Step By Step TDI Swap - Part 2: Adapter, Flywheel, Clutch

At this point I have the engine roughed in for fitment, I'll talk about some of the clearance issues and go over the adapter I am using, the flywheel, clutch and installation of those as well as fitting the starter and checking that it engages properly.
Part 1: • How can a 1.9L replace...
Part2: • Step By Step TDI Swap ...
Part3: • Step By Step TDI Swap ...
Part 4: • Step By Step TDI Swap ...
Part 5: • Step By Step TDI Swap ...
Part 6: • Step By Step TDI Swap ...
Part 7: • Step By Step TDI Swap ...
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This product is meant for entertainment purposes only. Your mileage may vary. Do not try this at home. Void where prohibited. Some assembly required. For off-road use only. Slippery when wet. Batteries not included. Do not use while operating a motor vehicle, heavy equipment, cherokee XJ, wrangler TJ, wrangler JK, or any Jeep vehicle, especially the newer Fiat ones. How-to videos may be too intense for some viewers and children under 30 years of age. Please remain seated until the 4x4 ride has come to a complete stop. Studies have shown viewing these videos causes increased cancer risks in laboratory test people. I am not a professional, I have no training, I'm not even particularly good at horse whispering. Don't believe everything that you know. Please keep your hands in the vehicle at all times. Do not tap on glass. Do not eat anything that has been on the floor for more than 3 days. Keep your hands to yourself. Not to be taken internally. Reproduction strictly prohibited. Driver does not carry cash. Objects in Bleepinjeep mirrors may be farther than they appear.
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[@haydentrottier5443]

You are great at explaining things, it gives me the confidence i need to start doing an ALH swap on my 2.5L MJ. I just hope my transmission doesnt cause me too much hassel.😂😂

[@jeremy8715]

This is what I'm looking for. It makes no sense why no one else has made a tutorial for this.

[@moedalgarny]

Every one is busy with donald trump wall and scandels 😂

[@RyanWithAviators]

I'm going to be making a similar tutorial for my 95 Ranger. Same engine, same adapter company. Should be fun. It'll be on my channel at some point after the current CJ7 project is complete.

[@michaelabsher8341]

Did a few of these long ago using a local machine shop to build some adapters... Nothing like wheeling all day and still have 3/4+ fuel left and keeping up with everyone else along the way.

[@DirtRoadTherapy]

haha for real it is amazing!

[@onetruebob_tj]

Excellent work. Great addition to the BleepnJeep Family. 👍

[@gearmonger1927]

really loving these tdi swaps

[@Gewels8787]

Best regards from Germany. I am planing to swap a Lr3 with a 1.9 tdi. Sadly no ready adapter plates around, but your videos convinced me that it must be doable. Thanks!

[@matts_.4494]

I'm a Toyota guy, planning to do this to my 1993 Xtra Cab pick up truck. Lots of good material here for me too. Love your channel. Keep up the good work.

[@gmwesbs]

Love you as an addition to the Bleepin Jeep Family!

[@DRTJon]

Thank you Greg, it's an amazing family and I'm honored to be adopted into it :-)

[@joellake26]

This is awesome! Gives me future ideas for my own XJ. When the motor gives out, or I come up with a donor and the parts.. awesome tutorial! 👍🏻

[@LordLancifer]

Keep up the good work! The audio is better in this video too!

[@Wooskii1]

Awesome, keep it up! Can't wait to see how this all goes!

[@DRTJon]

WoOsKii 1 thanks sir! @bleepinjeepjon on IG for some sneak peaks at what’s going on ahead of the video edits :-)

[@dankennerson2080]

awesome, i'm just pulling my alh for a cj 5. look forward to the videos!

[@Rossco139]

Just wanted to say that, first off, your explanations were awesome. I am doing a diesel/6spd manual swap into my 67 chevy. I am a machinist by trade, as well as a competent welder....so while my skill set is there, i cant build it if i dont know what i need! This video was excellent for filling in some of the gaps, so thank you! Crank adaptor......mint!

[@jeremy8715]

This is awesome.

[@shark180]

Jon this is awesome

[@tuckerwray8529]

Excellent 👌. Well thought-out, precise walkthrough. Made it look easy man!

[@DRTJon]

Tucker Wray thank you sir! Really nothing too complicated so much of it is already thought out it’s just sourcing the parts. Setting up the engine mounts (deciding on engine clocking) was about the most head scratching step thus far

[@matthewhatton3637]

I'm ready to see that beast on the trail! 😎

[@DRTJon]

Matthew Hatton 😩 you AND me, brother! It’s really close

[@matthewhatton3637]

@@DRTJon 🤘

[@matts_.4494]

Found a complete 2002 Jetta TDI yesterday!

[@Dhane-0]

Jon’s a solid addition to the bleepin jeep crew, keep up the good work fellas, can’t wait to see more of this project 👌

[@DRTJon]

Thanks so much Dhane!

[@jake-hy2zb]

I definitely second you motion. Not taking way from anyone else.

[@DO1TOB]

Nice Projekt 😁👌

[@buddy8225]

The AX15 manual is the same transmission Toyota used behind the 22RE engine. They called it the AR150. Loven the diesel conversion.

[@hillbillyxjstyle161]

outstanding work it will make you think thank you for sharing

[@jelly7310]

I'm still digging it....

[@moedalgarny]

And here is the like baby

[@TheIngoBeck]

"I went ahead and JB Welded that up..." 👀

[@my_name_is_chef4856]

What a coincidence. I just started researching this swap. I want to do it to my xj

[@DRTJon]

Wyatt Ditmanson welcome aboard 😎

[@Mr.EricMBlack]

I want to do this to my 01 Limited. Best XJ mod ever.

[@jake-hy2zb]

I did not see the 1st part due to time constraints but am really liking this. Lots of detail on a conversion like this is a good thing. I'll really pay attention as I have a couple of CJ's collecting dust at the moment. Of course my YJ is the opposite end of the spectrum with a 5.2 swapped in. And, ahead of time, I have 3 Grandsons so nothing is for sale. Sorry

[@markdemieville2941]

Putting a Mark on the flywheel bolts is for torque to yield bolts. Torque them to spec, paint a line on the bolt and another at 90 degrees on the flywheel. Then turn the bolt to Lin up the lines. It ensures proper clamping force and bolt stretch.

[@DRTJon]

Sure or if you’re like me and you leave it open for 3 days and do 86 other things before putting it together the rest of the way you can know at a glance that you’ve already torqued that bolt 😃

[@danhambrick6331]

Nice...

[@FiedtheNeedIT1]

What clutch did you go with? I didn't catch it in the video. Can the OEM luk clutch hold the increased torque ? Or should i go with the HD kit?

[@barrybruckner6919]

Good info thanks I want to do this can you update now since you lived with it for a bit

[@keepitsimpleson.withrogers7028]

TDI swap for my samurai would be great

[@bigteddy66]

Seen a samurai/jimny with a 1.3 Fiat td in it was really nice.

[@PMGaming101]

i am so doing this

[@DRTJon]

PMGaming101 do it!

[@michaelhite1433]

I’m working on putting a 02 alh mtdi in my 96 Discovery.

[@RyanWithAviators]

That is an awesome sounding project. Maaan, I always thought the Discos looked cool, but I don't love their wiring and engines.

[@horrified993owner]

If the race pipe eliminates the anti shudder valve, you run the risk of not having diesel run-on protection. Happened to me once with an ancient turbo when the seals blew. Anti shudder saved the engine by closing at redline. Drove the car home in fact.

[@DRTJon]

Conrad Aach debatable. Most people say ASV is not a guaranteed runaway protection. A properly maintained ALH is very very unlikely to ever runaway.

[@horrified993owner]

@@DRTJon good point. I did have mine well cared for. Even checked shaft play every 50,000km so I knew what was up. Didn't know I was lucky on the run on. Guess the charge pipes weren't leaky!

[@thomasj5722]

Are there any kits to use the original auto with the TDI?

[@johnbeechy2913]

Are there kits available for the Chrysler 3500 transmission five speed to adapt to a TDI 1.9?

[@tylerlowery6722]

Do they make an adaptor kit for an auto trans?

[@chorrohumodrift3520]

donde compraste el adaptador el embrague y demas, Buen video y buena adaptación, pienso hacerle lo mismo al mio Gracias por compartir la informacion

[@bobhope5259]

HI John

[@williamdomey7584]

Great videos, if my engine goes looking to do a diesel swap. Is your XJ Lifted? I haven’t been able to find a build on it other then the diesel swap.

[@DRTJon]

It's lifted about 3.5" which is the bare minimum for the track bar to clear the oil pan

[@kyle3861]

Would you please do a very in depth wiring video(s) to show that aspect fully? That for me is the most intimidating...

[@DRTJon]

I will be sharing everything that I have done with it, absolutely. The Jeep side is what I am still working on at this point to get gauges functional. As I talked about in the first video though I did outsource the VW harness modifications and I am VERY happy that I did that. Added benefits of doing that are: simplified removal of VW harness from donor (you don't have to dig wires out of the dash), all new wire, to your specified lengths, generic cheap relays for glow plugs (stock ones are $$), ECU is tuned for the things that are unneeded/removed, every wire is documented in a manual for easy reference, wires are bundled into labeled branches so you can easily divide them up to run them where they need to go, cruise control easily retained, I'm sure there are more benefits, but those are the major ones!

[@kyle3861]

Wow that's awesome and worth it regardless of cost... I can see integrating the stock xj electrical system with the VW being a pain... Definitely looking forward to the run down!

[@SV_Autumn]

Love just wish it was a bit more detailed as I am planning to do the same swap to my cherokee later this summer.

[@DRTJon]

katelyn O'conner detailed in what way? Would you want to see an episode giving a “build sheet”?

[@naterucker]

@@DRTJon That would be rad!

[@DRTJon]

Will probably do it a little later in the series once I am done buying stuff for it!

[@SV_Autumn]

I guess maybe what mistakes you made or things you wish you knew before you started. Also what you did to get the jeep preped for the install. Like what you left in the jeep and why. Hope that helped.

[@DRTJon]

katelyn O'conner for sure! Did you see the first one? I tried to cover a lot of that in the first one but I’ll definitely do a closing thoughts/build sheet episode!

[@matthewreynolds345]

Hey I’m currently doing a alh swap on my yj and my td adapter kits crank adapter doesn’t have a pilot bearing pressed into it. Kinda confused

[@zachary123904]

I used a 93 clutch pedal assembly in my 98 had to cut the top of it and weld some of my 98 mounting brackets to it other then that advance adapters make me a clutch line kit thinking about taking my 4.0 out and sticking a tdi in using a bosh pump off a 4bt so no computer to run it.

[@DRTJon]

I'll talk about that same clutch/brake pedal assembly mod in my next episode! As far as I know a 4BT pump won't work right on a TDI, or if it does it would require significant adapting. Guys running mechanical setups are using pumps from a Range Rover, you can get them for relatively cheap. Your best power and economy definitely come from leaving it electronic, but I think it would be fun to play with a mechanical one too. Join the group "TDI Swapped Trucks" on Facebook, lots of great discussion there

[@zachary123904]

Yeah definitely, your doing a good job though I’m gonna keep up on the progress hopefully everything goes turn key 🤞🏻

[@User-mb6kj]

How does the 1.9 do in a daily driver situation

[@LightWaIker]

You should keep the ASV (anti shutter valve) instead of that race pipe for runaway protection. Put a cable on the butterfly valve for cab control. Cheap insurance from busting the motor due to a oil leak that reaches the intake.

[@gregh7457]

good avice but if he has a manual trans he can just drop the clutch with the brake on

[@DRTJon]

a well maintained engine with a clean intake, and good turbo has very very minimal chance of running away. I'm really not worried about it. If it happens, another $800-1000 donor car which I can then make most of that back by parting out and I'm back rolling again.

[@DenverDaves]

Did you have to modify your transmission mounts at all? Or were you able to just move the motor and keep all of that the same?

[@DRTJon]

I am intending to build a custom cross member, but will be sure to cover that whole subject thoroughly when I get there. Because the engine/transmission needs to move forward you will need to do a bit of fabrication here. I will try to keep things as basic as possible for "stage 1" of the build. I will eventually be running a long arm setup, flipped Dana 300, and Strongbox doubler in between but it will just be stock to start out.

[@manuelmanzanares4175]

hello friends where can I buy the gearbox coupling kit for an xj 2.5 TD thanks

[@sky608]

Where at in pa are you from. I'm from mifflintown

[@Vcoldduck]

Can this be done with an automatic tranny? The jeep trans has a module and I don't know if this can be done.

[@madjeepernh6834]

You are experiencing Farfignugen!!! (sp) Right on man, looks like a fun swap. I don't know much about VW engines, how much of a hp/ torque gain are you expecting? Can't wait to see it rippp!!!

[@ubernewb3005]

zero gains.. 1.9l is 90hp/150tq while the 4.0l had 190hp/225tq

[@madjeepernh6834]

@@ubernewb3005 oooohhhh!........damn! ....ok then why do it?

[@DRTJon]

Justin Lounsbury that’s stock numbers. Stage 3 is a simple ECU tune and injector nozzles bumping to 135hp/240tq which is where I am starting out with this. My next option if I want more power is going to be a turbo upgrade, and new tune pushing to more like 160 hp and 300 ft lbs. All while getting 25-30 MPG

[@ubernewb3005]

interesting.. i definitely have my doubt on that mileage tho, but will definitely be following this series nontheless

[@madjeepernh6834]

@@DRTJon ok, I get it. Your still building up to maga power rangers in time.......I feel better now, lol!

[@keithlea6804]

Hey Matt i have a unrelated question to this video. I have a 96 Cherokee with a 4 inch RE lift. And I found a 99 Cherokee can I put all my running gear on the 99. The 99 is very clean no rust. I have all new every thing on my 96. Just given this super clean body.

[@bleepinjeep]

You sure can!

[@calebj5082]

This better have a hood stack

[@DRTJon]

Caleb Jackson 🤫

[@fazebanksisascammer311]

I got so lucky my boy had some 97-01 pedals laying around, I just 5 speed swapped my 98 in 7 hours lmao

[@DRTJon]

Nick 94 did you get the PCM from it also?

[@fazebanksisascammer311]

Jon BleepinJeep I had one from my last swap, no check Engine lights or anything

[@jared2235]

would love to do the same swap on my 99 sport I have the aw4 though

[@DRTJon]

Jeepn N Creepn easy swap to AX15 if you want, or you can look into making the AW4 work

[@nicholasimhoff1]

I have a manual electric shifter for my aw4 and 4.0 with a torque converter lock up switch. I have disconnected the tcu. I see no reason why this wouldn’t work with a TDI swap

[@maxst2]

@@nicholasimhoff1 think that would be possible in 42re in a WJ?

[@DOCTOR_KIA]

Is there a reason you didn’t use the manual trans that comes with the car? I’m wondering because when I got to do the swap I want to use the manual transmission that comes with the jetta

[@Axle347]

Because the transmissions is different from how the ax15 lines up. which means different crossmember mount. also you would still have to have a transfer case adapter. just easier to adapt at the motor

[@DRTJon]

Yes, the Jetta is front wheel drive/transaxle. It is far more practical to just adapt the engine to a different transmission than to adapt the transaxle to the Jeep.

[@johnathanalvarez6318]

Do you have to change the 4x4 train?? And can you have an automatic transmission?

[@DRTJon]

It can all be stock 4.0 stuff from the crank adapter back. Yes some have done it with the auto trans. You will need new driveshafts unless you want the engine to be tight up against the firewall with no room to change the vacuum pump on the back of the engine head

[@jasonbasonbobason]

Will the gearing in the transmission or diffs be affected?

[@DRTJon]

You'll need to run a gear calculator to determine that in your own build, but the power band of the TDI is not that much different from the 4.0, if anything the RPMs should be kept a little lower now. For me, this was an auto Jeep originally so it has the 3.55 gears (manuals were mostly 3.07) and I am running a 31" tire. It works out to be about perfect for highway cruising. When I bump up in tire size to about a 33 I will likely change out to 4.10 gears. I will give my thoughts on all this in a shakedown video once the swap is complete

[@adamparker8604able]

Is the an adapter for the jeep 4.0 Automatic transmission

[@DRTJon]

This same adapter works. The idea behind all the adapters TD conversions makes is that they make the back of the VW engine "look" like the engine they are replacing. So any transmission that works behind the 4.0 works behind the TDI with this adapter. Making it shift properly is going to take some research

[@yallhatebaadddyoung7356]

Can you use the xj auto trans?

[@DRTJon]

Yes you can, you'll need to give the AW4's TCU a throttle position input. The Facebook group TDI Swapped Trucks has some good info on this if you search

[@tylerwhite431]

Does this work with a auto trans ?

[@Vcoldduck]

I asked that same question -no answer

[@user-hh3lg4ro4g]

good stuff, but way more reasonable to get normal v8 with propane conversion !!

[@MrMrsregor]

but this will get more like 30mpg .!. and propane is not street legal due to no highway fuel tax ...

[@Adam-vc1xl]

I want to see an auto swap

[@Mitchumthegreat]

Lol, autos are for chicks.

[@EvanMoon]

Sweeet

[@juanalverdi8322]

Jon, do you have an email or any way to contactyou? I would like to do a tdi swap on a jeep comanche.

[@ramonpagan9089]

Si There a auto version of the swap

[@DRTJon]

The adapter I am using works just as well with the AW4, though you'll need to create a manual control of the shifting as some have done, or work out how to feed the TCU the signals it needs to shift properly. I will not be covering these steps in this swap. Changing out to a manual transmission is not a difficult step in the grand scheme of what I am doing here if that's what is intimidating to you. If you're just not a fan of stick shift, I understand and with a little research you'll find what you need to make the AW4 work for you

[@ubernewb3005]

maybe i'm missing something, but why do this swap? is it just to say "i has diesel" or what? specs on the 1.9l are a decent bit lower than the 4.0l in both hp and torque. why not just go FI with the 4.0l and actually get more power?

[@nicholasimhoff1]

The tdi responds well to tuning and the fuel mileage is impressive if you put miles on the truck

[@ubernewb3005]

i've seen a few tdi's that people have dumped a ton of money into, and most end up right around where the 4.0l starts off at. for the amount of money spent on motor/adapters/etc it just seems counterproductive to me. and mileage is good in a lightweight econobox, sure.. but add all the added weight of a jeep, with much higher rotational mass (and aerodynamics akin to a brick wall) and i doubt it'll be anything to write home about. hell, i lost 4mpg just putting a/t's on my allroad.

[@nicholasimhoff1]

I guess we’ll see how his swap turns out 🤷🏼‍♂️

[@ubernewb3005]

for sure.. i'm definitely curious to see the results

[@RyanWithAviators]

If you’re interested in the gas mileage comparison between the TDI conversion and the 4.0, check out bleepin jeep’s channel for the video they did on it.

[@poet99999]

slider bolts a a girls best friend when stabbing the trans

[@stevebucuris8420]

That starter is awfully close to the heat from that turbo.

[@DRTJon]

steve bucuris it’s really not, but I’ll be heat wrapping the exhaust down to the flex pipe

[@fixins]

Lock washers don't do anything. From NASA's fastener design manual: "The lockwasher serves as a spring while the bolt is being tightened. However, the washer is normally flat by the time the bolt is fully torqued. At this time it is equivalent to a solid flat washer, and its locking ability is nonexistent. In summary, a Iockwasher of this type is useless for locking."

[@seahorse5677]

what a waste of time, money and a great american engine