Got another one! Project: PolarXJ

[6DoF]

well i got the b!tch stripped! what an absolute epic pile of crap it was ... except the stuff i needed! hopefully scrap is up, and i can sell the axles wheels/tires for something and really make this a cost effective deal.

trans feels nice n smooth, and the dude wasn't lying about the brand new clutch/slave. t-case feels smooth, pedals assy is in great shape, hydro's were like new, this should be great. still need to try swapping some more parts on to figure out what's causing my running issue though first ...

[6DoF]

well ... fukkall is making a difference.

swapped from the running donor jeep:
Crank sensor
Cam sensor
coil pack
computer

fuel psi is quick and stable, can hear the pump, pretty sure i can smell fuel after it cranks a bit.

spark was there at every plug when i turned the pack up, shoved in a plug and grounded em.

at this point the entire 5spd kit has been loaded into the back and she'll sit til i have enough room in the shop to pull it in next to the 55 for work.

[jeepkid05]

Matt. I just tried to send you a PM. But PMs suck.

I’ll post it here.

Hey Matt. I know you used to work for Dewalt and are definitely more versed than me. I’m looking for a 1/2 impact. Mainly for whizzing off lugnuts etc. what would you recommend. My friend works there and is gonna bring home some deals for thanksgiving.

Lemme know what you think.

[6DoF]

we used to have a DeWALT thread ... or maybe it was just a tool thread? "old" forum maybe? worth re-starting if you don't find one.

the newest compact 1/2" cordless impacts are getting right to the point they are good enough for lugs, but are still just not quite beef enough for me as a 1/2" gun. if you'd rather compact over all the ugga-dugga, they'd be a good choice. this holds for any major brand really. the digital simulation has come a LONG way in the last few years, so every generation is like 30% smaller and 30% more torque, it's nutty.

[6DoF]

pulled the XJ back in to mess with recently ... a few evening of testing EVERYTHING and still wouldn't run. finally bought the compression tester adapter i needed while i was eliminating all possible knowns as issues. because how could every cylinder be so low that there's no fire. i mean, it ran!

aaaannnndddd fubar

#1 - 20
#2 - 25
#3 - 15
#4 - 30
#5 - 40
#6 - 20

so i thought, fine, i'll just re-ring it and drive it for a bit ... just make it run. well Dietz came over n helped wrench. i pulled the aw4 n broke the shifter rod in the process trying to remove the nut, fine whatever it's scrap. pulled the 4.0 pan and there is over an inch of sludge in the pan!!!! start pulling the pistons, got one rod stuck on the cylinder wall n chipped the piston skirt. bearings are all 60%+ copper. then trying to dig out the stuck BS rings i fudge up the ring land on one.

fawk it, this XJ obviously doesn't wanna run ever again on a 4.0 ... so it's getting a TDI.

yes, that is coolant pissing from a freeze plug ...

[6DoF]

got a buddy with a 1.9 ALH he'll sell me for a reasonable price so that helps. found an MTDI pump to swap for the electronic pump to get mechanical injection cheaper than i thought too. more power potential, and only slight more than a basic ECU tune. after some hoses n fidly bits i suspect the whole swap would be in the $3500 range. after a lift n shocks n ball joints, i should be into a 2dr, TDI, 5spd, lifted XJ for reasonable money

[nblehm]

I wish I had your motivation

[6DoF]

Originally Posted by wrath

I always expect to see a bunch of MSA stuff in the background, like Sordins stacked up like cordwood. But it's still DeWalt yeller everywhere.

yeah ... the employee discount isn't good enough to be worth buying anything like that. i've actually found them cheaper online before. really the only thing i've picked up was a Packers hard hat cuz the steelers ones are watched too closely.

[6DoF]

so it's officially back in the shop, and it's officially 1.9 TDI time! more specifically, MTDI time! i'm working thru prepping the jeep while figuring out all the parts i need and getting them ordered. a buddy is coming up on the weekend of the 15th to play and hopefully get it running/driving that weekend.

fuel tank is out, cleaned out, and return line figured. i have ordered everything needed for the fuel system including a new fuel sock, fuel filter, and tank filler lines. the factory jeep tank/pump will run diesel up to a dead-headed PSI reg and then into the injection pump.

i even get to use the stock ASD, starter, and all the gauges pretty easy. obviously fuel, volt, and speed are all stock still. oil psi and coolant just requires getting the jeep senders into the TDI. the tach runs off the CPS, and i'm using the stock trans/flywheel so that's a bolt in, but the ECU needs a single cam position sensor pulse to wake it all up. some guys wire it to a button, some piggy back the CPS, others install a relay that closes with the starter relay to short the cam wires and send a single pulse. the last one is my plan.

ordered a 3-in-1 gauge like i put in Hank for EGT, boost, and fuel PSI

got the center console ripped out, shifter is gone, but the stupid floor plate is stuck because the t-case shifter bracket screws have all spun the nut-cerst. freaking lame, but easy enough.

bought the trans adapter from Whitbread performance, and conversion engine mounts from TDI Conversions. got the MTDI pump and bigger injectors from Hans auto parts. biggest injectors i could, so that was stupid. also got the 12mm injection pump, also too much fuel ... so it's probably going to suck to tune without it smoking.

[xj_man_646]

This should be pretty cool!

[6DoF]

Originally Posted by xj_man_646

This should be pretty cool!

[6DoF]

last night i found a pair of 2" lift pucks in case i need more clearance for something in the front end. some guys say you do. i think i might have "acquired" these from Christian's XJ at 611

the rear springs are SOOO shot though, i really hope i don't need to lift it right now.

[xj_man_646]

What would you need more clearance for, in going from a 4.0 I6 to an I4 TDI?

[6DoF]

Originally Posted by xj_man_646

What would you need more clearance for, in going from a 4.0 I6 to an I4 TDI?

i've read things about UCA mount clearance to things, or balancer to housing. not totally sure, but we are going to find out. seams like a pretty easy fit to me.

[MBood82]

Nice seeing this hitting the shop!

[6DoF]

fawk ... you think the wife will believe it was Mitosis tonight when she find a 2nd ALH in the shop?

[Cobound]

[6DoF]

engine teardown and inspection going well, looks like i'll need to run the turbo from engine 1 though. learned a lot of little thing tearing this down that were good, like the back of the head has a steam port i hadn't noticed before! measured some things, decided some things will just get cut up.

whoever thought it was a good idea to put an EGR on a diesel was a complete and utter jack-a$s. even the stock engine had some soot, combined with the oil from the crank vent and it makes a sludge on EVERYTHING.

[xj_man_646]

Originally Posted by 6DoF

whoever thought it was a good idea to put an EGR on a diesel was a complete and utter jack-a$s. even the stock engine had some soot, combined with the oil from the crank vent and it makes a sludge on EVERYTHING.

You can thank CARB and the .gov for that. You're lucky the intake wasn't completely plugged requiring a torch to clean out.

[nblehm]

Yeah those things carbon up bad. Glad there aren’t very many of them.