Step By Step TDI Swap - Part 7 : Electrical Wiring

This time on part 7 of the step by step TDI swap, we're diving in to the dreaded electrical wiring. If you can spare the cheddar, a harness from Fast Forward Automotive takes a TON of the guesswork and time out of this portion. You're going to need to plumb in your factory Jeep coolant temperature sensor and oil pressure sensor for those gauges to work, but otherwise everything else is cake. I also took this opportunity to upgrade to some Mean Lemons 2 Gauge battery cables to ensure the high torque starter would have the juice it needs. Let's get into it!


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*This product is meant for entertainment purposes only. Your mileage may vary. Do not try this at home. Void where prohibited. Some assembly required. For off-road use only. Slippery when wet. Batteries not included. Do not use while operating a motor vehicle, heavy equipment, cherokee XJ, wrangler TJ, wrangler JK, or any Jeep vehicle, especially the newer Fiat ones. How-to videos may be too intense for some viewers and children under 30 years of age. Please remain seated until the 4x4 ride has come to a complete stop. Studies have shown viewing these videos causes increased cancer risks in laboratory test people. I am not a professional, I have no training, I'm not even particularly good at horse whispering. Don't believe everything that you know. Please keep your hands in the vehicle at all times. Do not tap on glass. Do not eat anything that has been on the floor for more than 3 days. Keep your hands to yourself. Not to be taken internally. Reproduction strictly prohibited. Driver does not carry cash. Objects in Bleepinjeep mirrors may be farther than they appear.*

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[bleepinjeep]

This time on part 7 of the step by step TDI swap, we're diving in to the dreaded electrical wiring. If you can spare the cheddar, a harness from Fast Forward Automotive takes a TON of the guesswork and time out of this portion. You're going to need to plumb in your factory Jeep coolant temperature sensor and oil pressure sensor for those gauges to work, but otherwise everything else is cake. I also took this opportunity to upgrade to some Mean Lemons 2 Gauge battery cables to ensure the high torque starter would have the juice it needs. Let's get into it!

[jordanl]

as someone who has owned both an XJ and a manual 03 TDI, I'm a big fan of this project !

[shark]

I'd never do a swap like this, but damn this has been super interesting to watch.

[jeffreywilliams]

Hi just wanted to thank you for the great videos. I’m definitely a fan of yours now. ☺️

[obi-wankenobi]

can you do an update for the driving manners compared to stock 4.0 and overall review of the new engine in the XJ for daily/off-road use?

[hughlancaster]

I completed a 1.9 TDI swap out of new beetle 2002. Love my truck. Had issues with adapter plate. A great learning experience. I have an issue the last couple of days. First my break light fuse randomly blows. Then as I reversed and back up the engine shuts off. Now I will be driving down highway and engine will shut off. I have to shut key off and then restart. It takes several revolutions before starting.I have a brake switch logic synchronizer from fastforward and noticed it was getting hot but maybe that because I had post in between my seat and break pedal. I was testing to see what is causing the fuse to blow. Still can't determine. Stumped!

[Jeepy]

I have the ALH, and the wiring harness. Once I settle on a trans, tcase, and rear axle, its all going in my dead quadratrac CJ7. I'm hoping the dirt simple CJ wiring, a GPS speedo, and fully intact vw harness (including all the dash wiring in one piece) will make it fairly painless.

[evan_alexanderr]

Trying to see if this swap will also work with my 2006 jetta tdi engine since I already own both cars but idk if it’s the same 1.9 L engine you used

[ForceBuilt]

Did this project die? I don't see a next video 8 months later.

[cfh]

Sooo I’m swapping a tdi into my 04 mini. I can pretty much use this process for my set up ya?

[danieldobrin]

Not sure if someone asked this or not but did you use the TDI alternator? If yes, then did you connect the Jeep alternator wires to the Tdi alternator to get the gauge in the cluster to work?

[jstutzman]

Add your neutral safety wire to the tach switch on the column.

[diomarfernandez]

Amigo me me gusta como te quedó la adaptación

[RWLD]

Well, looks like the timing belt will be easier to change! lol

[chrisoneill]

Howdy, I’m doing a bhw tdi into a Jeep tj. I was wondering if you wired in your own check engine light from the vw ecu?

[natemasterson]

I'm certainly no electrician. But could you use a relay between the cam signal wire and signal ground that uses the starter control signal to switch closed/open? The example I found online has a 12V 4 pin single pole single through relay, pin out 87 to signal ground, 30 to cam signal wire, 85 to the starter control wire, and 86 to chassis ground. That may not be the correct pin out, but I would think that would work, yeah?

[timfisher]

those ECUs generate heat, make sure there is plenty of air circulation and protect them from radiant heat from the exhaust & turbo

[psementalist]

Bravo excellent good video content 👏 👌 👍

[RyanWithAviators]

Always good to see another episode of this swap. A few questions as usual.
Any particular reason why you decided to route the relays inside the cabin? I have mine outside, under the hood in my Ranger swap, but now you have me second guessing myself on my decision. Lol
Also I don’t know why I never thought of doubling up inside the wiring loom the long wires provided by fast forward automotive. I’ll have to do that. Good thinking.

Also if you know where to get that plastic ECU slot that attaches to the metal ECU bracket, I would love you forever because I do not at all like my tiedown that’s holding my ECU down to my bracket currently.

[coreymedors]

Question what did you do about the hole in the timing cover ? Mine will be subjected to water worried about the hole from the motor mount in the timing cover.