Had to swap the battery and airbox from side to side.
A Ranger 3L airbox fits well with some modification.


and the battery fits well on the drivers side.

[url=https://flic.kr/p/wwzfd8]

 

So purdy. Apparently the rust on the coolant bottle bracket isn't factory

What did you need to do to the Ranger air box? It looks significantly smaller than the one in my Mk4.

 

It's amazing what you can do with modern chemicals, not that you want to get any of it on you.

The airbox was one of three that I got from the wreckers.
All three were the same and were from 3L and 4L trucks in the 05-08 range.
I did have to remove a good portion of the bottom/firewall side to snuggle it up to the wheel well but that's all below the filter so its not very important. Still have to add a hose barb fitting for the crank case vent.

 

I thought I would post this short video.
This Ranger conversion is the reason I have not got much done on the Cherokee.
Now that the Ranger is finished I can get back to the Jeep.
Should have lots to posts next week!

Ranger TDI video:

 

Wow. What a great build! Very impressive work. Sub'd for sure!

 

That ranger is a work of art! Looks like it came factory if you hid those vw/audi logo's However I can't quite help to think it needs a tune, larger turbo, and larger injectors!

 

Thanks!
The Ranger was the "test run" with just a Malone stage 2 tune.
The Jeep engine has a bigger turbo, Colt stage 2 cam, Malone stage 4 tune and 2.5" Magnaflow exhaust.

 

That's such a clean Ranger. Couldn't help but notice that those 1.9's are pretty darn loud. Was it the camera maybe? I love so much about the idea for a diesel jeep, but the diesel clank and fumes are usually what turns me off from most of the swaps I've seen personally.

What kind of steps do you guys take for dealing with smell on your swaps? Or is smell not usually an issue considering the whole fuel system has just been overhauled in prep for diesel?

If i could choose any motor for a DD truck or small SUV it would be a small displacement turbo diesel. But if it truly is a DD, then things like smell and exhaust db's and diesel clank have to be at a bare minimum. Any sort of special steps that you guys in particular take? You're fab work is excellent, just thought you might have a few tricks up your sleeve concerning that stuff too.

Cheers

 

I was quite surprised at how loud the video was. Its not like that in person.
Once the hood is closed its pretty quite, still a bit of diesel rattle but not too bad.
Just have a listen and smell ;>) of a late model VW Jetta TDI. They are pretty quiet and unless you are sniffing the tail pipe they don't smell.

 

Nice! So that was just a stock BEW with a Malone Stage 2? Sweet

 

Continued great work; I cannot wait to see you button up the TDI in the XJ. As I am saving my pennies for this swap, you are providing tons of inspiration!

 

I started to deal with the TDI wiring harness.


After stripping off all the looming on the harness it became obvious that this is really two separate harness and might be much easier to deal with as two separate harnesses.


One is just the engine harness and one is mostly the chassis harness.
There were only a few wires that crossed over from one to the other so I installed a Weatherpack 6 pin connector between the two harnesses.
Here is a modified harness and the added 6 pin jack at the top middle.



I called my local VW dealer and gave them the VIN# of the TDI car and they printed off a stack of diagrams showing each pin on the ECU and where it went. Too bad they did not email it or I would post them.
I'm sure "most" dealerships would do the same.
Just have to finish looming this engine harness and its ready to go into the Jeep.
The chassis harness is next.

 

Slick. Your VW dealer is nice! Surprised they didn't tell you to pony up for the FSM

I'm impressed that you're doing this without a Bentley

 

Yea, I don't have a Bentley but I do have a Westley and he is doing pretty good at figuring out the VW info.

 

nice build super clean work!!