Project: PolarXJ (M-TDI XJ)

PickleRick

Veteran Member
Joined
Nov 29, 2017
Location
Greenville sc
TDI
05 GLS BHW sedan 5 speed conversion. BHW Carver SantaCruz in progress
There will be no Lord Stanley's cup playoffs in Pittsburgh this year for the first time in 16 years. Other than to buy a diesel xj, there's no reason to go to Pittsburgh until football season starts. Even then be very aware you'll still have to put up with a predicable Canada offense.
 

6_DoF

Veteran Member
Joined
Sep 23, 2022
Location
Black n Gold Territory
TDI
1.9 ALH XJ
There will be no Lord Stanley's cup playoffs in Pittsburgh this year for the first time in 16 years. Other than to buy a diesel xj, there's no reason to go to Pittsburgh until football season starts. Even then be very aware you'll still have to put up with a predicable Canada offense.
oh man! i hadn't even heard the Pen's were out yet ... *** is my dad going to do now!?!?

i know my wife would be pretty excited if this XJ found a new home :LOL:
 

6_DoF

Veteran Member
Joined
Sep 23, 2022
Location
Black n Gold Territory
TDI
1.9 ALH XJ
went thru my spreadsheet and have more into this little thing than i originally projected. that coin could have (might still?) really helped my other projects.

Buying the jeep, jeep repair parts, completely new adjustable suspension, wheels/tires, plus some DIY rock bumpers i haven't built yet
... "invested" $3350

the TDI, mounts, fuel system, repair parts, intercooler bits, more bits, Whitbread trans adapter, Fast Forward stand alone harness/ECU tune/ .260 injectors
... "invested" $5750

then the unused parts, the Hans MTDI pump and .216 injectors
... wasted $550
 

6_DoF

Veteran Member
Joined
Sep 23, 2022
Location
Black n Gold Territory
TDI
1.9 ALH XJ
Funny how quick you dump money into projects... I'm just as guilty of it.
no joke ... this jeep was all good stuff, i just didn't plan on lifting it when the engine dictated that. the "efi to carb" fuel pressure regulator made the fuel system more than i thought. and it really went south when i found the MTDI was a scam.
 

6_DoF

Veteran Member
Joined
Sep 23, 2022
Location
Black n Gold Territory
TDI
1.9 ALH XJ
bump, the jeep is officially for sale. asking for just what i have in it.

 

6_DoF

Veteran Member
Joined
Sep 23, 2022
Location
Black n Gold Territory
TDI
1.9 ALH XJ
well, as expected, no one wanted to buy the jeep in it's current state for my current investment. was hoping i might get lucky. i hadn't fallen in love with it, but now that i've been driving it more i'm starting to. so back under the knife it goes to start fixing some of these issues.

first big question, the .216 injectors i got from Hans before realizing the scam ... opinions on if they could hurt the motor? when i ordered the FastForward harness/tune, i also ordered .260 injectors with the idea of future proofing the build and diching hans injectors. probably too much injector for anything i would do anyways, but also didn't realize he didn't have a can'd tune for them. even though i bought tune and injectors together. his stage-whatever tune is for something less and it's just pig-fat on fuel if you get into the throttle much. it's a very fine line between enough throttle to request full boost, and too much fuel it's putting the fire out.
 

J_dude

Veteran Member
Joined
Jan 9, 2020
Location
SK Canada
TDI
2003 1.9l “Jedi”
well, as expected, no one wanted to buy the jeep in it's current state for my current investment. was hoping i might get lucky. i hadn't fallen in love with it, but now that i've been driving it more i'm starting to. so back under the knife it goes to start fixing some of these issues.

first big question, the .216 injectors i got from Hans before realizing the scam ... opinions on if they could hurt the motor? when i ordered the FastForward harness/tune, i also ordered .260 injectors with the idea of future proofing the build and diching hans injectors. probably too much injector for anything i would do anyways, but also didn't realize he didn't have a can'd tune for them. even though i bought tune and injectors together. his stage-whatever tune is for something less and it's just pig-fat on fuel if you get into the throttle much. it's a very fine line between enough throttle to request full boost, and too much fuel it's putting the fire out.
Not sure I’d want to run questionable injectors, that could end badly. If you need tuning talk to @burpod.
 

PickleRick

Veteran Member
Joined
Nov 29, 2017
Location
Greenville sc
TDI
05 GLS BHW sedan 5 speed conversion. BHW Carver SantaCruz in progress
Another vote for contacting @burpod or trying to barter for a set of smaller injectors. There's gotta be someone with a Jetta here who's tired of 250hp and needs bigger injectors.
 

burpod

teh stallionz!!1
Joined
Nov 27, 2004
Location
cape cod, ma
TDI
82 rabbit vnt ahu, 98 jetta vnt ahu, 05 parts car, 88 scirocco.. :/
if you're unhappy how it's running, it's amazing what a change in tuning can do... :) i absolutely love the 11mm/.260 combo.. (regardless of how big your turbo is). drives absolutely fantastic in my mk1 rabbit tdi. no moke.. stellar mpg.. gobs of power when desired.....
 

03Golfer

Veteran Member
Joined
Apr 8, 2020
Location
Canada
TDI
03 Golf, 92 Toyota swap (ongoing)
Which .260 injectors do you have? I have some .230 polish injectors setup by Giles at performance diesel, I'm interested in a swap.
 

burpod

teh stallionz!!1
Joined
Nov 27, 2004
Location
cape cod, ma
TDI
82 rabbit vnt ahu, 98 jetta vnt ahu, 05 parts car, 88 scirocco.. :/
Which .260 injectors do you have? I have some .230 polish injectors setup by Giles at performance diesel, I'm interested in a swap.
i have the ones from xman (i believe powertdi supplies them) and have tuned others from them, .230s
 

03Golfer

Veteran Member
Joined
Apr 8, 2020
Location
Canada
TDI
03 Golf, 92 Toyota swap (ongoing)
Sorry for the confusion, was asking OP since he indicated he has. 260s he ordered at the same time as his harness and he would like to trade them for some smaller ones.
 

burpod

teh stallionz!!1
Joined
Nov 27, 2004
Location
cape cod, ma
TDI
82 rabbit vnt ahu, 98 jetta vnt ahu, 05 parts car, 88 scirocco.. :/
oh. smaller. smaller is bad lol. bigger is better with the right tune, IMO. but everyone can choose their own path... i would never consider going back to baby nozzles. .like i said, even if i had a baby turbo :D
 

6_DoF

Veteran Member
Joined
Sep 23, 2022
Location
Black n Gold Territory
TDI
1.9 ALH XJ
he did try and sell me the custom tune/service, but i knew i might be changing things around before too long and didn't want to have to pay the extra again. i didn't figure the generic would be that different. oh well, miscommunication i guess.

i just picked up a VNT-17 from an 05 Passat, needed to move the turbo up and forward for better engine mount access. shout out to @jimbote for that. the extra air should also help. guess i'll be staring a chat with burpod! if you say the .260's are good, then game on.

wife was bored and i was able to talk her into helping re-cover the headliner in the jeep. she set it all up and cleaned off all the old foam, i just helped lay the new fabric and screwed it in. that was a huge win.

while she did that, i started tearing things apart. everything out so it can go back better. swapping trans with a buddy from the nv3550 to his AX15. he wants the lower 1st in the 3550, and I'm more familiar with the ax15. i have one in another jeep, already rebuilt them a few times, etc. so it'll get a rebuild before going back in too.

it's amazing how well the TDI and jeep trans/t-case hang from the one lifting eye on the head!

lots of other to-do's ... gettin my a$s in gear!



 
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6_DoF

Veteran Member
Joined
Sep 23, 2022
Location
Black n Gold Territory
TDI
1.9 ALH XJ
i gotta say ... i expected to see more difference between the 15 and 17. doesn't matter though since it was all about location. this 05 Passat set is WAY better for the jeep!

 

6_DoF

Veteran Member
Joined
Sep 23, 2022
Location
Black n Gold Territory
TDI
1.9 ALH XJ
so i traded the NV3550 that was in the XJ for an AX15. it needed rebuilt and I'd rather rebuild an ax15 for it. when i traded my buddy straight up trans for trans ... mine came in a sh!tbox 🤦‍♂️ it was so bad i knew everything was going to fight me, forget working under it. quick can-opener'd that junk and easy access!

after seeing in the bell, I'm worried this trans needs an exorcism, not a rebuild ...





 

6_DoF

Veteran Member
Joined
Sep 23, 2022
Location
Black n Gold Territory
TDI
1.9 ALH XJ
That 1st Gen is a beauty
thank you! i've jumped off the new vehicles bandwagon officially. picked this up a year and a half ago in Mississippi n drove it back to PA. slowly going thru and mechanically detailing out the truck to hopefully drive it for years to come. lots of work done, lots to go.

build thread:


 

PickleRick

Veteran Member
Joined
Nov 29, 2017
Location
Greenville sc
TDI
05 GLS BHW sedan 5 speed conversion. BHW Carver SantaCruz in progress
Have you rebuilt an ax-15 before? A thread I follow on ih8mud had a few pages where he built an r150f with some upgrades marlin crawler parts. Didn't look too difficult if you have some pullers and a press.
 

PickleRick

Veteran Member
Joined
Nov 29, 2017
Location
Greenville sc
TDI
05 GLS BHW sedan 5 speed conversion. BHW Carver SantaCruz in progress
I have an r150 that had water in it when purchased. A few bumps to the output shaft while in gear she spun freed up. Had a 3rd gear up shift grind most of the time unless you revd it up pretty high to speed shift and always had a 3rd down shift grind. Id love to swap in an ax-15 5th and install some heavy duty marlin crawler internals. Would you mind posting pics of your rebuild process and any common wear areas id want to examine while in there? I'm going to tear it down to inspect this winter, if it looks salvageable I want to do the work myself but don't want to do it blindly. My first go at a Ford RTS top loader wasn't very successful, luckily the parts were cheap and didn't take much other than a tow bill to get it right the second time. The aisin parts are much harder on the wallet.
 

6_DoF

Veteran Member
Joined
Sep 23, 2022
Location
Black n Gold Territory
TDI
1.9 ALH XJ
i'll do what i can, but feel uncomfortable posting a full how-to without doing more first. anything i find for tips n tricks, tools, etc though ... stay tuned!
 

6_DoF

Veteran Member
Joined
Sep 23, 2022
Location
Black n Gold Territory
TDI
1.9 ALH XJ
step 1: dump oil on yourself forgetting you didn't drain the trans first.
step 2: drain the milkshake out of the trans from the prior owner
step 3: tape the holes up and pressure wash the BS off and the demons out of the trans
step 4: dump more oil on yourself cuz why wouldn't it have all come out before
 

6_DoF

Veteran Member
Joined
Sep 23, 2022
Location
Black n Gold Territory
TDI
1.9 ALH XJ
well ... that chit did NOT buff out ...

most of the trans came really nice and clean. worst case more staining than pitting from the rusty bits. 2nd and 3rd gears however are fully fubar, no hardened gear face left on too many teeth. i ordered those 2 gears from Allstate Gear, hopefully they come soon.

so i figured i'd try this. after using a 2-bolt puller to get 5th off the counter shaft, and unbolting the plate to get reverse out of the way, pulled the bearing circ-clips and the shift fork bolts. both shafts slid out the front while the shift forks slid off the rails. i feel like this might take 3 hands to get back together, but is way less teardown and less parts to loose by leaving the shift rails entirely intact. even the complete reverse lever is still mounted to the mid plate.


 

6_DoF

Veteran Member
Joined
Sep 23, 2022
Location
Black n Gold Territory
TDI
1.9 ALH XJ
that damn TJ keeps getting more entertaining! this POS tail housing must have felt left out and now identifies as rusty ... :james:

trying to decide what to do about it.

NP231 i was using is now all back together with the long input shaft for the ax-15, and all new seals. i cut up the exhaust down pipe so i can remake it for the new turbo location. and got the passenger engine mount cut up for reworking for the new hydraulic mounts, along with fitting the new turbo brace. new 2nd n 3rd gears show up today, hopefully get the trans together except the tail housing ... i'd really like this thing running again soon.




 
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