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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 21st, 2018, 12:30   #31
Millennium Falcon
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"photobucket hotlink fix"


Quote:
Originally Posted by bwk9087 View Post
Hi, what extension do you run to see them?
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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, 20:05   #32
1.9ZOOK
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Thanx MF
That's good to know,keep yer build photos comin'.
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Old February 22nd, 2018, 06:10   #33
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I set the engine in the frame just now to get an idea....and I realized just how much this thing doesn't want to go in there. The biggest issue is the steering box and how far back the drive train is. This engine is tiny but the front edge of the bell housing is recessed about an inch behind the firewall. I just stared at it for about an hour trying to come up with a game plan. I need to find some inspiration! haha. Im taking a day or two off from working on it to see what I can come up with. On a positive note.....I will have plenty of clearance for the hood. and the differential misses the oil pan.


Does anyone have a technical drawing of the back of the vw block? Specifically the dowel pins and crankshaft?


Ive been loosing some steam. Lots of obstacles. My plate came today so I can start working on the block adapter. I holding off on anything else until my new starter gets here. That will pretty much make or break this project for me. If the starter doesnt clear the turbo im kinda dead in the water. so.....friday I will find out. If it clears then im going ahead full steam....if it doesnt, the l-head may be going back in.











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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

Last edited by Millennium Falcon; February 22nd, 2018 at 06:21.
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Old February 22nd, 2018, 06:37   #34
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Found one! Thanks TDIclub!

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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 22nd, 2018, 11:04   #35
1.9ZOOK
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Maybe go with an outside the frame type of steering box and use a pillow block to get the steering shaft out of the way?
Is there enough room to move the round frame bar forward 8 or 10" so you can move the engine forward?
Just throwing more thoughts at ya.

Last edited by 1.9ZOOK; February 22nd, 2018 at 11:07.
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Old February 22nd, 2018, 18:18   #36
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I have been researching steering conversions. There are a few options. I was hoping not to change the steering setup, but i may not have a choice. Oil filter relocation may be an option. It may come down to which one is cheaper. I emailed a few vendors about oil filter relocation setups. Waiting to hear back. If I knew where all the ports in the block go, im sure I could make one. Just have to figure out what route i need to go. Still waiting on the starter before I do anything.
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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 22nd, 2018, 18:38   #37
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remote adapter plate---http://gastodiesel.tdconversions.com/accessories/
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Old February 23rd, 2018, 06:49   #38
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im hoping the starter will work out because i put in a lot more time today laying out, boring, and milling my plate. I will still need to drill it for the transmission, but the VW block side is done. It took a long time to mill out the center hole. My machine is small so lots of little passes. I still have to trim it up some and cut the starter area out. I did bore the back side for the VW dowel pins. So far so good.



https://www.youtube.com/watch?v=8ftV...ature=youtu.be
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2003 Jetta TDI wagon, 5-speed, swap, Sprint520 nozzles 165k
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1949 Willys cj3a ALH tdi swap
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Old February 23rd, 2018, 16:45   #39
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Love your posts and projects, wish I had your energy. I’m thinking I should quit working on vehicles and just drive them��, won’t happen though. Getting older and smarter doesn’t necessarily go hand in ����
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Old February 24th, 2018, 23:25   #40
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Thanks Jmodge! I would love to quit working on this things and drive it! hopefullt sooner than later.

Well the moment has finally come..... Its kinda bitter sweet. I have been really excited to bolt everything up, but also have been stressed about the starter/turbo clearance. Im kinda hinging the project of this.



So.....My starter came and i milled down the side of my engine plate where the started goes so I could test fit it. It was really close to the turbo so I drilled an extra set of holes in the clocking ring to swing the motor down farther away from the turbo. Its better but still close. The starter is cast into the bell housing so Im kinda stuck with it there. I think I can get creative with an elbow to make the down pipe go upward a few inches to give the starter extra room, but Im worried its going to cook the starter. Maybe i can make some sort of heat shield/header wrap, turbo cover or something. What are your thoughts? Ive heard some guys that do toyota truck tdi swaps often have starter clearance issues. Im not sure if its a problem or just an inconvenience.





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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 25th, 2018, 02:05   #41
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Mine sits about 3/4" away at the back end and no problems.It's a Toyota T-100 starter.
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Old February 25th, 2018, 05:31   #42
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This is interesting, I have an '85 4runner i hope to get to before I end up in the ground. But, unfortunately it is down the list for now.
I looked at a Toyota with an acme adaptor, but thought I might want to clock it different. Is that crank and bell bolt pattern in a pdf file somewhere by chance/
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Old February 25th, 2018, 06:14   #43
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Great! That looks very similar to mine if not a little tighter. Good to hear you haven't had any issues! I found the alh print on here somewhere. I blew it up to see the block better.. PM your email and I can send it to you. Not sure how to attach a file on here.
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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 25th, 2018, 07:24   #44
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pm sent, thanks
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Old February 25th, 2018, 18:24   #45
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Adapter kit is done!







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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

Last edited by Millennium Falcon; February 25th, 2018 at 18:33.
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