Salutations all, I am collecting information on swapping a 1.9 TDI ALH or similar small diesel engine into my TJ. I have intentions of crossing the country (multiple times) and venturing down to the states and exploring and this would be my ride of choice. The milage/range I currently get from my 4.0L will not cut it to do that. 13-15 MPG is terrible for road tripping. I do NOT want a V8, so please kindly keep your opinions about that to yourself. Currently the Jeep only has 108,000 ish km, still young. Though the 4.0 has started the lifter tick 
I am keeping the 4.0 after I pull it for potential future use. I am going to keep this Jeep till either it or I dies. So I am going to do it the right way.
I have read up on many of the TDI build threads on this forum and will continue to do so, but I would like to know what I will all need for parts to make this happen. I can source a non running 1.9 TDI ALH still in the car locally for $800. There are running ones local as well, but I imagine it would be smart to rebuild the engine anyway. I've done 90% of the work that has been done on my Jeep and while I am no mechanic, my brother is and I have family that can weld, an uncle in metal fabrication and a cousin who is a semi mechanic. I have my bases covered for sourcing help and parts for the most part. I just want suggestions of engines or to know which parts I am missing from my list.
Engine (have a source for a TDI)
Adapter for NV3550 (is the Cody built one worth it for the price?)
Wiring harness and ECU (I am assuming standalone would be ideal, would like to retain original gauges however)
Motor mounts (can be fabricated)
Rad and cooling (pull it from the car?)
Exhaust (local shop that does fantastic work, plus the Jeep's is still in good condition, small cat leak, may just pull it or something while I am at it)
I know for a fact that there is a ton I am still missing. Any good advice is appreciated. I am not married to the idea of the TDI, but I would love a diesel TJ. As far as I know the TDIs are the better engines for reliability and decent power. Note, I am not looking to make 1000hp and 1000ft-lbs. The power of the 4.0 is perfectly fine for me, maybe a tad more would be nice. If there are better engines one can source (not V8s unless its somehow getting like 30mpg) I would love to know. I live in a very agricultural based area, so Kubota, John Deere etc are all brands I can easily get parts from if they make a decent engine I overlooked. Unfortunately the R2.8 is beyond what I want to afford, otherwise I would do that (where are they available used?).
It is long but there it is. Thanks Evan.
I am keeping the 4.0 after I pull it for potential future use. I am going to keep this Jeep till either it or I dies. So I am going to do it the right way.
I have read up on many of the TDI build threads on this forum and will continue to do so, but I would like to know what I will all need for parts to make this happen. I can source a non running 1.9 TDI ALH still in the car locally for $800. There are running ones local as well, but I imagine it would be smart to rebuild the engine anyway. I've done 90% of the work that has been done on my Jeep and while I am no mechanic, my brother is and I have family that can weld, an uncle in metal fabrication and a cousin who is a semi mechanic. I have my bases covered for sourcing help and parts for the most part. I just want suggestions of engines or to know which parts I am missing from my list.
Engine (have a source for a TDI)
Adapter for NV3550 (is the Cody built one worth it for the price?)
Wiring harness and ECU (I am assuming standalone would be ideal, would like to retain original gauges however)
Motor mounts (can be fabricated)
Rad and cooling (pull it from the car?)
Exhaust (local shop that does fantastic work, plus the Jeep's is still in good condition, small cat leak, may just pull it or something while I am at it)
I know for a fact that there is a ton I am still missing. Any good advice is appreciated. I am not married to the idea of the TDI, but I would love a diesel TJ. As far as I know the TDIs are the better engines for reliability and decent power. Note, I am not looking to make 1000hp and 1000ft-lbs. The power of the 4.0 is perfectly fine for me, maybe a tad more would be nice. If there are better engines one can source (not V8s unless its somehow getting like 30mpg) I would love to know. I live in a very agricultural based area, so Kubota, John Deere etc are all brands I can easily get parts from if they make a decent engine I overlooked. Unfortunately the R2.8 is beyond what I want to afford, otherwise I would do that (where are they available used?).
It is long but there it is. Thanks Evan.
