hi, ive scanning the internet for weeks and this seems to be the best diesel conversion site by far

im looking into getting an old YJ wrangler to swap a diesel engine into.
ive been given a vw1.9tdi complete car and was thinking of going that way, but it looks as though a 2.5td cherokee swap would be a lot easier?
i could probley swap the 1.9tdi for a 2.5td cherokee as both of the cars are pretty cheep and quite common over here.
any tips and advice welcome

 

Hello and welcome here.
A swap isn't that difficult just make sure to change the AX15 manual tranny with it.
The Diesel engine won't fit on a AX5. You also need the bellhousing.

Be warned with the Diesel 2.5Td engine- you need to make it reliable because the heads will crack due to overheating.
(maybe that explains it to you why those engines or trucks are so cheap, hehehe)
Be warned spare parts aren't cheap!


The head ( 4 single heads)will develop cracks in the 3.rd and 4.th head between the water channels and the precombustion chamber.
The engine will die after being switched off- heat rises to the heads and the head cracks.
Otherwise than that it is an engine to have fun with.
If you need further advice just let the Weasel know.
It isn't that simple, but can be done.

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Cracks start to develop at 60.000miles or 100.000km.
Depending on your driving style. And you can bet on ithappening. 90% of all Diesel drivers in Germany had this painful experience already- some of them twice.

If you buy an engine check the odometer and the manufacturing date stamps on the injector side.
You won't see or recognize the cracks- but they will be there. Just waiting for their chance to develop themself.
We x-rayed the heads, but due to it's thickness they aren't visible.
I don't like that Aluminum casting.
The engine itself needs metric tools only.

 

so whats to be done?
avoid the engine altogether or take my chances.
how do you make them reliable?
i would buy the whole car use what i need, then scrap or sell on whats left.

thanks for the quick response.

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ive just read that the rover800 and ford granada scorpio have the same block and heads.
this could help with future spares.

 

Don't get fooled-due to the reason of being an Italian VM engine parts may only be slight cheaper.
You find this engine also in:

- Alfa Romeo 155
- Opel or Vauxhall Fontera A
- Range Rover Discovery

To run this engine reliable you also have to:

- replace the waterpump( original!), rebuilt parts are crap
- replace the radiator( likes to leak at the end tanks) But you need the copper radiator
due to lower heat resistance! Forget about only flushing the system-thats not enough.
- always proper coolant mixture
- proper warmup and cool down procedures

Some have tried to get away with slots in the hood or lifting the hood in the rear, but it didn't helped at all.
Lamps or bull bar installed in front of the bumper are an absolute nono- its also mentioned in the manual.
A non working or low heat heater should alert you- something is going wrong!


-and the cooling parts down here in the signature.
Don't try to get away without an added oil cooler with a size smaller than 500cm²-Of course not mounted in front of the radiator...
Even if this engine needs a lot of attention, I do like it.