CJ3A Volkswagon TDI

Hi guys. I havent been on here much lately but thought I would share my current build with you. I bought a basket case cj3a back in November. The previous owner had done some work to it but all that needed corrected and there was a lot of other work to be done. From November to February I worked at bringing it back to life. I finished the tub and got the old flat head running but then got the great idea to do a tdi swap. No one makes an adapter to use the t-90 with the VW diesel so I made my own. I wanted the jeep to look and fell like a willys only with the diesel engine. To the drive train is all willys and its in the stock location. Here are some pictures of the past few months. I will try to post updates as I finish it up. THanks!

The day i brought it home.


Body and seat frame work




Body mock-up


After gettting through 1" thick bondo


Rebuilt trans & t-case


Primer and paint begins

 

More paint work and wheels!




New Rubber:


Small details coming together

 

What tires are those? They look tall and thin, just like I like

 

This is about the point that I decided to do the diesel swap........
I started taking measurements and making my transmission and flywheel/crank adapter.

Here is the engine before I started working. its a 2001 alh tdi. rated at 90hp/160 ft.lbs. It have kept it electronic so I can easily upload new tunes to increase the power if I want. I have the same engine in my daily driver it has a tune and different injectors and it its at 135hp and 235ft.lbs! So there is great potential for more power if needed. Accourfing to the internet this engine weighs 200 pounds less than the l-head.



Prototpe adapter made out of corian.






L-head removed


Starting crank adapter






TDI engine with willys flywheel



1" thick plate for trans adapter.


Adapter almost done....

Adapter with mini willys starter complete!

 

The tires that came with the jeep were 9x34 super swampers.....but they were way too big and heavy for my tastes. SO I got a set of coopers 215/85-16's still aggressive but much more proportioned. I also removed the 4" lift springs and installed new stock height springs.

 

Engine mocked up in frame. I had to cut the firewall in order to maintain the factory location of the drivetrain.



Because the TDI has a big filter housing and oil heat exchanger I had to make a relocation plate. It took me forever to make it....then I realized I made it more complicated than I had to, but it works so now I know for next time..... haha!



Steering box/shaft was super close. I made some changes and its all good now.


Done: It retains the electronic VW sender and also the willys mechanical gauge.


Collecting parts:


Switched to a bronco II radiator:


Radiator in place. It fits really well and should cool much better.



Could be a good option for other jeep engine swaps.


Custom Coolant lines! haha!


Diesel Fuel return line from injection pump.

 

Oil cooler install:


Intercooler install.


Its alive!


I am running a reverse alternator setup since i have so much room in front of the engine, so I fitted a reverse cooling fan for the alt.


The whole shabang!




alt. setup




Its running and charging!





This engine requires a MAP sensor so I made this port. It will be welded to the intercooler piping.

 

Your work is awesome! I cant wait to see you post video of this thing running and driving! The Bronco 2 rad looks like a direct fit... What did you need to modify to make it fit? Stoked on this.

Well you beat me to the running part..

This is great!

 

The engine also needs a MAF sensor, so I converted the factory filter housing to a paper element and adapted it to fit the VW MAF sensor.







This engine needed a new turbo so I pulled the old one and prepared the new one and cleaned/ painted the intake.

I had to install the egr delete, and re-clock the compressor for my application.



Getting the block ready for turbo/intake.


So this is where I am currently at with the jeep..... I am working on intercooler piping and some other plumbing. Once its all buttoned up and im happy with everything I will pull the engine, weld up the firewall, paint the front end and re-assemble everything. I will keep you posted. Thanks for looking!

 

I seriously love this.

 

Thanks chris! I had to lower the plate with holes that the stock radiator bolts to. About 1.5" Then I had to notch the bottom of the rad to clear the nut on the bell crank. Then just made little tabs to hold the top of the new rad. I would be about an hour or two to put one in a stock cj2/3. Plus its only $75 and in stock at advanced auto parts.

 

Thats great! Great price too. I think my radiator is too big for my purposes and takes a long time to heat up all the coolant which make the temp fluctuate quite a lot when the thermostat opens and closes until I get about 10 miles into a drive.

 

Wow! Really nice work. Has to be the fastest build ever. I am going to have to go back and read it slower to absorb everything. Thanks for answering the tire and radiator questions. I was ready to ask both of those.

 

Incredible!!

 

that's a little bit of awesome right there.

 

Wow.....just.......awesome!!

 

Thanks guys! sorry to withhold from you. It wasnt meant to be a secret....I was documenting it over on the cj2a page, just because it was a flatfender. lol I will post to both pages for the rest of the build. Im waiting on some parts and free time to continue. Stay tuned. Let me know if you have any questions. I hope someone else decides to do a TDI swap!

Here is a little side project I did... Since i have no need for the stock timing hole cover from the l-head engine dust tin, I made a key chain out of it. Willys on one side, VW on the other.

 

It's all beautiful.

 

I saw it on Facebook a couple days ago. Looking sharp