Yet another diesel conversion project (YADC)

[budojeepr]

Ready to rock and roll

Well, I've buttoned up the oil leaks, taken care of (most of) the loose wires, and reassembled the big parts. After I took the pics below, I put on the hood and took her for a drive today - took the dogs out to the local "nature preserve" for a bike ride/dog run, then off to the store to pick up a couple things.

This vehicle is MUCH more fun to drive than my diesel Jetta! The dogs think so too.

It's really strong, I can hear the turbo whine, and since it's only got a 3" or 3-1/2" downpipe and no exhaust pipe or muffler, it really sounds like a hotrod. The 4-speed auto works great except I have to start out in first and then go through the gears manually. I wonder if I set up the valvebody with a full manual setup. I'll have to go look at the steps I went through again.

I'll take a video next time I drive it, but in lieu of my venture into Hollywoodland, here are some pics:

It was a beautiful day, temps in the 80's, light breeze. GF's on a trip out of town, so it was a nice peaceful day.

If you squint you can see the Mercedes pusher fan in front of the radiator. Works like gangbusters!

Oil cooler is in the 2nd headlight hole in the driver's side. I'd like to find a couple of those headlight guards they put on the Baja 1000 trucks for those holes.

Had cardboard down because I wasn't sure if I'd fixed the oil leaks - valve cover, bulkhead fitting into the oil pan...


There's a lot in that little engine compartment!


Dig the Ace Hardware/AutoZone air intake plumbing.


I still have a bunch of things to do.
- I'd like to get that full digital dash setup. Current gauges do not work properly.
- Figure out how to put in an EGR valve, if it's required by CaDMV.
- Get water injection system. Maybe wouldn't need EGR if I have water injection.
- Figure out how to get heat and A/C.

This of course presupposes I still have any ready cash during/after the holidays.

[budojeepr]

Driving videos!

Here are a couple videos I took with my digital camera this morning...

I haven't had the exhaust made yet, so the downpipe terminates just under the front passenger side floorboard.

Enjoy!

Link: Leaving the driveway

Link: Cruising 55mph

[Mikel]

Here are a couple videos I took with my digital camera this morning...

I haven't had the exhaust made yet, so the downpipe terminates just under the front passenger side floorboard.

Enjoy!

Link: Leaving the driveway

Link: Cruising 55mph

Wow, that sounds so much better than my can-full-of-marbles

[budojeepr]

Wow, that sounds so much better than my can-full-of-marbles

I couldn't see your speedometer, but it's encouraging that you're passing other cars! That never happened to me when I had the 258 in it. Perhaps I'll experience that pleasure soon.

[budojeepr]

OK, let's close this thread. The rig's essentially done, and anything interesting that happens later can be shared later.

Here's the list:

Was: '81 AMC 258
Is: '94+ GM 6.5L diesel (turbo added)

Was: TF 727 auto transmission
Is: GM TH700R4 auto transmission

Was: Vacuum-boosted brakes
Is: GM hydroboost brakes

Engine work:
- Major cleaning job
- New (reman) heads
- New injectors
- New glow plugs
- NOS intake manifold for turbo
- NOS exhaust manifolds for turbo
- New gaskets
- GM-5 turbo from GMC Yukon
- Jeep 6-blade cooling fan (original GM had 5 blades)

Transmission work:
- Major cleaning job
- Transgo full (not Jr.) shift kit, set up for diesel
- Derale extra-capacity pan with cooling tubes
- New TV cable

Transfer case (Jeep NP208) work:
- Major cleaning job
- Rebuilt with new bearings and seals
- Transferred GM input shaft to Jeep case to handle driver-side drop

Other stuff:
- Oil cooler from 5.7L Grand Cherokee
- Aftermarket transmission cooler
- New diesel torque converter
- Aluminum cross-flow radiator from Summit Racing
- Stainless steel radiator hoses
- Modified Jeep fan shroud
- Dual batteries (one in rear)
- Homemade air filter manifold for turbo
- Novak transfer case adapter to allow correct clocking
- Full 3-inch exhaust with single glasspack muffler
- Downpipe and crossover from eBay
- Balance of system from local shop
- B&M shifter, mounted on driver's left floorboard
- Stock GM glow plug controller
- Stock GM lockup controller
- Seats from Chevy Astro van
- Seat covers from Grocery Outlet ($6.99!!)
- Mercedes pusher fan for auxiliary cooling
- Autometer electronic turbo boost gauge

My first real test-run was last weekend. The Jeep performed admirably, with great power and smooth operation. The turbo works great, it stayed cool throughout (although the outside temps were in the low 40's). Got 18.3 mpg, mixed mountain, dirt road, and flat highway.

It still has one major problem: Sometimes it will not start when warm. Cold starts are a breeze; run it for a while, stop, and it will not start after a few minutes' rest. I believe it's a fueling problem, perhaps a leak in the supply side, but it's hard to diagnose.

Potential problem: I may yet go for a professionally-rebuilt transmission. I'm suspicious of it because I don't understand autos all that well, and I worked on it anyway.

Inconveniences: No heat. No A/C. No stereo. Crap interior. No 4wd (need to re-gear front axle). These things will be rectified as time and money allow.

Major future show-stopper: still need California registration. I'll write that one up separately.

Things I'd like to add:
- Water injection.
- Stronger cooling fan.
- Manual wastegate controller.
- Manual torque converter lockup controller.
- Aussie lockers, front and rear.
- New paint - thinking matte black on lower half,
blue to match interior painted surfaces on upper half.
- Headlight rims, covers for big holes in front fascia.

Joys: Pulling out into traffic, the only worry being the hope that I don't spin out. Cruising at 75mph with no effort. 18 mpg (hoping to boost that with various small adjustments). Driving a Jeep instead of a VW.

If anybody has any questions about the swap that aren't answered in the rest of the thread, feel free to PM me.

Cheers,

Brad