Looks great !!

I have to ask since you did not use an adapter , where did you find an industrial engine from an application that had an automotive trans, flywheel and clutch ; that also had a hydraulic pump / power steering pump ???

 

sorry i kind of lied i did use a adapter But all it is a flat 1/4 plate steel I had the short flywheel housing I bolted the plate to the flywheel housing then welded the bolts to the plate then cut all of the heads off to make it flat then i welded studs to the plate to bolt the tranny to the plate I used the stock clutch and flywheel I had to have the Cummins flywheel turned on the lathe to open it up a little then i drilled holes threw the flywheel and bolted the jeep flywheel to the Cummins flywheel The power steering pump is the stock jeep pump

 

Nice job! What crank & water pump pulleys are those? I like the way you routed the belt to keep correct water pump rotation.

 

I understand ; that is kinda what I did to get the 3.0L mercedes diesel into my JEEP !!

 

Was just wondering ; since you reused the stock jeep P/S pump , did you fabricate the mount to put it on the engine ???

 

The water pump pulley is off my old 2.5 and i made the crank pulley out of my cummins pulley and the 2.5 pulley. I did fab the ps pump bracket I did all of the fab work on my Jeep .

 

Am on the road now with my A-series (A2300T) in the YJ! Working out the bugs, driving short distances and what-not. Seems to be a similar drive compared to the 2.5L gasser that was previously in the jeep. But, I probably have only driven about 10 miles or so, so far.

My big question now, after re-searching through the thread and pictures within this thread, is how did everyone modify the fuel fill nozzle on the YJ to allow for filling diesel at the pump? I went to fill last night, and it didn't fit. I also drive a diesel Jetta, and so I know that there are two sizes of fuel pumps at stations (one for cars, one for big rigs). My jetta does not accept the big rig fuel nozzle, but does accept the smaller car diesel nozzle. I went to use the exact one that I use all the time for the jetta, and it wouldn't fit.

Will probably have to cut the hole, but was wondering if someone had some other solution on the YJ for filling at the pump.

been doing most of the write-up on my jeep here: http://www.mn-jeep.com/forum/showthread.php?t=5938

 

I removed and washed it and then used an Oxy-cetylene rig to blow a hole !! Very quick , but rather messy with the slag !

And my son used a drill bit and wallowed it out, but was still kinda messy with the slivers , so we used air gun to clean it !!

Good Luck !!

 

I used the bottom portion of a plastic funnel for awhile before doing the "drill bit" method mentioned above. The funnel was small enough on one end to go into the jeep and the other end big enough to fit snuggly over the nozzel. Just carried the funnel around in a small, sealed, plastic coffee can inside the vehicle.

 

I appreciate you sharing your experiences. Nicely done. Looking to do the same conversion in mine.

 

Hey Guys ,

Sorry it has been so long ; but with this unbearable heat and two daughters in high school and the oldest on homecoming court, I could not get my schedule and my welders schedule to come together till this past saturday morning !!

So, my Cummins QSB 4.5L is now permanantly attached to my 1994 YJ's frame !! I could not stop smiling with a feeling that I had finally accomplished " something " !! I have been upgrading to an XJ cherokee dual diaphram brake booster / master cylinder / proportioning valve for the rear disc brakes !! I found a way to install the YJ sending units into the 4.5L to give me oil pressure and engine temp in my stock guages and the computer sends a tach signal so looks like I may have to carry a GPS unit for speedometer/trip miles for the time being !

Well, here are a couple pics and there are more on my flickr acct !! If you would like any specific camera angles that I have not shown feel free to ask and I will post to flickr asap !









flickr link :::::::::http://www.flickr.com/photos/42246689@N06/
Can any of the " MODERATORS " look into the idea why the site randomly chooses to list our " signatures " at the bottom of our posts ?????

 

And more progress yesterday !! Now it actually looks like a JEEP again !!
I chose to remove the pulley that a cooling fan would mount to; I could have moved my electric fan up to prevent contact, but removal of the pulley also makes it easier to mount my 2005 power steering pump to the front of the engine !!

 

Almost got her installed and running !!! Only have a couple more hurdles to overcome and she will be running !!

The radiator hoses were interesting, to say the least !! Had to reduce the engine side from 2 1/4 OD down to radiator side of 1 3/8 OD !!







Mounted the Dodge Cummins throttle control and SSBC vacuum pump !! Also found a place to mount the Silicone Intake's Air to Water Intercooler's Radiator + Fan Assembly !!

 

That's looking good.

Regarding the SS electric vacuum pump. I had to tweak mine a bit recently as the vacuum switch wasn't deactivating the pump anymore (it was just running continuously). Turns out it's really simple to do. Unplug the electrical connector and use (I think it was a 7/8) wrench to loosen the switch mechanism and then use a small straight edge screw driver to adjust the center "plug".

Nothing new to report about my conversion. It's been trouble free and still runs well with no drama. It's getting a bit boring actually . . .

 

I got everything together so I could attempt to start the motor !!!

The motor has a build date of 12-5-05 and I am trying to start it for the (possible) first time on 10-7-10 !! There is fuel leaking where the Fuel Rail bolts to the Intake Manifold !! I will have to call Macet and see if it is a warranty issue ( since its in service date is 3-2010 ) or if I have to fix it myself !!

In this photo there are 2 bolts and the small bolt on the left holds the Fuel rail on the Intake manifold, the large bolt to the right is the motor lifting plate !! And there is some grey silicone to the right of the small bolt and this silicone is where the fuel is leaking from !!

Got some " unnerving " news today !! Seems that since no one owned the engine immediately after assembly, Cummins starts the " in-service " date 30 days after the engine's date of build; and there is a 2 year or 2000 hour warranty from that date !! So, even though I am the first registered owner and it has done nothing but sit on a shelf in a pallet; I have NO warranty !! On a possible " upnote " ; the company who sold me the motor had a FINE print area that says " warranties " and there is a line with a box that says None ! Sale is FINAL !! and on the next line they checked the box and typed in " NEW ENGINE GUARANTEED " !! So, I guess if it gets too expensive I can seek a lawyer for what ever that is worth !!
After alot of phone calls to Cummins and my local distributor; it seems that the fuel " log " must have a crack in it !! Can't imagine what that is gonna cost me to replace !! I must admit for as high as I was floating to finally be ready to start the engine; this has been a quick way back down to earth !!

******* EDIT **************

Removed everything to inspect it, and found NO visible cracks anywhere !! While doing this I was racking my brain........... since Macet told me that every engine gets test run before they leave the assembly line !!!! I started thinking ..... What have I done that could have caused this ???? And, I came up with ...... I tweaked the high pressure fuel line ( going from the pump to the fuel rail ) to not hit the motor mount near the pump !!! SO, I tweaked it some more and tested it, and the leak slowed down; but, I can't stop it !! I will order a NEW high pressure fuel line on monday since I will be kicking myself in the rear all weekend for causing this headache !!!