Step By Step TDI Swap - Part 6 - Coolant System and Intercooler

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This time we're talking about cramming all those fancy finned aluminum boxes up behind the grill. Will they all fit in there?
Here are some common questions about this stage of the swap that we'll talk about:
Can you use the XJ radiator?
Is the stock radiator too large or small for the TDI?
Are the outlets in the right place?
Do you have to relocate the radiator?
Can you still fit an AC condenser?
How large of an intercooler can fit, and where to mount it?
How did you route the hoses?
Should I buy cheap silicone?
This one is a real information dump, and answers a ton of helpful tech info that could otherwise slow down your swap progress significantly. Cozy up with a note pad to watch this one and hit that SAVE button cuz this is one you're gonna refer back to a bunch!
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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1 мар 2020

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Комментарии : 78

@dre04mach 6 месяцев назад

The diagram at 10:58 is spot on the best bit of information I found for this swap!

@idjeepindude320 4 года назад

Thank you for all the info, really informative. A lot of work goes into a swap like this more than most people realize!

@DRTJon 4 года назад

FUN FACT: every shot of the Spool Bus driving at the beginning is with the stock VNT15 turbo :-)

@bradtyson 4 года назад

Gtb2060vklr is good for 300 and spool very well with ball bearings rather than journal for longevity and reliability* an ASZ or ARL engine code intake manifold is a good mod over standard too 👍🏼

@andrewsapp856 Год назад

Jon these videos are the best. The time you put into these did not go unnoticed. Thank you!

@DirtRoadTherapy Год назад

@@andrewsapp856 Much appreciated brother! Saw you subbed to the DRT Jon YT but I don’t post there really. You can see current Spool Bus adventures by clicking on my Dirt road therapy user name here 👈🏼

@amorag59 4 года назад

The coolant routing drawing helped a ton!

@nicholausstraach458 3 года назад

This looks like a daunting task!

@10feetup 4 года назад

In the UK we have a few choices for diesel swap that are fairly cheap and easy, 1 being the 1.9 xud tdi, no ecu and can manualy tune, other option it the VW/Audi/Seat PD130 or PD150, both can be mapped to 300bhp.

@tonyb2086 4 года назад

Looks like a high quality project! Great attention to detail going on there👍 I'm on a fence about the VW emblem

@DRTJon 4 года назад

Tony B it was just something I stuck there for a picture LOL. I don’t have any VW badging on it anywhere except a small “TDI” on the tailgate from a MK5 Jetta

@tonyb2086 4 года назад

I'm droolin' over this swap👍

@tonyb2086 4 года назад

I've been thinkin' and I hate to bring this up.... But I can't be the only one thinkin' Zombie Jeep!!🍻

@daveg4963 4 года назад

The adds on this!

@Chrislinfordnl 4 года назад

That is strange to watch. Over here in Europe Jeep sold Diesel Cherokees. Very popular in France and in some other countries when new but now they are much unloved while the prices of old 4.0 in good condition are rising. Impressive conversion though. Well done.

@halcyon1030 4 года назад

We have an abundance of 4.0 liters around . I just sold a running car for $500 to a family member . They last for 300 to 450 thousand miles .

@user-xx5dy7dm7u 4 года назад

Will you do a video on the wiring harness?

@doddgarger6806 4 года назад

I like my cammed 4.6 😎

@pacemetalfab 3 года назад

Love the yellow. This was a rare color? Maybe government issue? Great video. Very informative.

@handydanny3859 4 года назад

I got a 84 xj withthe gm 2.8 and 3spd auto im seriously wanting a different motor and diesel seems reliable and stronger

@marciomartins1823 3 года назад

Yes it show very

@f.l9716 2 года назад

Esta lindicimo

@RyanWithAviators 4 года назад

Jon, regarding the stock coolant hardpipe at the rear of the engine where you cut that tee off so it was just one outlet, how did you keep the coolant hose from blowing off the pipe without a lip at the end of the pipe?

@drunkshooter4156 3 года назад

I have an Audi A4 B5 Avant AVG 1.9TDI 110hp and there is a lot of them in europe with 400k miles and more, mine has 240k miles without a single problem. And Portugal has a 1.9tdi with 600+hp. Many have 300/400 reliably. VP engines are more mechanical so the PD engines you can get more hp with less work, but stock the VP are bulletproof.

@gdazey1 4 года назад

I can understand now, why some companies charge 20k for a diesel swap

@DRTJon 4 года назад

Gareth Dazey yep it’s not a one weekend job!

@danieldobrin3867 3 года назад

How did you set up your serpentine belt and tensioner on the drivers side? From what I can see in the video it's different from the 1.8 T Passat.

@flyaz11 4 года назад

Hey @BleepinJeep, question for you? This has nothing to do with this current video. I have a 1999 Cherokee 4.0 . It hasn't been running for 1 year or so. It starts up, I let it run for a while, then I drive it in my neighborhood for like 1 min. and I come back to my house and engine cuts off. I start back up and it will stay on for a couple secs. and stall out. I'll wait 30mins, it starts back up and can drive for a 1min, then I put in park and let it run, then it slowly stalls out. What could be the problem?? I appreciate any help. I already change the dis. cap and rotors, spark plugs, and spark plug wires. I clean out the trottle body and ACI. Thanks

@adamsyclone7409 6 месяцев назад

Great work but don’t use the stock xj coolant reservoir the tdi motor needs to flow its coolant steam outlet line (top back of the head just under the vac pump ) continuously to the vw style coolant bottle wich continuously purges any air bubbles trapped in the head as it is one of the highest points the xj reservoir is just not equipped for that as it’s just an overflow catch that alows the rad to overflow into it and back out were the vw reservoir is flowing constantly threw its reservoir bottle and is always a part of the coolant system and will eliminate any air pockets as it runs I also noticed on some of your new videos that u have switched to the vw style reservoir hope u didn’t hurt your motor like I did dealing with pesky air pockets

@RyanWithAviators 4 года назад

A few questions. Did you make your MAP bung or did you source it from a site? And also what was the name brand of the tubing couplers you ended up using? I will need to look into using the 1.8T A/C stuff for my build.

@DRTJon 4 года назад

I bought a MAP bung from USP Motorsports. I ended up using siliconeintakes.com for all my intake parts

@RyanWithAviators 4 года назад

@@DRTJon Awesome. I'll do the same thing you did with the MAP bung, or I'll TIG it into one of the intake charge pipes. Thanks! Btw, I think I speak for everyone when I say that we'd love to see a driving/offroad compilation of the Spool Bus.

@mastermoarman 4 года назад

Thank you for the videos. How bout one wheeling?

@DRTJon 4 года назад

MasterMoparMan there will be plenty 😎

@danh655 4 года назад

Ever consider doing top mount IC ? Great excuse for a hood scoop

@DRTJon 4 года назад

Dan H never did. Hood scoop was definitely not the look I was going for

@generaljackson649 4 года назад

How much would you say that you have invested in this engine swap so far and do you really like the end results.

@DRTJon 4 года назад

General Jackson I love the end results. With the stock turbo and injectors I had right around $5000 in it. More like $7000 now, part of that is because I’ve had to re-do things I wouldn’t have if I knew everything I’m sharing here, and had started with the upgraded turbo instead of setting up one way then changing

@crazydeathcar 4 года назад

what awesome song is playing?

@inspireonex 4 года назад

Moral of the story: if you have a clusterfuck of hoses that need hooking up, just get it done.

@DRTJon 4 года назад

three wheela 😂😂😂

@1MattFugazzi 4 года назад

Matt, you had a “weld your own rear gears” to make a locking spool. Wanted to know how to get rid of that lincoln locker setup. Do I need a whole new set of gears and the full time locker that was welded in place is just removed as a unit? Sorry I had to post that here but didn’t know how to contact you otherwise.

@DRTJon 4 года назад

Trout Soup you’ll likely need a whole new carrier and spider gear set or a new full carrier locker (such as a PowerTrax or ARB for example). Your current ring and pinion can be transferred over

@1MattFugazzi 4 года назад

Jon BleepinJeep Thanks Jon. I know have 35 spline axles in there from Mark Williams. The guy who put it together for me is no longer in business, and he welded the spider gears together so I’m locked at all times. I want to just have an open differential in the back with the option to put a locker in there. Where do I get a set of spider gears that I need for my Ford 9” with 35 spline axles and 4.88 gear ratio? I appreciate your help! Have been a subscriber since Matt started this channel I believe

@your2nd 2 года назад

I couldn't find where you covered the exhaust system ???

@mikekerby814 4 года назад

Is the hose from the oil cooler rubbing on the bell housing bolt? shouldn't you bush that somehow?

@DRTJon 4 года назад

Mike Kerby No, when finalized and zip tied together it’s not touching anything

@user-xx5dy7dm7u 4 года назад

any update on the jeep? and can yall make a video on how to rewire the vw harness to work with the jeep and the engine.

@bleepinjeep 4 года назад

that video is in the works

@user-xx5dy7dm7u 4 года назад

@@bleepinjeep thanks alot to everyone working on it

@johnjavillonar6195 Год назад

Is it necessary to run a hard pipe from the flange to the upper radiator? Can it be normal radiator hose?

@DirtRoadTherapy Год назад

Hey John, follow along with latest updates and ask me questions over on my new channel, just click my icon here! But no, it's not necessary to run a hard pipe , though with it running close to the turbo I didn't want a long rubber hose running across that area. And in my opinion it looks cleaner to have the hard pipe.

@jamesolivier3192 4 года назад

What is the part numer for that UMP airbox?? i want to know more about it.

@DRTJon 4 года назад

James Olivier 3” Superfilter

@joshuapoche5137 4 года назад

Part 6? I must've quit getting notifications cause i haven't seen anything about 1-5

@DRTJon 4 года назад

check the playlist section for "Project Spool Bus"

@rheccountryboy3491 4 года назад

Second me to 😄¬

@tangodown2721 3 года назад

Can't fit ac condenser then?

@xTinBenderX 4 года назад

What's the weight difference between tdi and 4.0?

@DRTJon 4 года назад

Mikie Peters I believe around 50-100 lbs. The TDI weighs just a few lbs shy of 400 fully dressed not including adapter and flywheel

@xTinBenderX 4 года назад

@@DRTJon Wow! That's not bad at all!!!

@keithw372 4 года назад

is that an ALH motor?

@DRTJon 4 года назад

yes

@Mukdaar 4 года назад

How dare you ! :)

@jp9579 4 года назад

Is this swap street legal? You must not have state inspections. Where I live you cannot change the engine size unless it was offered as a factory option that year. So basically no engine swaps. Certainly cannot go from gas to diesel

@jp9579 4 года назад

Plus this swap would set the check engine light on. Cannot have any warning lights on and they plug into the obd2 and make sure the vehicle has run through all its monitors. This swap would makenit impossible

@mikebarnea4789 4 года назад

Different states have different rules. Tx you can swap newer engines into older vehicles, but not the other way. The vehicle still has to meet regulations for that year.

@DRTJon 4 года назад

In Pennsylvania you can have the title changed from gas to diesel by a notary for $80. There’s no emissions for light duty diesel vehicles before 2008, and the VW OBDII port is in place of the Jeep, and the check engine light for the XJ is disabled. If the inspection mechanic plugged into the OBD port (they won’t) they’ll be scanning the VW ECU for codes. But you’re correct, some states will not allow a swap like this which is why you need to do your research before starting this kind of swap. My engine and vehicle are also the same year but that never was a question by any governing authority in my state

4 года назад

Excellent video. Keep it up! Would you like to be RU-vid friends? :]

@randyanderson6110 4 года назад

Nice black smoke donation to the enviroment.

@superchili9057 4 года назад

When someone tells me "Love is in the air" Love is a damn pollution 😀

@msboston01 3 года назад

@Vigor Od Bgda I think he didn't install whatever catalytic converter exhaust the VW had (hence the need to have the whole donor car). I agree thought... seeing all the work involved and this pollution is a total turn off

@adamsytsma5112 3 года назад

Hug a logger, you’ll never go back to trees...

@davidlee3290 4 года назад

first, does this mean free sticker??

@rd4660 4 года назад

Rolling coal, not cool.

@DRTJon 4 года назад

W RD With the new lever turbo, it still can but you have to try. It does not just load up and spew coal on every moderate acceleration

@tonyb2086 4 года назад

Diesel=less Co2 emissions than gasoline. Coal is a Fossil Fuel, Carbon is an Element. Carbon is what comes out of a diesel engines exhaust. If your an EV type, that's an entirely different kind of being environmentally un-friendly.

@superchili9057 4 года назад

That's how I failed my smog test.