it spelled is the plural of backside ... hahaha!!!!
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Old May 27th, 2014, 06:59   #11
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Quote:
Originally Posted by jimbote View Post
very nice project ... good info on the audi a4 tdi bracket that has power steering ... looks like it's coming together ... BTW its spelled "assess" the way you have it spelled is the plural of backside ... hahaha!!!!

Thanks. yes. its moving along ok now. It was slow going for the first 8 months and the price of winter diesel this past season did not help my motivation. Now things are coming together quick. Hoping to floor test the engine in 2-3 weeks and then I will do a 7 day marathon to get it in and driving. I have an OEM diesel pump from the Thailand Colorado..not sure if it will fit my NA tank yet so that is a bit of a variable.

Thanks for the spell check. normally I use Word and then paste but in a big hurry these days.
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http://forums.tdiclub.com/showthread.php?t=270527
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Old May 27th, 2014, 15:36   #12
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Quote:
Originally Posted by TDIsyncro View Post
Thanks. yes. its moving along ok now. It was slow going for the first 8 months and the price of winter diesel this past season did not help my motivation. Now things are coming together quick. Hoping to floor test the engine in 2-3 weeks and then I will do a 7 day marathon to get it in and driving. I have an OEM diesel pump from the Thailand Colorado..not sure if it will fit my NA tank yet so that is a bit of a variable.

Thanks for the spell check. normally I use Word and then paste but in a big hurry these days.
I just replaced my intank tacoma FI pump with a bosch unit from an 85 ford ranger.... this particular application uses a low pressure in-tank pump which feeds a high pressure frame mounted pump ...the nice thing about this pump is if it fails the fuel can still be sucked through very easily ....it's rated from 3-6 psi and 55gph ...initial impressions: easily more power over 3k rpm and the power delivery is smoother, I owe that to eliminating the restrictive bypass regulator I was using....just an option if the thai sourced pump does not work
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Old May 27th, 2014, 17:41   #13
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Great thread. Are you on any of the Colorado/Canyon forums? I'm sure those guys would get a kick out of this. Makes me want my Colorado back so I could do this to it.
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Old May 27th, 2014, 18:39   #14
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Awesome, love these threads and idea's.
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Old May 27th, 2014, 19:48   #15
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Quote:
Originally Posted by jimbote View Post
I just replaced my intank tacoma FI pump with a bosch unit from an 85 ford ranger.... this particular application uses a low pressure in-tank pump which feeds a high pressure frame mounted pump ...the nice thing about this pump is if it fails the fuel can still be sucked through very easily ....it's rated from 3-6 psi and 55gph ...initial impressions: easily more power over 3k rpm and the power delivery is smoother, I owe that to eliminating the restrictive bypass regulator I was using....just an option if the thai sourced pump does not work
Sorry to hijack. What made you think your fuel regulator was restrictive Jim? Were you monitoring fuel pressure at the inlet to the pump? I'm intrigued by your find... I take it you still needed to run a 2nd return line?
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