Got another one! Project: PolarXJ

[6DoF]

Originally Posted by xj_man_646

They're converting it to stand alone?

kinda like the LS harness stripping ... removing all the BS, adding some nice-to-have's, labeling everything, etc. the vehicle side of the ECU from VW was really just an ECU connector and a firewall connector, but they make it into a few different wire groups well labeled for cruise, throttle pedal, etc.

they are also doing the tune, removing connectors for sensors removed in the tune, bigger injectors I'm also getting from them too. one nice ad is they convert to use engine RPM with the cruise control so there's no need for a VSS to be wired in. lets you set high idle for warm-up, winching, PTO's etc.

[xj_man_646]

That sounds pretty cool. I like the cruise based on RPM idea. That is neat.

[6DoF]

i keep seeing good reviews ... so i'm just super hopefully this fires up and runs nice! i really want to start driving it and get to working on Hank. Fast Forward officially received my cores too! hopefully he's not all backed up and i can get the set-up soon.

Stage-3 tune (18psi across the board)
harness with the nifty tach-to-vss
.260 injectors (this time properly build and tested)

last night when i got home from work, had ZERO motivation ... but just couldn't sit still. wife threw me out to the shop. ended up fully swapping everything over from M-TDI to 'e-TDI', got everything timed, and wiring laid out ready to tie into the new harness. only thing left is to figure out the throttle-by-wire pedal and i'll be ready.

should be a nice pc to install

[6DoF]

Originally Posted by wrath

You should have your MIL show up for 3 weeks. Even though it's miserable outside... it's good motivation. Plus there is only so much TV to watch.

mine has sequestered herself to her basement kitchen baking hundreds of dozens of cookies!

[xj_man_646]

I am not sure exactly what you need for the drive by wire pedal in this application, but I know guys have used the 95+ GM 6.5TD pedal assembly in drive by wire LS swaps.

[6DoF]

i have the MK4 TDI pedal/sensor, it just looks like an odd-duck that wasn't going to fit into the jeep firewall/floor very well. i was thinking i would cut up the pedal bit and make a bracket to attach the XJ cable to under the hood. clean, all XJ pedals, and could place it anywhere i wanted. well i got to researching what others have done, and it looks like i can just make a basic sheet bracket to weld to the factory XJ pedal bracket and it should line up great. might be one of the easier things it needed actually.

[MBood82]

Originally Posted by 6DoF

i have the MK4 TDI pedal/sensor, it just looks like an odd-duck that wasn't going to fit into the jeep firewall/floor very well. i was thinking i would cut up the pedal bit and make a bracket to attach the XJ cable to under the hood. clean, all XJ pedals, and could place it anywhere i wanted. well i got to researching what others have done, and it looks like i can just make a basic sheet bracket to weld to the factory XJ pedal bracket and it should line up great. might be one of the easier things it needed actually.

I really liked the original idea, seems elegant and keeps a factory look in the interior. However, I bet that sensor isn't truly weather proof, putting it in the engine bay instead of the cabin may result in a short life, or even worse, inconsistent throttle application as it gets dirty. I'm glad the bracket ended up being a fairly simple fix.

[6DoF]

maybe 2 weeks before i sent off the ECU and harness, i got the headliner re-glued in the XJ. not the best job ever, but re-using the factory fabric and lining up the holes on overly stretched fabric was a b!tch.

i also got the electronic TDI throttle pedal installed. i did basically the same thing as Bleepin from his YouTube and it was right there. i ended up adding some washers on final install to tip the pedal fwd more though. just some bent sheet welded to the factory pedal mount and 3 nutserts.

[MBood82]

Originally Posted by 6DoF

If that had vertical lines running on the "gas" pedal instead of the diagonal lines that would look 100% factory. Very nicely done!

[6DoF]

i really want a set of these

[Cobound]

Those are awesome

Headliner, I've put them in...used fabric from Joanne's that my daughter picked out and we cleaned off the original headliner, scraped it to remove all the old fuzz, then sprayed, stretched and laid it down...felt pretty good about it, but there were definitely areas that could have stuck better.

Using the original material, whoa - nightmare! Why did you go that route vs just putting on new stuff and cutting the holes?

[6DoF]

Originally Posted by Cobound

Using the original material, whoa - nightmare! Why did you go that route vs just putting on new stuff and cutting the holes?

being a cheap-fawk ... should have done something interesting.

in the end though, this is still a bit of a beater and the stock came out fine. just not amazing.

[Cobound]

LOL, I hear that on the chap fawk front

Here are some shots of my daughter's project...she picked out one that was her style, NOT MINE

This has been sold now, and her current XJ will probably need one next year...maybe



Had to remove all that fuzz...was a project in itself!







Even removed and used the original stickers

[6DoF]

the XJ i didn't even clean the foam, i just blew the dust off and sprayed the glue!

[Cobound]

[6DoF]

PARTS WERE DELIVERED!!

Fakk i wanna go home n wrench!

[TJTodd]

I've been lurking on this thread and I need 6DoF to go home and wrench so I can see the next update!

[Cobound]

[TJTodd]

6DoF - you called in sick today, right?

[6DoF]

not only was there no calling in sick ... there is much fail.

got basically everything hooked up Wednesday, thursday i routed the throttle pedal wires and OBD inside and tried to start it. this is when the BS started. as far as i can tell, the injection pump isn't leaking, but is sucking air somehow.

i have +10psi clean fuel pressure at the inlet ... but after bleeding 2 injectors and trying to start it, i'll get another huge bubble of air blasting into the tank from the return line. today i need to look for leaks after letting it sit longer with fuel in it and call around to a few shops for ideas. this pump sat 10yrs on a buddies shelf installed on this motor, and had fuel run out, but probably has some dried out o-rings or something.