Trimmy

Well I sold my 1999 Cherokee with an IRO Long arm kit and 33's because it was very rusty and I was offered more than I had in the Jeep and more then I would every get out of it. I have been surfing the net for a while when I came across a nice 2000 Cherokee with what ?I thought was JUST a cracked 0331 head. I forked over $600 for a Cherokee that was Ziebarted and still had the original floor. The only rust I saw that needed attention was on the passenger rear rail above the rear axle. I figured it was just the 0331 head that had cracked and bought an 0630 head before I pulled it apart. Well I pulled it apart and the head was cracked but it also had damage to the #2 and #3 cylinder wall so I looked around and everyone wanted a lot of money for a 200k motor. Well I have been into TDIs for a while, my wife and I each own a 2010 TDI. So I started talking to my contacts in the TDI community and I have a buddy thats going to source me an ALH motor, harness, and ECU. While he is doing that in the mean time I ordered a gallon of Olive Drab Green fromm Summit Racing because my Jeep came in three different colors and being a Veteran I have always loved OD (even though most of my equipment was Tan).

This is going to be a slow build but it is more for my reference to see what I had and where it goes. The Ultimate goal for the Jeep is OD Green, a 17/22'd TDI pushing close to 180hp, Ford 8.8/HP30, and 4.10 or 4.56 gears with 33's or 35's on an IRO 4" long arm.



So far I have completed and ordered the following.

IRO 4" Long Arm Kit
ALH TDI
AX15
Complete OD Green Color Change

Trimmy

Trimmy

Well I got the motor out. I am kind of sitting idle because I have to purchase all of the big ticket items at this point. I am going to have to give up my Colt AR15 to my buddy for the TDI, harness, and ECU but I hardly shoot it so its worth it to get this build going.



I decided I was going to do a FULL color change so I stripped the engine bay and started to degrease and sand the engine bay.



I pulled the fenders to make it easier to move some of the harness that stayed in so I decided to trim and seal them with paint while I had them off. I missed a small spot on both front fenders, you can clearly see them in the pics, When I fix the hood, and prep the header panel I'll touch it all up.

FRONT BUMPER WILL NOT BE USED I WAS JUST TIRED OF THE BRIGHT RED

Trimmy

I am using an HPA adapter I bought off of EVguy who is also doing a TDI swap, and because of this I had to swap to an AX15 transmission. A little searching the internet and I found a AX15 that was pulled from a 99 because it was popping out of 1st and 4th gear. A little haggling and I had the tranny for $80 with shifter, bellhousing, clutch fork, and pivot ball/spring.

Here it is after I started the tear down to rebuild it. Turns out I needed a full rebuild kit so I only have it split not completely disassembled at this time.

Trimmy

Well today I bought a cheap 12ton harbor press to rebuild my AX15. Everything went well, I didnt get really any pictures because the gear oil was nasty and I didnt want to change gloves every few minutes or touch my phone.

Here is one picture I did manage to take during the rebuild. I bought this tranny for $80 because it was popping out of 1st and 4th gear, bought a rebuild kit with new cage bearings for $165 and glad I did the 1 and 4 synchros were messed up and the inside of this thing looked terrible and the cage bearings showed wear.



I have gotten a little time also to get some more of the jeep painted. I got the drivers side door jambs prepped and painted, got the bottom of the hood, header panel, headlight buckets and grille painted. I also trimmed down the engine harness incase I decided to try to make my gauges work instead of buying HPA's CAN box. I then installed all the wiring back into the jeep.






I absolutely love this color. My engine/tranny adapter should be here Tuesday or Wednesday. I really hope to have more time to get the passenger side jambs prepped and painted, and get the hatch prepped and painted so I can build a makeshift paint booth in my garage to paint the rest of it so all I have left to do is get the motor, lift, and wheels figured out.

Trimmy

Well yesterday I picked up a wrecked 2000 Jetta TDI 5spd for $1000. It runs and drives, best thing is with the 5spd transmission and a few other good parts on the car I will be able to make all of my money back after selling it all off.

Here are some pics of the car.

Trimmy

Well today was a good day for me. I pulled the motor and trans, wiring harness, and tranmission out of the Jetta. My HPA adapter also showed up today.

HPA Adapter




Here is my complete powertrain for the jeep. TDI in the middle, rebuilt ax15 on the left and np231 on the right.

Trimmy

Here is whats left of the Jetta after pulling everything I needed.

TFitzPat87

Subbed! I'm subbed on evguys build too. Love this idea! I have no where near the knowledge to do something like this though.

Looks good! Usually I'm not a fan of the OD green but what you've done so far looks real nice! Can't wait to see where this goes! Keep it up!!!

Trimmy

I was hesitant of the OD green at first because I have seen so many shoddy jobs but I absolutely loved it on our humvees I used in the military so I figured why not. Summit Racings Urethane Single Stage is a very easy paint to use and it has turned out awesome so far. I really hope to have the rest of the jeep in OD green within the next 2 weeks so I can focus on getting the motor in.

Trimmy

Honestly its not that hard of a swap, there is a lot of info on the internet to get you goin. The wiring isnt as bad as most people think or at least do far it hasnt been to bad lol.

TFitzPat87

Well, I'll do my research and maybe down the road look at taking it on.

Good luck!

Trimmy

I hope to be able to post the hard stuff like the wiring for everyone else so its not a hard swap for someone to take on.

Trimmy

Well I tore down the TDI today to get it ready for the timing belt kit I ordered Sunday from IDparts. This is my fourth TDI timing belt job and this is the absolute worst looking timing belt I have ever seen. I hate it even being on the motor while I am waiting for the new one to come in.





I also decided to do a little sand blasting today. The bottom of the Jeep is in great shape, rust wise so I decided to sand blast the the rusty areas to keep it from rusting out from under us.







After I got the sandblasting done I decided I was still up for working on the Jeep. Well I really need to get it all one color so I decided it was time to finish the door jambs. So I prepped and painted them. The hood was also ready and I mixed a little extra paint and didnt want to waste it so it got sprayed as well. This is a Jeep it will be used offroad, it does have dents and will have more after we start using it. So with that said you'll see some dents in the hood. I am not wasting my time fixing dents that more than likely will be back in a year or so.







This was a good place for me to stop today.

Trimmy

Well I have been working on my harness a lot lately and decided to post up some pics of it. I have used a haynes manual for the wiring mainly because it was free and so far has provided everything I need. The following is what I have so far and think its all I need.

Harness
12v constant supplied to pins T121/1&2
Ground supplied to pins T121/4&5
Keyed Power from jeep supplied to T121/37 (10a fuse)
Keyed Power from jeep supplied to T121/88 (5a fuse)
Keyed power supplied to T10f/5 (N146 quantity adjuster/injection pump harness 15a fuse)
Keyed power supplied to T10f/10 (N108 cold-start injector/injection pump harness 15a fuse)
T10h Connector unmolested running to the gas pedal
G70 (MAF) (10a fuse) and N75 (10a fuse) running from sensor to ecm
Keyed power being supplied to T5/2

109 Wiring
12v Power (110a fuse) coming in to red, 2/30,
T121/18 connected to 9/85
Blue 6/87 running to power N108/G70/N75/N146.

Glowplug Relay Wiring
Pin 1: T6/2 to ECU t121/42
Pin 2: 12V Power
Pin 3: Ground
Pin 4: Glowplug harness
Pin 5: No Connection
Pin 6: Glowplug harness
Pin 7: T10e/8 to ECU Pin T121/33
Pin 8: No Connection
Pin 9: 12v from 109 relay

Misc Wiring
T121/27 is Tach Signal
T121/40 is Glow Plug Light
T121/16 is Signal to OBD Port
T121/24 is CEL