TDI Ranger Build

[greengeeker]

Cant wait till you have this done! would love to see your wier by wier how to once its done!

Thanks John. It will be indicative of what you have to do...remember the one I'm currently working on is for the earlier ALH's with the 81pin ecu. Your 121pin is very similiar but does have some differences.

 

[RangerSVT]

Then why do the OBD2 ports have 16 pins?? Seems they could have made a much smaller/cheaper hook-up.

OBD2 was standardized across the board for all manufactures, allowing one diagnostic port to be used, no matter the make, allowing one diagnostic tool to read all makes and models, without the use of multiple vehicle-specific adapter cables, like OBD1 models...


SVT

 

[greengeeker]

ECU box, part 2

I finally got around to finishing up the ECU box and sealing up the opening into the passenger compartment.

Load up the back of the block off plate with some silicone and slap it into place with some self-tapping screws (after checking the backside for anything that might be damaged). Also notice the weld nuts I added for the ecu box attachment. I did add some fuel line around the washer line (upper right corner of the opening) where it will be sitting against th ecu box.

All done!

 

[greengeeker]

Alternator wiring

I got crazy lucky with the alternator wiring. The VW alternator wire is the perfect length to make it up to the Ranger fuse. I did have to modify the end to convert it to an eyelet. The connector in the center is the Ranger alt wire. I didn't use it because it is a much smaller gauge, the eyelet on the alt end won't fit over the alternator stud and lastly it is WAYY too long as it needed to run over to the pass side of the 2.5L.

I did change the direction of the power wire at the alternator (when in a vw this wire routes downward):

The connector in the above picture has two wires that need to be wired up: the blue one goes to the instrument cluster (batt light) while the brown/red one goes to the ecu.

I'll tap into the harness upstream of this main connector. You can see the 'alt bulb' wire label which will end up at the ecu....I'll splice into this with my brown/red going downstream to the ecu and the blue one going upstream to the cluster. Will post more on this.

 

[bobbywalter]

oh the joy

 

[greengeeker]

A little help?

Hey guys, has anybody ever added fuses to the battery junction box? I'm looking to run my glow plug power and fan power through the maxi fuses and likely will also add a couple 20 or 30amp circuits to the panel.

 

[bobbywalter]

yeah....cake. go rob some at the junkyard.... get a few pdb's like yours and start splicing.

 

[greengeeker]

A quick update/teaser

A buddy over on tdiclub just dynoed his car that is setup similarly to what I intend to have as my Stage 4 power level (5.0 equivalent):

234whp, 373ft-lbs

I also did some more testing of circuits and have made more progress on wiring:

http://www.youtube.com/watch?v=RCGgyZ7U_1E

(I repurposed the "Check Susp" light for my glow plug light. )

 

[dragogt]

Wow that's impressive for a small 4cyl engine, I bet that'll do great in a non lifted truck..

Sent from my SGH-T989 using Tapatalk 2

 

[greengeeker]

We'll find out drago!

To put his power level nto perspective, that would equate to a 800+ whp Duramax.

 

[chucky2]

Question:

I know you're concentrating on making your own build work...however, have you thought of measuring what 2WD auto and 4WD manual and auto clearances there are, to make a kit for those as well?

Selfish example: I've got an '03 4.0L auto 4WD with almost 190k mi on it. When the engine goes, going your route seems like a winner given the mpg and the torque involved. I'm wondering if you've considered selling kits like 2WD manual, 2WD auto, 4WD manual, 4WD auto? (and I don't know if the different engine combinations of those would affect the plate you had to make or not)

Thanks either way, love this thread!

Chuck

 

[greengeeker]

Hi Chuck,

I am starting to think about my next build which I'm hoping will be 4wd. I've already got the wrecked TDI

There wouldn't be a difference in adapter plates whether it is 2wd or 4wd. For a 4wd I'm not crazy about moving the engine forward 2" (like I did with my swap) as it would of course require you to mod both driveshafts which adds expense to the swap. You can run the motor in the original location but as noted earlier in this thread it really doesn't leave any room for service (you need to work on the backside of the head for a timing belt change) , requires you to run an electric vacuum pump, fab up a vacuum pump delete plate, move your alternator, etc.

I've been trying to wrap my head around how to control the auto trans but would really rather use the manual for a number of reasons. If any have ideas how to control the lockup I'd love to hear them. One nice thing is the gearing is nearly a perfect match for the TDI (well, my 94 B4000 auto revs exactly where I would want a tdi on the highway).

 

[bobbywalter]

be controls has the auto trans covered.


screw the driveshafts....worth 400 bux to mod them.

if not and you want the oem shafts to stay in place, you just compromise a bit.... when its time to deal with timing belt maintenance it will simply require a few more steps to slide the engine up and forward. not a problem really if your doing your own swap, its a scheduled thing. plan for it



those potential power numbers achieved on the dyno are awesome!!! hats off to that guy

what kind of coin to get to that?? anybody know for sure.??

 

[chucky2]

Hi Chuck,

I am starting to think about my next build which I'm hoping will be 4wd. I've already got the wrecked TDI

There wouldn't be a difference in adapter plates whether it is 2wd or 4wd. For a 4wd I'm not crazy about moving the engine forward 2" (like I did with my swap) as it would of course require you to mod both driveshafts which adds expense to the swap. You can run the motor in the original location but as noted earlier in this thread it really doesn't leave any room for service (you need to work on the backside of the head for a timing belt change) , requires you to run an electric vacuum pump, fab up a vacuum pump delete plate, move your alternator, etc.

I've been trying to wrap my head around how to control the auto trans but would really rather use the manual for a number of reasons. If any have ideas how to control the lockup I'd love to hear them. One nice thing is the gearing is nearly a perfect match for the TDI (well, my 94 B4000 auto revs exactly where I would want a tdi on the highway).

Oh, I have no idea haha. I'm like an oil change and tire rotation level of knowledge guy...changing the oil and seal on the rear diff is as far as I go.

I'd have no problem though moving it forward and having a custom shafts made, along with a trans controller, depending how much it all cost vs. putting in a low mileage Ford 4.0L again. Thing is, if it's going to put down comparable power to a 4.0L and get high 20's on the highway, over time, it'll pay itself back no problem. The question would be, what is the mpg? Will be interesting to see what you get out of yours.

Chuck

 

[greengeeker]

Well the problem is that my build is going to be the best combo for mileage - lowest weight, 2wd, 5spd.

I think with the weight, 4x4, and the auto you'd be looking at something lower but I hope it would at LEAST be in the high 20's on the highway.