Building a diesel powered RHD TJ Wrangler (Picture Heavy)

[RustyAutoholicGuy]

R2.8L NSG370 5”lift 35” tires 4:10 gearing

That is such a great combination. I considered the NSG370 for a LONG time before I figured out the idling issues with my BEW TDI. That 0.84 overdrive in 6th gear is just fantastic for diesel engines. I don't even use 4th gear in my AW4 with it being 0.75, I just treat my AW4 as a computer controlled 3-speed auto and it works great.

 

[NDSpeed]

That is such a great combination. I considered the NSG370 for a LONG time before I figured out the idling issues with my BEW TDI. That 0.84 overdrive in 6th gear is just fantastic for diesel engines. I don't even use 4th gear in my AW4 with it being 0.75, I just treat my AW4 as a computer controlled 3-speed auto and it works great.

i can’t remember the exact numbers. i posted it in another diesel thread.

75mph at 2800rpm roughly. if memory serves

 

[RustyAutoholicGuy]

Hey TJers,

Installing a resonator did wonders for further reducing how loud my BEW TDI swapped TJ Wrangler is when driving down the road. However, getting the resonator to fit and have all my exhaust components line up was a challenge that took longer than expected. One last note, I had to reset my phone, so I lost some pictures, so I had to grab screenshots from my videos.

Until very recently, one of my biggest dislikes about my TDI swap on my Wrangler has been how loud my swap was when going down the road. It's not that I don't like hearing my engine and the turbo making noises, but when it's so loud that you don't want to drive it for long periods of time, that's an issue.

One thing going against me for the noise issue was my muffler, it's a straight through design, and going to a chambered or one that is a three-pass would make the exhaust quieter at the cost of exhaust flow. I've known about resonators for years, but I've never had the need to install one either. So I went and got a cheap generic one online so I could see if it would make any difference. Part of the reason for getting a cheap one was that, at some point in the future, I'm upgrading my exhaust from 2.25" to 2.5. Because of that, I consider my current setup a proof of concept.

The resonator wasn't too difficult to install, though I did have to modify my down pipe to make basically an offset pipe so I would have the room to clear my frame rail for all the components to fit properly. To make the offset exhaust pipe, I took a 45° bend exhaust pipe, cut it in half, rotated one piece 180°, and then welded the exhaust pipe back together.

To be 100% honest, when I removed the downpipe to make the offset section, I did discover that 2 out of the 3 nuts holding the exhaust flange onto my turbo were loose, which I'm guessing is where some of the exhaust noise was coming from. Once everything was assembled, I took my Wrangler on a test drive and was blown away by how much better everything sounded. What I can't tell you is how much of a difference the resonator makes from just tightening up the downpipe to the turbo. All I care about is that I can drive my swap without the exhaust noise droning, and I no longer need hearing protection.

Unfortunately, a week later, I was back to fighting some cooling issues when I discovered what looked like oil underneath my radiator cap. It's always something with this swap.

Here is the video if you'd like to watch:


Thanks
Grant

 

[Wildman]

Hey TJers,

Installing a resonator did wonders for further reducing how loud my BEW TDI swapped TJ Wrangler is when driving down the road. However, getting the resonator to fit and have all my exhaust components line up was a challenge that took longer than expected. One last note, I had to reset my phone, so I lost some pictures, so I had to grab screenshots from my videos.

View attachment 631679

Until very recently, one of my biggest dislikes about my TDI swap on my Wrangler has been how loud my swap was when going down the road. It's not that I don't like hearing my engine and the turbo making noises, but when it's so loud that you don't want to drive it for long periods of time, that's an issue.

View attachment 631680

One thing going against me for the noise issue was my muffler, it's a straight through design, and going to a chambered or one that is a three-pass would make the exhaust quieter at the cost of exhaust flow. I've known about resonators for years, but I've never had the need to install one either. So I went and got a cheap generic one online so I could see if it would make any difference. Part of the reason for getting a cheap one was that, at some point in the future, I'm upgrading my exhaust from 2.25" to 2.5. Because of that, I consider my current setup a proof of concept.

View attachment 631681

The resonator wasn't too difficult to install, though I did have to modify my down pipe to make basically an offset pipe so I would have the room to clear my frame rail for all the components to fit properly. To make the offset exhaust pipe, I took a 45° bend exhaust pipe, cut it in half, rotated one piece 180°, and then welded the exhaust pipe back together.

View attachment 631682

To be 100% honest, when I removed the downpipe to make the offset section, I did discover that 2 out of the 3 nuts holding the exhaust flange onto my turbo were loose, which I'm guessing is where some of the exhaust noise was coming from. Once everything was assembled, I took my Wrangler on a test drive and was blown away by how much better everything sounded. What I can't tell you is how much of a difference the resonator makes from just tightening up the downpipe to the turbo. All I care about is that I can drive my swap without the exhaust noise droning, and I no longer need hearing protection.

The resonator looks good on there. And yes I'd agree that it is quiet too.

Unfortunately, a week later, I was back to fighting some cooling issues when I discovered what looked like oil underneath my radiator cap. It's always something with this swap.

View attachment 631683

Here is the video if you'd like to watch:


Thanks
Grant

Are you sure that is oil? Not to question you but it's hard to tell looking at the picture.

If it is oil then that would mean some engine repairs?

 

[RustyAutoholicGuy]

The resonator looks good on there. And yes I'd agree that it is quiet too.




Are you sure that is oil? Not to question you but it's hard to tell looking at the picture.

If it is oil then that would mean some engine repairs?

Not sure honestly, I'm tearing down my BEW TDI now and I've already discovered that I have oil coming out of the exhaust port on cylinder #4 so something is not right

Also the last time I tried driving it my water temps spiked to 240° so I'm not even sure if I'm fighting one issue or multiple issues

 

[NDSpeed]

Not sure honestly, I'm tearing down my BEW TDI now and I've already discovered that I have oil coming out of the exhaust port on cylinder #4 so something is not right

View attachment 631722

View attachment 631721

Also the last time I tried driving it my water temps spiked to 240° so I'm not even sure if I'm fighting one issue or multiple issues

i was reading that Diesels need to be between 190 and 220. 230 is fine on steep inclines. 240. a bit high.

i’ve got an adjustable rheostat to control the fan and had it set to 174. so i’ve been running cold

 

[NDSpeed]

had a place in Fairbanks that wired that one in for me.

 

[Wildman]

Not sure honestly, I'm tearing down my BEW TDI now and I've already discovered that I have oil coming out of the exhaust port on cylinder #4 so something is not right

View attachment 631722

View attachment 631721

Also the last time I tried driving it my water temps spiked to 240° so I'm not even sure if I'm fighting one issue or multiple issues

DAMN.....

Oil coming out the exhaust & spiking coolant temperatures sounds like maybe a blown head gasket? Hopefully nothing more major... You & I seem to have similar luck on our builds it seems... We're always chasing one issue after another.

 

[RustyAutoholicGuy]

DAMN.....

Oil coming out the exhaust & spiking coolant temperatures sounds like maybe a blown head gasket? Hopefully nothing more major... You & I seem to have similar luck on our builds it seems... We're always chasing one issue after another.

Yup exactly, the more I tear it down the worse it's looking, I actually made a MASSIVE mistake, I'm still investigating but I think I caused a majority of these issues and I'm not sure yet how I did it. I'll post pictures when I get a chance.

I ordered a straight edge that was suppose to get here today but like everything these days it now says it will be here tomorrow.

I need to check the deck of my block and the cylinder head as well. What's weird is I think the head gasket was okay . . . maybe. I'm going to replacing the Volkswagen's stretch bolts with ARB Head Studs so I don't have to worry about that in the future.

I'm going to have to completely tear down the cylinder head, but I'm really hoping it's just a bad valve stem seal or something simple that would explain the oil in cylinder #4.

-Grant

 

[Rickyd]

Yup exactly, the more I tear it down the worse it's looking, I actually made a MASSIVE mistake, I'm still investigating but I think I caused a majority of these issues and I'm not sure yet how I did it. I'll post pictures when I get a chance.

I ordered a straight edge that was suppose to get here today but like everything these days it now says it will be here tomorrow.

I need to check the deck of my block and the cylinder head as well. What's weird is I think the head gasket was okay . . . maybe. I'm going to replacing the Volkswagen's stretch bolts with ARB Head Studs so I don't have to worry about that in the future.

I'm going to have to completely tear down the cylinder head, but I'm really hoping it's just a bad valve stem seal or something simple that would explain the oil in cylinder #4.

-Grant

You have a tune right? How hard is the motor being run?

Sorry man,a sick motor is always a sinking feeling

 

[BlueC]

I've known about resonators for years, but I've never had the need to install one either. So I went and got a cheap generic one online so I could see if it would make any difference. Part of the reason for getting a cheap one was that, at some point in the future, I'm upgrading my exhaust from 2.25" to 2.5. Because of that, I consider my current setup a proof of concept.

You might want to try a race muffler (race bullet in some circles) as a resonator. They're somewhat like an old glass pack, specifically made for knocking a few dbs out of the exhaust to meet some track regulations, but I've seen guys use them as resonators in front of better mufflers over the years.

2.5" in this series. https://www.dynomax.com/mufflers/race-series-bullet-mufflers

3"+ in the mini series. https://www.dynomax.com/mufflers/race-series-mini-bullet-mufflers

 

[NDSpeed]

i drove 50 miles with only this can in benefit i installed the rest of the banks exhaust. i heard no difference in sound volume. Cummins calls it a DOC

haven’t looked up what it actually is

edit: it’s a different name for catalytic converter.

 

[RustyAutoholicGuy]

Hey TJers,

Well this is the end of the road for the Right Hand Drive TJ Wrangler. I had something let go in the BEW TDI Head and I have oil coming out of Cylinder #4 which caused me to step back and make several hard decisions on what I wanted to do moving forward.

I haven’t talked about this online at all, but since I got the Right Hand running and driving in November of 2023, it became very apparent to me that I’m not comfortable driving a Right Hand Drive. It’s no issues when off road but one the road and especially with some of the upgrades I’d like to make, the Right Hand Drive just added unnecessary complexity. I especially don’t like my kids riding with me when they are closer to oncoming traffic than I am from sitting on the other side of the Wrangler. It really does come down to safety for me.

So last year I went out and bought a 2005 Left Hand Drive Impact Orange TJ Wrangler.

I also plan on using a different diesel engine. The BEW TDI is a great engine but has a few minor shortcomings when paired with an automatic transmission, so I’ll be switching to the CJAA TDI engine which is a common rail engine that came in newer VWs.

I’m going to go over all this in detail later, but I also plan on starting a new build thread on here as well. This thread has been the journey of my 2006 Right Hand Drive TJ Wrangler, and this build has come to a close, though not how I originally imagined it would be.

The end goal is to have my 2005 LHD look nearly identical to how my 2006 RHD looks today, so I’ll be stripping the majority of the RHD down for all the parts and pieces to be used on the 2005 LHD TJ Wrangler.

I did publish a video about this today so if anyone wants to watch it, here is the link:


Thank you to everyone on here for all the comments and help over the years. This has been a MASSIVE learning experience and without communities like this one, I would have never gotten as far with this build as I did and I want to thank everyone for all the help and support!

-Grant

 

[Wildman]

Glad you're going to KEEP AT IT.... Even with a new platform.. You and I seem to have some crazy tenacity to never say never and just keep on pluggen away at our builds. Look forward to the NEW Build.

 

[RustyAutoholicGuy]

Glad you're going to KEEP AT IT.... Even with a new platform.. You and I seem to have some crazy tenacity to never say never and just keep on pluggen away at our builds. Look forward to the NEW Build.

Thank you @Wildman, I’m working on the new thread now with photos and more details though it’ll probably be later today before it gets posted.

I’ve been reflecting on this build alot over the last several months and honestly I’m grateful for the RHD, I learned so much but I also get an opportunity to address all the mistakes I regret making during the build as well.

I’m keeping the majority of the body panels as color matching spare parts and the experience I learned from it will be a huge help as well!

I’m looking forward to the day we can meet up and both take our TJs on a trail ride together, though mine is more aimed at daily driving that can been a decent weekend wheeler !

-Grant

 

[Wildman]

Thank you @Wildman, I’m working on the new thread now with photos and more details though it’ll probably be later today before it gets posted.

I'll be watching for it...

I’ve been reflecting on this build alot over the last several months and honestly I’m grateful for the RHD, I learned so much but I also get an opportunity to address all the mistakes I regret making during the build as well.

There have been times I would like to start all over again. I know there are things I'd do differently.

I’m keeping the majority of the body panels as color matching spare parts and the experience I learned from it will be a huge help as well!

Love the Orange...

I’m looking forward to the day we can meet up and both take our TJs on a trail ride together, though mine is more aimed at daily driving that can been a decent weekend wheeler !

-Grant

Grant,
I'm hoping that I'll be traveling here in the next year or two more and able to come visit a bunch of you guys.... Be fun to put faces with rigs... And check out ya'lls neck of the woods too.

 

[RustyAutoholicGuy]

I'll be watching for it...

Here is the new build thread:

Take Two: Building a CJAA TDI Turbo Diesel with an AW4/A340 Automatic (Left Hand Drive) TJ Wrangler

Love the Orange...

Same here

Thanks
Grant

 

[k1n3k]

I had something let go in the BEW TDI Head and I have oil coming out of Cylinder #4

I had the same issue on my ALH swapped Samurai. It was the valve guide seals, but also an oil drain issue. Keep in mind these VW diesels are designed to be clocked over something like 15 degrees to the right... or rear? I'm not sure what the BEW head looks like for oil drainage, but the ALH would keep a ton of oil under the cam, enough to submerge the valve guide seals. if they are soft and sealing well, not an issue. if they are original, they let oil drain down the valve and into the exhaust and combustion chamber when its parked. I hydrolocked the # 4 cylinder because of that, and it constantly drooled oil out the exhaust when running. So on your next build, check on oil drainage in the head and replace your valve guide seals.