'03 Jeep Wrangler TDI (ALH) conversion. @ K-Moes' request

This project was brought to Wetdog's Auto (where I work) last summer. It has been an ongoing since, filling the time between our other customers general repair, and now, my Seca project.

 

As I get the pictures organized, I will post.

 

This swap was based on Cody Built's adapter plates, but required a few modifications, as their kit is for the newer, common rail PD 1.9 TDI. We used an ALH TDI from a 2000 Jetta. The Jeep had a blown 2.4l 4 cylinder engine, and the donor Jetta had a wasted automatic trans. We like to recycle at Wetdog's.

 

First things first. New timing belt and water pump for the TDI.

 

The 2.4l wranglers were fitted with baby transmissions on the U.S. market. So we procured a 4.0l NV3500 and put a heavy duty clutch in.

 

Nice R&D at Cody Built. Flywheel fits perfectly.

 

Clutch mounted.... Shop embarrassingly filthy...

 

"sculpting" room for the new starter position....

 

Cutting passenger side mount base from frame, in order to relocate it farther forward to make room for turbo/manifold.

 

Passenger side mount base relocated.

 

Mocking up the beginnings of the passenger side mount bracket...

 

I decided it was best to pass both pipes through the bracket. That would send things in the proper direction. This presented challenges....

 

With reinforcements, 1/4" plate is incredibly strong.

 

I regret the duplicates. Perhaps I should take a course on posting threads!!

 

The drivers side offered very little room. A ton of massaging here....refitting, grinding... And thats just the base plate.

 

...But eventually this is what it wound up being. Stout. In the top picture you can see I drilled a hole.... I decided to pass the oil pressure switch connector through here. It was almost touching the mount bracket. And I don't like wires touching anything but their conduit. Prudish wires are good.

 

I pulled the radiator and condenser out of the way and began mounting the intercooler......

 

Note the difference in thickness of the grille slats. I had to hand trim each one. I masked them and used a reciprocating pneumatic saw with a broad 24tpi blade. Then sanded smooth with 400 grit, then touched up with paint mixed for us by our friends at Beste Automotive. Thanks Keith for the perfect match!

 

Having fixed the positions of the engine and intercooler, it was time to make paths for boost plumbing, and start tig welding boost pipes...

 

I really cut my teeth tig welding on this project. I suppose I threw my self, deliberately, under this bus. I always wanted to learn. So I read and read. Ultimately, it's trial by fire. One of the more challenging things I've set out to learn. But fun!

 

Boost pipes fabbed up. I had to make my own cones. I used an old trick with masking tape get the reductions. I plan to use a more accurate method when making the exhaust for my Seca.

 

More to come..... I am so inefficient at a posting, mostly due to the fact that I need to come up with a completely new way of capturing and organizing images. It's time for a camera that uses an sd card..... And its time for me to find a way to have view-able thumbnails in my folders so i can search the pictures by image rather than file number or name....Still open to suggestions.

 

Oh....and FYI.... if anyone needs to use a 3.5" hole saw on sheet metal, especially that isn't a flat plane, brace yourself well.... In cutting those pass-through holes in the core support (where the boost pipes loop in and out of the fender wells), my DeWalt drill took me for a few very jerky rides. I still wonder if this wasn't a contributing factor in blowing out my back. Meantime, I'll keep eating bacon cheeseburgers until I'm more firmly anchored.

 

phewwww...... And a correction... The company that provided us with the adapter plates for this swap, is called COTY Built. Not "Cody".

http://www.cotybuilt.com/hardware.html

 

That shouldn't help with the anchoring.

 

As I get conferences over, and myself organized, I will comment.