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XJ to KJ CRD conversion
http://www.lostjeeps.com/forum/phpBB3/viewtopic.php?f=5&t=5348		 Page 1 of 1
Author:  casm [ Sun Jan 29, 2006 5:19 pm ]
Post subject:  XJ to KJ CRD conversion
Hi folks. I've been toying with the idea for the past couple of years of converting my XJ to the KJ CRD engine, and was hoping that folks here could fill me in on (or point me towards) some of the basic techical points regarding the CRD drivetrain. What I really need to know for now is:

- Weight of a fully-accessoried (i.e., long block plus alternator, power steering pump, A/C compressor, etc.) CRD enigne.

- Information on the 545RFE TCU - is it divorced from the ECU or integral?

- Electrical compatibility with late (2000-2001 model year) XJ gauges.

I'll be swapping out the 4.0 in my 2000 Limited if this ends up happening, and plan on using the 545RFE rather than keeping the AW4 already in it to gain the higher cruising gear; since the ECU will need to be swapped out anyway, it makes sense to replace the tranny as well.

From what I've been able to turn up so far, this should pretty much bolt up to the NP242 already in it though I expect mounting points for the engine and transmission to change and/or require reinforcement. And when I say 'bolt up' I'm not expecting this to be a straight swap by any means - what I'm trying to do is evaluate whether it makes more sense to convert the XJ using donor parts from a rolled KJ or buy a used KJ out of state and bring it in (I'm in California, so screwed on getting one straight off the lot).

If anyone can help me out with the technical side of things, I'd appreciate it. FWIW, I really don't think I'm interested in the older 2.5-litre VM unit that was installed in the European-spec XJs - I grew up around those vehicles, and don't recall them having the greatest reliability. I'd also like to install something that's modern (so no Isuzu, Peugeot, or Mercedes conversions) and has parts supply in this country, so the CRD seems like the best all-around bet.
Author:  Ripple [ Sun Jan 29, 2006 7:41 pm ]
Post subject: 
sorry I can't really help, but I think your conversion idea is on-the-money. I would like see a dodge dakota 2x4 diesel conversion sometime, or OEM. it would be a hit!
Author:  ManicMechanicJoe [ Mon Jan 30, 2006 2:08 am ]
Post subject: 
I don't have any info but google a place called Burnsville Off Road. They are currently doing a CRD Wrangler Rubicon conversion. Since that wrangler had a similar drive train they may be able to help you out. They build some wild set ups like the Viper powered TJ or the Hemi TJ (before AEV did it)... I will look for the link and post back if I find it.

EDIT: I found the link and good luck: http://www.burnsvilleoffroad.com/Articles/05_11_08.aspx
Author:  0311_DoC [ Mon Jan 30, 2006 2:11 am ]
Post subject: 
http://www.burnsvilleoffroad.com/Articles/05_11_08.aspx
Author:  casm [ Mon Jan 30, 2006 3:31 am ]
Post subject: 
Thanks for the links - I appreciate them (and have seen them before), but figure that a fair amount of what they're saying doesn't apply to the XJ due to the differences in suspension layout, body construction, etc. If someone could let me know answers to my original questions, though, that'd be great.
Author:  ManicMechanicJoe [ Mon Jan 30, 2006 5:20 am ]
Post subject: 
talk to burnsville off road they have all the info you want about the transmission/wiring/measurements and they will be able to tell you more info then anybody on this board (unless one of you has pulled a CRD and done extensive measuring/rewiring/etc)
Author:  jinstall [ Mon Jan 30, 2006 12:48 pm ]
Post subject: 
Try www.acmeadapters.com for yur VW TDi conversion needs. They might have something also for you. Most use the 1.9TDi in the Suzuki Vitara but I am sure they can give you an idea.
Author:  Dutchy [ Mon Jan 30, 2006 12:50 pm ]
Post subject: 
There is already a diesel engine for the XJ, but only in Europe, try to get one from here or import a complete XJ diesel to the US, saves you a lot of time and probably money.
Author:  kj lad [ Mon Jan 30, 2006 12:52 pm ]
Post subject: 
In the UK there was a 2.5 diesel version of the XJ. It may be worth checking out some of the UK Jeep builder sites to see if it has been and how......

Here's some websites that might help:

http://www.fte.co.uk/index.html

http://www.offroadmdg.co.uk/

http://www.surreyoff-road.com/index.htm

Hope this helps.

Ian
Author:  casm [ Mon Jan 30, 2006 1:59 pm ]
Post subject: 
ManicMechanicJoe wrote:
talk to burnsville off road they have all the info you want about the transmission/wiring/measurements and they will be able to tell you more info then anybody on this board (unless one of you has pulled a CRD and done extensive measuring/rewiring/etc)


Ah, OK, now I see what you're saying :) Thanks, that's actually a really good idea; I'll get in touch with them later this week.

jinstall wrote:
Try www.acmeadapters.com for yur VW TDi conversion needs. They might have something also for you. Most use the 1.9TDi in the Suzuki Vitara but I am sure they can give you an idea.


Thanks, but I don't think that engine will really work for my application. The CRD looks like the best bet.

Dutchy wrote:
There is already a diesel engine for the XJ, but only in Europe, try to get one from here or import a complete XJ diesel to the US, saves you a lot of time and probably money.


Problem with that: I can't register it in California since it was never an approved model for sale here. It would save me a lot of time and effort - my parents are in Ireland and spend enough time on the continent that I could relatively easily have them source an LHD diesel XJ. However:

kj lad wrote:
In the UK there was a 2.5 diesel version of the XJ. It may be worth checking out some of the UK Jeep builder sites to see if it has been and how......


Thanks, but I really don't want to use the 2.5 VM engine under *any* circumstances. I remember them not being terribly long-lived, and down on power compared to the CRD. There's also the issue of parts availability: because it was never sold here, DCX won't sell parts for it.

To give you some idea how strict they are about this: I had to call no fewer than 11 dealers before I could order a battery tray - you know, just the plastic part that the battery sits on - for a diesel XJ. Why? Well, because it was technically an 'export' part, they didn't want to deliver it to a dealer in the US. I finally got it by telling them that I had a friend visiting from Mexico whose battery tray mysteriously broke. Two days later I had it. And this is just an inanimate hunk of plastic, nothing mechanical. For anyone wondering, this part was needed for my dual-battery setup.
Author:  Ranger1 [ Mon Jan 30, 2006 8:39 pm ]
Post subject: 
Don't think the gauges would be a direct replacement - according to the FSM, the Liberty gauges use pulses from the ECM for tach, gas, speedometer, and other idiot lights. The BCM and ECM seem to be inextricably involved with the Libby's gauge cluster. It's not too likely the XJ and KJ used the same gauge/ECM/BCM design.
Author:  casm [ Wed Feb 01, 2006 3:09 am ]
Post subject: 
Ranger1 wrote:
Don't think the gauges would be a direct replacement - according to the FSM, the Liberty gauges use pulses from the ECM for tach, gas, speedometer, and other idiot lights. The BCM and ECM seem to be inextricably involved with the Libby's gauge cluster. It's not too likely the XJ and KJ used the same gauge/ECM/BCM design.


Yep, that's a good point. But remember that we're talking about the 2000-2001 XJ here - they had their own differences to the prior models, and the '01s were kind of a run-out model to test the waters when the first KJs came out. Still not expecting a straight swap, though.
Author:  jinstall [ Wed Feb 01, 2006 8:25 am ]
Post subject: 
casm wrote:

Problem with that: I can't register it in California since it was never an approved model for sale here. It would save me a lot of time and effort - my parents are in Ireland and spend enough time on the continent that I could relatively easily have them source an LHD diesel XJ.



Good Luck finding a LHD in there, you have to go to mainland europe to find a LHD. Try www.mobile.de to find a LHD KJ
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