Forest Service 3A

I surgically removed the throttle pedal from the car today. The torch made short work of it.



After cleaning it up and adding some mounting tabs, it’s mounted in the Jeep.

 

A little progress during the week. I bent up a piece of steel tubing for the heater/oil cooler suction. I could have used hose, but eh, it would look like . I used a molded 5/8" U shaped hose on one side and a molded 5/8" 90 on the oil cooler side. I also made up my lower radiator hose/tube.





And then I made up my upper radiator pipe.





I welded bungs in for my electric fans, temp gauge and hot water for the heater.



And its all installed!

 

Brilliant!!

 

is this all after the thermostat?

 

So, the tdi cooling system is bass awckwards. The thermostat is where the lower hose connects to the water pump. Hot water will be flowing through the upper radiator hose and to the heater core and sucked back to the pump via my steel tube I bent.

 

Finally it’s done! Lots of aluminum welding which I was enjoying. I was really getting into the piping aspect of the project.

 

Here's a short video I put together of my jeep.

 

So what's the summary of TDI vs L134 in initial use?

 

It certainly has more giddy up and go and more torque. So far I like it, just need to drive it more to see how it really compares.

This swap certainly isn’t for the novice. There is tons of fabrication work involved, more so than a V6 swap. No to mention the wiring and having everything look neat and tidy.

 

Very nice job! Quiet and smooth diesel.

 

Ace.

 

Been driving it around quite a bit. I am impressed. Hills that I could only climb in 1st overdrive before I can now climb in 3rd overdrive!

 

Like a whole different Jeep.

 

That's for sure, I towed the Bantam today with 4 jeep wheels and tires in it. I didn't even know it was back there.

 

Very,Very Nice work , Nate.......You do Cool Stuff, my Friend.

 

Now that my Jeep can cruise down the road and maintain speed, I wanted a set of street tires. I cleaned up some aluminum wheels I had and mounted some more road friendly tires on them.

 

Those swamper arent nice on the road, i understand the need for a road friendly tire

 

So on Thursday I learned, DO NOT TAKE THE INJECTION PUMP APART! Why you might ask? Well, it was leaking fuel, so I researched it and there are two rubber gaskets that looked easy to replace. I ordered the $26 kit to do the repair myself. That turned out to be a mistake. I put it all back together and it wouldn't start. I did all the proper bleeding procedures and blah blah blah. No go. Checked codes, had a code for fuel quantity adjuster max limit reached. Back on the computer I go. Seems like that is a death code for the injection pump!

Luckily, I knew the local junkyard had the same exact car that my engine came out of. I went there Friday and pulled it out. A whopping $10 later, I was the proud owner of a $1000 part. I think this one is a remanufactured one too. It has all the markings that come with rebuilt pumps and was very clean. The injection lines are in much better shape as well. I would say it was a major score!



The tight working conditions.



Old pump removed.



Both pumps side by side.



I just finished putting it back together and what a difference! Ted starts much easier now and a whole lot less smoke upon starting. I think my old pump was on its way out. Glad I did the swap now and I have a core to send in for a rebuilt one.

 

Thanks for the TSB, " DO NOT TAKE THE INJECTION PUMP APART! " ...... I'll say this for all of us : Now, most of us will never attempt that repair. Until, of course , one of our members will be an injection Pump genius.

 

But youtube made it look so easy!