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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 26th, 2018, 09:30   #46
ManicMechanic
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Nice work.
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Old February 26th, 2018, 21:06   #47
Millennium Falcon
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THanks! Engine/Trans is all bolted together and sitting in the frame. No motor mounts yet but getting there. You may want to look away is you get squeamish around firewall cutting. I had to make room for the vacuum pump and water outlet on the back of the head. I will make a nice box that will close it all up, and paint it to match. I hooked up the battery and cranked it over a second or two with the starter to make sure engagement was good. It turned over just fine. I cranked it in gear with the clutch depressed to make sure it would release. So far so good. Now time to fix the firewall, make motor mounts, and plumb everything.







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Old February 27th, 2018, 05:16   #48
Millennium Falcon
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BIG OBSTACLES
1) steering box/oil filter clearance
2) water outlet clearance on the back of the head.
3) Exhaust downpipe



LITTLE ANNOYANCES
1) Motor mounts
2) Box in firewall
4) run coolant lines
5) run fuel lines
6) inner cooler
7) oil cooler
8) wiring
9) Plumb return line to fuel tank


Im sure there will be more these are just the ones that come to mind.....easy peasy right? hhaha!
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Old February 27th, 2018, 05:33   #49
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No small project there, looking good. what are your thoughts on making that box removeable for servicing? Leakage and timing belts come to mind.
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Old February 27th, 2018, 05:45   #50
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Yes, My plan is to make a removable panel big enough to put the cam lock in for timing belt service.... this engine needs a timing belt before its put on the road. I will just have to figure out the best way to do it and keep it sealed up well
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Old February 27th, 2018, 23:00   #51
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I started messing around with making my own relocation plate.... I only have like an 1" of clearance. I may try to move my drivetrain over at least 1/2 or so. Because when the engine rocks i dont want it to hit the plate.







Replacing this

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Last edited by Millennium Falcon; February 27th, 2018 at 23:03.
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Old February 27th, 2018, 23:04   #52
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I still need to add add the turbo line and the oil sensor.
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Old February 28th, 2018, 09:46   #53
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Are you going to tap those holes and use A/N fittings?
If you haven't removed the turbo oil line yet be super careful,they twist and break real easy. I replaced the hard line with a braided one,I twisted the hard line
when trying to remove it.
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Old February 28th, 2018, 20:02   #54
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Yeah I avoid solid turbo feed lines.... I had one blow on me at work one time.
Lost almost all of the oil in a minute. I went to a braided line.
I just ordered another one for this engine. SO much nicer to work with. Yes I am going to be using -8an fittings and hoses on everything. I am just going to run a spin on oil filter and remote oil cooler. I know the filter wont be as good as the stock VW one, but spin ons are cheap. I will just change the filter more often. The plate will still have the port for the turbo banjo bolt and the oil sensor. I am also going to tap it 1/4 npt for the factory oil pressure gauge inside.
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Originally Posted by 1.9ZOOK View Post
Are you going to tap those holes and use A/N fittings?
If you haven't removed the turbo oil line yet be super careful,they twist and break real easy. I replaced the hard line with a braided one,I twisted the hard line
when trying to remove it.
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2003 Jetta TDI wagon, 5-speed, swap, Sprint520 nozzles 165k
2004 passat 1.8t auto 104k
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Old March 1st, 2018, 08:16   #55
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Hello everyone, my name is Uli I live in Freiburg Germany.Selber I have a Unimog 411 rebuilt on Tdi. 35 years ago, I also had a Willys I've converted to Mercedes 508 gearbox and 3 liter Ford V6. I can not speak English well, so I use the Google translator. I am very impressed by the Willys conversion and I am looking forward to the performance and of course the consumption. Should the 3-speed transmission remain in the future with your Willys? With us, many Willys were converted to Mercedes diesel with 4-speed gearbox. With the enormous torque of the Tdi, it is certainly possible because even at the front there is still a lot of space to use a 5 or 6-speed gearbox. VG ULI
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Old March 2nd, 2018, 05:36   #56
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Ive made some progress over the past few days.... Made my motor mounts and modified my water neck so it exits towards the passenger side. It was pretty much pointing right at the brake pedal. I also shorted it some so it doesnt stick out as far. The engine is now bolted in and supported in the frame! Waiting on shipping of a bunch of fittings and stuff for my oil system.


My biggest concern now is whether or not I will have room for my radiator!!















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Old March 2nd, 2018, 09:43   #57
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Nice!
Looks like there is no heater,so I think you can just 180 rubber hose the outlet
to the metal tube that goes to the water pump.
Maybe a stand alone Mojave heater for heat?
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Old March 2nd, 2018, 12:45   #58
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Great looking job - my suggestion is that you find better motor mounts - those rubber ones look rather hard and it will be vibration city for you when done.
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Old March 2nd, 2018, 16:38   #59
Millennium Falcon
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Im not planning on ever putting a top or heater on this jeep so one less thing to worry about. Yeah these motor mounts are experimental. If/when they suck I will find something better. I used these on my Mercedes diesel and have been happy with them for 4 years. But it wont be a big deal to change them out if they rattle my fillings out haha! What ever mounts I use cannot allow too much movement because my steering shaft is about 1.5" from hitting my oil filter plate.
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Old March 2nd, 2018, 16:39   #60
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Thanks Zook! I couldnt have done it without your inspiring pictures and info!



Quote:
Originally Posted by 1.9ZOOK View Post
Nice!
Looks like there is no heater,so I think you can just 180 rubber hose the outlet
to the metal tube that goes to the water pump.
Maybe a stand alone Mojave heater for heat?
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2003 Jetta TDI wagon, 5-speed, swap, Sprint520 nozzles 165k
2004 passat 1.8t auto 104k
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