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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 15th, 2018, 17:10   #1
Millennium Falcon
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Default ALH 1949 willys cj3a

I am planning of putting a VW diesel in the jeep. Im in the early stages but I think it should be a good swap. I started working on the adapter plate. I have the template made, I just need to finish it and bolt it all together check the alignment before I start making chips.. It is physically the same size as the l-head. It has obvious performance gains. I think it will be a good fit. The plan is to make the back of the VW block/crank mimic the L-head. The adapter is pretty simple and once I get the flywheel depth figured out I will start making the crank adapter. If all goes as planned I wil use the stock willys bell,clutch,starter(gear reduction) and stock the t-90 trans.
Here is what its going in.....


(I cant get my IMGUR pictures to post in the correct size. They take up like 10 times the normal size)
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1949 Willys cj3a ALH tdi swap

Last edited by Millennium Falcon; February 15th, 2018 at 17:16.
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Old February 15th, 2018, 19:45   #2
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you need to resize the picture in imgur once you upload them. Need to click on the pencil thingy. I always just change the largest dimension to 1000px and leave it at that.
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Old February 15th, 2018, 21:30   #3
1.9ZOOK
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Cool Swap!
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Old February 15th, 2018, 23:13   #4
Millennium Falcon
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Let me try uploaded a picture now with exenos's advice.









I used a dummy shaft and a bearing retainer to help me center the crank to the trans.
https://youtu.be/iYSohDaMOvs
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2003 Jetta TDI wagon, 5-speed, swap, Sprint520 nozzles 165k
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1949 Willys cj3a ALH tdi swap

Last edited by Millennium Falcon; February 15th, 2018 at 23:19.
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Old February 17th, 2018, 06:40   #5
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nice project! i would bolt a dial indicator to the crank and rotate it inside the bell bore to get center ... the rod in the pilot bore might seem like an accurate way to detect center but just a tiny angular error at the crank can equal way over spec at the bell bore
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Old February 17th, 2018, 08:26   #6
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What is "spec" I am at .0015-.0020 at the bell bore right now.
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Old February 17th, 2018, 08:28   #7
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Quote:
Originally Posted by Millennium Falcon View Post
What is "spec" I am at .0015-.0020 at the bell bore right now.
what is your measurement method ?
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Old February 17th, 2018, 08:29   #8
Millennium Falcon
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The hardest part at the moment is clamping the bell to my adapter to get it centered. Im not drilling any holes yet. I may lay the engine on its nose to remove gravity from the equation. An extra set of hands would be helpful.
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Old February 17th, 2018, 08:35   #9
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Quote:
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what is your measurement method ?

I used two different dial indicators. I indicated the crank like you said then the did the same thing with the dial indicator attached to my test rod as well to compare my findings. I got about a extra 1.5 thousands out on the rod... but im still only at like .003-.004 all the way out at the trans. Im happy with that.
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2004 passat 1.8t auto 104k

1949 Willys cj3a ALH tdi swap
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Old February 17th, 2018, 08:41   #10
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any centering method that does not incorporate rotating the crank in reference to the bell bore has inherent inaccuracies... very simple rig, you can borrow mine for a security deposit
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Old February 17th, 2018, 08:42   #11
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Originally Posted by Millennium Falcon View Post
I used two different dial indicators. I indicated the crank like you said then the did the same thing with the dial indicator attached to my test rod as well to compare my findings. I got about a extra 1.5 thousands out on the rod... but im still only at like .003-.004 all the way out at the trans. Im happy with that.
sounds good
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Old February 17th, 2018, 15:28   #12
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Do you know what the allowable run out is at the crank/flywheel? The willys manual say .002 Not sure about the VW

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sounds good
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Old February 17th, 2018, 16:12   #13
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Do you know what the allowable run out is at the crank/flywheel? The willys manual say .002 Not sure about the VW
your numbers sound fine.... iirc the radial limit is around .007 or .014 total but that's from a guide for centering a v8 bell housing
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Old February 17th, 2018, 18:55   #14
1.9ZOOK
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I shot for 0,and ended up around .005.
It's been going fine for 2000 miles.
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Old February 18th, 2018, 10:57   #15
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Nice! Any vibrations or issues?
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I shot for 0,and ended up around .005.
It's been going fine for 2000 miles.
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2004 passat 1.8t auto 104k

1949 Willys cj3a ALH tdi swap
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