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VW 1.9 2.0L TDI to Jeep 4.0L (1992-2006) Transmission Adapter Kit
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- KIT CONTENTS
- VW ENGINE CHART
This adapter plate kit allows you to replace your Jeep 4.0L i6 (1992-2006) Wrangler TJ, YJ, XJ engine with any 4 cylinder Volkswagen/Audi engine. The most commonly used engine is the VW TDI (ALH, BEW, BHW, CJAA). All VW/Audi 4 cylinder engines have the same bellhousing bolt pattern and crank hub. This means you can install any 4 cylinder gas or diesel engine made by VW/Audi using this kit.
Alternatively, you can attach any AX15, NV3550, NSG370 or AW4 transmission (Jeep 4.0L) to any Volkswagen TDI engine.
***NOW AVAILABLE WITH OEM STYLE STARTER MOTORS. All our new kits have been modified to fit a Toyota 4.7 V8 starter motor. This is a Denso style starter motor, high torque, 2 kW power rating, affordable and readily available!***
Our kit has numerous features that set us apart from the competition.
PREMIUM BILLET ALLUMINUM ADAPTER PLATES. We do not skimp on quality, and only use high quality 6061 Aluminum billets. Our tempered 6061 is far superior to the cheap cast non-tempered aluminum adapter plates typically seen with cheaper adapter kits. Our billets undergo a tempering process of heat treating and artificial aging to achieve the perfect strength and toughness for our application.
EXTRA FIRE WALL CLEARANCE. Our 2 inch thick adapter moves the TDI engine forward 2 inches from the transmission bellhousing. This gives you extra fire wall clearance for the TDI vacuum pump and coolant pipe. The transmission remains in the original position, keeping the shifter in the factory position for most vehicle conversions.
HIGH PERFORMANCE CRANK ADAPTER. Our nitride case hardened alloy steel crank adapters are designed for high performance applications. Rated at 800 ft-lbs of torque, we set the bar high and make sure our parts are not the limiting factor in your build. Nitriding is a low temp, low distortion heat treating process that significantly improves fatigue strength of the metal. Crank adapters undergo significant stress cycles, making them a critical failure point. This is not where you want to cut corners on quality materials or design. Shockingly, our competitor's kits only offer aluminum or untreated steel crank adapters. Is it cheap and dirty, does it make the wheels turn at the end of the day, sure! Are they engineered to be the best? Not a chance!
2.0kW HIGH TORQUE STARTER MOTORS. Our kits now come with two or three starter motor options. The Toyota 4.7 V8 Denso style starter motor is now our go to starter motor for all our TDI kits. It has an OEM proven track record, compact design, and best of all it is readily available and very affordable to replace! We still offer the 2 kW PowerMaster Chevy V8 for those who prefer aftermarket starters. These starter motors can be clocked to two or more positions to avoid any fitment issues in your engine bay.
MULTIPLE ENGINE CLOCKING POSITIONS. Our 2 plate system allows the engine to be clocked at 0° (vertical), 10°, and 15° degrees for fine tuning engine clearances. The transmission stays stationary while the engine rotates towards the passenger frame rail.
(2) Adapter plates, billet aluminum, anodized finish, 3 engine clocking positions.
(1) Crank adapter; nitride case hardened alloy steel for high performance applications (800ft-lbs torque). Pilot bearing pre-installed for manual kit.
(1) Multiple starter motor options:
-Toyota V8 high torque starter motor, Denso style compact 2.0kW
-Power Master high torque starter, aftermarket custom compact 2.0kW
(1) Starter motor clocking adapter; billet aluminum, anodized black
Installation hardware for bellhousing, crank adapter, and starter are included. No flywheel/flexplate bolts are included. You need to use OEM equivalent flywheel bolts.
OEM flywheel bolt size: 6 bolts, 1/2 - 20 x 0.875"
This kit was specifically designed to replace the Jeep 4.0L i6 (1992-2006) engine. This kit makes the back of the VW TDI engine look like the engine block it is replacing. This means you can bolt any Jeep 4.0L (1992-2006) transmission to any VW TDI engine using this adapter kit.
***1987-1991 4.0L engines will need a different pilot bushing, please order the 4.0L pre-1992 adapter kit if this applies to you.***
Compatible Engine codes: Jeep 4.0L (1992-2006)
Compatible Auto Transmission: AW4, 32RH, 42RLE
Gear Ratios for the AW4: 1st: 2.80, 2nd: 1.53, 3rd: 1.00, 4th: 0.75
Compatible Manual Transmission: AX15, NV3550, NSG370 (2005-2006)
The NV3550 superseded the AX15 and is attached to the Jeep 4.0L 2000-2005. It is rated conservatively at 300 ft-lbs.
- Jeep Comanche: 1987-1992
- Jeep Wagoneer: 1987-1990
- Jeep Cherokee: 1987-2001
- Jeep Grand Cherokee: 1993-2004
- Jeep Wrangler: 1991-2006
***If your vehicle is not on this list, please cross reference and perform your own research. Other similar vehicle models may also be compatible. ***
Any 4 cylinder Volkswagen/Audi engine will work with our TDI adapter kits. All VW/Audi 4 cylinder engine bolt patterns are the same.
Check out the chart below for all compatible VW engines.
Note: Our kits are specifically tested on TDI engines, so if you choose to use a VW gas or older TD diesel engines please do your own fitment research.
|VOLKSWAGEN DIESEL ENGINES (NORTH AMERICA)|
|Engine Name||Engine Code||Year||Model||HP/TQ||Notes|
|1.5 D||D||1976-1983||Rabbit||50||Naturally Aspirated|
|1.6 D||CS, CR, JK, ME||1980-1992||Rabbit, Golf, Jetta||50-54||Naturally Aspirated|
|1.6 TD||1V, CY, MF||1981-1991||Rabbit, Golf, Jetta||59-68||VE injection pump|
|1.9 TD||AAZ||1992-1999||Golf, Jetta, Passat||74/107||VE injection pump|
|1.9 TDI||1Z, AHU||1995-1999||Golf, Jetta, Passat, Beetle||90/145||VE injection pump|
|1.9 TDI||ALH||1999.5-2003||Golf, Jetta, Beetle||90/149||VE injection pump|
|1.9 TDI||BEW||2004-2006||Golf, Jetta, Beetle (MK4)||100/177||Pump-Deuse|
|1.9 TDI||BEW||2006||Golf (MK4)||100/177||Pump-Deuse|
|1.9 TDI||BRM||2006||Jetta (MK5)||100/177||Pump-Deuse|
|2.0 TDI||CBEA||2009||Golf, Jetta||140/236||Common Rail|
|2.0 TDI||CJAA||2010-2014||Golf, Jetta||140/236||Common Rail|
|2.0 TDI||CKRA||2012-2014||Passat||140/236||Common Rail|
|2.0 TDI||CVCA||2015||Golf, Jetta, Passat||151/236||Last year of the TDI engine in North America|
VOLKSWAGEN GASOLINE ENGINES (NORTH AMERICA)
|Engine Name||Engine Code||Year||Model||HP/TQ||Notes|
|2.0||ABA, AEG, AVH, AZG, BBW, BDC, BEV, BGD, AGG||1992-Present||Golf, Jetta, Passat, Beetle||114 hp||Naturally Aspirated, fuel injected|
|1.8 T||AEB, AGU, AJH, APH, ARX, ARZ, ATW, AUM, AWC, AWD, AWL, AWT, AWW, BJX, BKF, BKV||1998-2006||Golf, Jetta, Passat, Beetle, Audi A4||148/155||Turbo Gas|
|1.8T||AWP, BNU||2001-2006||Golf, Jetta, Beetle||178/173||Turbo Gas|
|1.8T||AMU, BEA||1999-2005||Audi TT||222/207||Turbo Gas|
|2.0T (Turbo FSI)||BPY||2006-2008||Golf Mk5, Jetta MK5, Eos, Passat B6, Tiguan, Audi A3||197/207||Turbo Gas|
|2.0T (TSI)||CCTA, CBFA||2008-Present||Golf, Jetta, Passat, Tiguan, CC, A3||197/207||Turbo Gas|
|2.0 T (TFSI)||CESA||2009-2014||Audi TT, A3, A4||221/258||Turbo Gas|
|2.0 T||2015-Present||Golf R||276/280||Turbo Gas|
HOW DOES THE ADAPTER WORK?
Our adapters make the back of the TDI engine physically resemble the back of the original engine it is replacing. No drilling or welding required, no custom flywheels, or shorted input shafts. Any transmission that originally bolted to your engine will work with this adapter kit.
WHY ARE THERE TWO ADAPTER PLATES?
Our two plate system allows you to clock/rotate the engine while keeping the transmission in the stock orientation. There are three different clocking positions: 0 degrees, 10 degrees, or 15 degrees.
DO I NEED A FLYWHEEL OR FLEXPLATE?
Our TDI kits utilize the original flywheel or flexplate from the original engine being replaced. You will not need the VW TDI flywheel, clutch, torque converter, or starter motor.
HOW ACCURATE IS THE TRANSMISSION ALIGNMENT?
We use our Aerospace Grade CMM to pull all the dimensions off the original engine. It allows us to precisely reverse engineer the bolt pattern down to 0.0001". Incorrect alignment will cause premature failure of the pilot and input shaft bearings, excessive clutch plate wear, and internal gear binding.
HOW EASY IS A DIESEL CONVERSION?
-It depends on which vehicle you want to convert and how much mechanical experience you have.
-If you approach the conversion in stages you can get the vehicle driving in less than 5 days.
-Stage 1, do your research first, and lay out all your required tasks.
-Stage 2, focus on getting the engine in and driving with very minimal changes to engine and wiring harness.
-Stage 3, after you confirm the engine runs and drives, start your performance upgrades, custom wiring harness, gauges, engine rebuilds, etc.. This method reduces the number of variables you introduce to the project, and significantly increases your conversion success. Too many people make too many changes right from the start or try to make it perfect the first time round. Take it slow, minimize the number of changes all at once, and you will have a successful conversion!
-You will need regular mechanic tools, engine hoist, welding machine, basic fabrication knowledge, some electrical knowledge, and beverages.
DOES TDCONVERSIONS DO CONVERSIONS ON CUSTOMER VEHICLES?
-Not currently. We sell the conversion kits to get your engine into the vehicle and bolted to the transmission.
WHAT IS THE COST TO CONVERT?
-Conversion cost depends on the vehicle you are converting and the performance level you want.
-The TDI comes stock ranging from about 90hp up to about 150hp. The 1.9L and 2.0L can easily achieve 175+ hp and 300+ ft-lbs with only a turbo upgrade, injector nozzles, and a tune. Upgraded turbos start at $600, nozzles $250 plus installation/calibration, and ECM tunes $400.
-Our adapter kits are $1199 USD with free shipping.
-A used 1.9L TDI engines can be purchased for $500, and up to $1500 for the newer common rail 2.0L TDI.
-Add in some motor mounts, a little fabricating with your favorite electric metal glue gun and you could be on the road for under $2000.
AM I GOING TO SAVE MONEY BY CONVERTING?
-Yes the diesel should get at least double the fuel mileage compared to your gasoline engine.
-Diesel is typically cheaper than gasoline, plus the increased MPG nets you excellent savings and eventually pays for your swap.
-But lets be on honest, you are doing this because you want to save the polar bears and love sexy anodized parts.
DO AUTOMATIC TRANSMISSIONS WORK FOR CONVERSIONS?
-Yes an automatic transmission will work with our adapter kits.
-You will need a standalone TCM controller for your specific transmission. These controllers are highly tunable and have manual shift modes.
-Be aware of your torque converters stall speed and full lock RPM. You may need to purchase a new converter that better suits the TDI.
CAN A FULL SIZE TRUCK BE CONVERTED?
-Most certainly yes! For TDI conversions into half ton trucks we would recommend at least a Stage 4 Malone tune or equivalent with supporting mods (turbo, injectors, etc..). The little TDI can easily achieve 315ft-lbs+ with a larger turbo, injector nozzles, and a tune. In comparison, a Chevy 1500 with the 5.3L V8 is 320hp / 335 ft-lbs. It won't be a rocket ship but it is possible!