Topic: TDI Swap Updates Anyone Done it?

[RNandKT]

I was sifting through old threads on the VW TDI swap from HPA motorsports and several people have said they were going to do it, but can't seem to find any write ups ... pictures ... reviews ... even HPA seems to only have 1 YJ they have done it on.

So anyone done the swap and how did it turn out? How hard was the swap and what was the final cost? Most importantly how does it drive and what kind of MPG's? HPA says 40-47 MPG but I have a hard time believing that with big tires and the aerodynamics of a cinder block ....

[sharpxmen]

hasn't been done here yet

[RNandKT]

Too bad ...

I found a couple of videos of people running the TDI in Wranglers's

http://www.youtube.com/watch?v=yM7480iKNuc

http://www.youtube.com/watch?v=JMbetbc7OBE

[Jeffy]

Wow, I haven't been to HPA's site in a while.  They sure have jacked the prices up quite a bit.  $5980 will get you everything but the engine and gas pedal, if I read it right.  Also for an AX-5 you need to ship the flywheel to them and so there is a $200 core charge.  Might as well swap to an NVG-3550 or the NSG-370 while you're at it. Though they don't say which one they're using.  I'd assume the 4.0L as it was more common.

Mileage, I'd guess to be mid-high 20's in the City and mid to high 30's on the Highway.  Although they run 4.56's with 35's and that's pretty high for gearing.  I'm sure you could coax the highway mileage into the 40's if you tried.  Keep the speed down below 65 mph, or more precisely 50-55 mph. I could see it happening.

Like with most swaps, cost is the biggest factor.  That and the skill set to be able to install it.  Then there's time.  I think the majority of members drive their jeeps daily and it may be their only vehicle.

Other thing to consider is for the price of the "kit" you could do a reman. 4.7L Stroker with complete drivetrain and have it in a fraction of the time.  A pre-Vortec 5.7L could be done as well.  You might even be able to do a Vortec 5.3L.

[Mozman68]

http://www.wranglerforum.com/f5/my-diesel-tj-202985.html

[Jeffy]

http://www.wranglerforum.com/f5/my-diesel-tj-202985.html

Was he ever able to get it SMOG'ed?  That's the only thing that not really mentioned on any swap.  The emission check diesels from 1998 and up which sucks.  At first it was 2006 and up, IIRC. Might have to ask HPA and see what they say.  Here's what CA checks;

Diesel Inspection Procedure:

Visual Test
OBD II Test
Visible Smoke Test
Visual Check List:

Positive Crankcase Ventilation "PCV" or Crankcase Depression Regulator "CDR"
Diesel Oxidation Catalyst "DOC"
Diesel Particulate Filter "DPF"
Nox Absorber
EGR
Fuel Injection
Temperature and Pressure Sensors
Wiring of Sensors/Switches/Computers
Vacuum Line Connections to Sensor/Switches
Other Diesel Emission-Related Components: Turbo/Supercharger, Exhaust/Intake, etc.
OBD II Check consists of:

"Check Engine Light" (MIL) is Operational
MIL on/off
OBD Readiness Status Codes

[Mozman68]

 Thankfully, something I don't have to worry about in Michigan. No inspection...of any kind...

[aw12345]

No inspection needed in Michigan after a year or two you can pretty much see through the whole car or truck anyway 

[Jeffy]

Thankfully, something I don't have to worry about in Michigan. No inspection...of any kind...

I was just curious if he did it before moving.  It looks like 2003-2006 just have cats before the muffler.  When you get to 2009, you get this mess.

<a href="http://tdi.vw.com/files/2009/05/exhaust2_568x345.jpg" target="_blank" rel="noopener noreferrer" class="bbc_link bbc_flash_disabled new_win">http://tdi.vw.com/files/2009/05/exhaust2_568x345.jpg</a><a href="http://tdi.vw.com/files/2009/05/exhaust1_568x345.jpg" target="_blank" rel="noopener noreferrer" class="bbc_link bbc_flash_disabled new_win">http://tdi.vw.com/files/2009/05/exhaust1_568x345.jpg</a>

[grumpygy]

 

[Jeffy]

Hmm, I doubt that since the pics are from VW.com.

[chardrc]

picture works for me... thats a lot of extra emissions equipment to fit in. that stack looks longer than the entire run from downpipe to muffler on a yj (from what i remember). Would be tight on a 2 door jk also unless you put some of it where the stock muffler is.

[Jeffy]

picture works for me... thats a lot of extra emissions equipment to fit in. that stack looks longer than the entire run from downpipe to muffler on a yj (from what i remember). Would be tight on a 2 door jk also unless you put some of it where the stock muffler is.

I think the setup pictures is the reason HPA uses the 2003-2006 engine.  I think 2007 was when they started selling in CA and some other restrictive states.

[stan98tj]

The wranglerforum guy seems to describe being more or less on his own when doing the swap. Talking to HPA made it seem like they provide a healthy amount of the components including wiring harness (that can be purchased separately). Wonder if this is a far larger headache than I originally thought. I'm gonna have to talk to them again and see exactly what I'll need to complete this. Of course, on my end I'll be trying to swap this for an automatic and it's still up in the air as to whether I'll be able to use that trany.

[jagular7]

I really liked the write-up on a kubota v2203 install into a tj. Check out bigfootexpedition on youtube. IIRC the write-up is on 4btswap.com under other diesel or something like that. It's dual turboed as well.