Heres a quick story...
I started the project in Feb 2011, we had a lot things worked out, most of our designs finished ect. ect.
I was welding holes shut on the firewall when I realized I had an ASME meeting in the next room. I hastily left the room, and did not triple check to make sure there was no hot metal anywhere.
5 minutes later the power went out in the whole building, and I immediatley knew what had happened, I ran back to the shop and it was already filled with smoke....
So long story short, the jeep, my laptop, wallet, some tools and just about everything in the shop was destroyed, luckily the enine was on the other side of the shop and was not touched.
So by the ime the fixed the shop, I had about 6 weeks, a frame, a body and a driveline to make it all work in order to graduate.... yee haw...
The main design of the project was the motor mounts, we did stress analysis and everything on them in ANSYS. We also had another engineer doing a biofuel project, so we had big plans to set the whole thing up to run on bio fuel ect. ect. but with the time constaints, we never actually ran it on biofuel, mainly because I was just to nervous about something going wrong, and killing the enine 3 days before we had to present, so we just told everyone it ran on a 50/50 mix of diesel and bio haha.
I got the Jeep done enough to drive it an hour home, no problems. Then I moved to Richmond VA for a job, and it sat at my parents house for a few months.
A few weeks ao, I drove it 5 hours down, no problems, she cruised at 70 mph the whole way, so no I'm tieing up loose ends in my spare time, an taking it out for quick drives.
It has crazy torque, it is definitely geared too low, it is very difficult to pull out in 1st without chirping the tires, and the 600 hp pulling clutch just grabs no matter what, it does not slip a bit, so it kinda drives like a tractor at the moment. I am hoping a re-gear and 35's will improve that a little.
The thing is loud! I have a 2.75" straight exhaust, and the turbo screams! I am only making about 10 lbs of boost under heavy load (5th gear pinned uphill). my EGTs dont go over 700 deg F, which is good, and absolutley no cooling issues, once it is warmed up, its sticks at 190 deg, and does not move.
I installed an air/air intercooler in the front, and just got random bent 2" exhaust tube to run all the turbo piping, and had to fabricate an intake manifold plate
The NP 231 has a super short SYE, and I put in a CV driveshaft, I dont even know who made the driveshaft, my friend at Novak wanted to try some new driveshaft, so he set that up for me, works great so far, I have never liked Tom Woods, I broke 3 on my last Jeep.
The in tank fuel pump is removed and just has a tube pickup, the lift pump on the engine does all the work.
I had to install a vacuum pump to keep the power brakes and vacuum controls, since deisel engines do not creat a usable vacuum anywhere.
Wiring is a peice of cake, you just need power to the fuel shutoff solenoid in the run/start key position, power to the stater and start wire to the starting solenoid, and it'll run.
I used a taurus electic cooling fan, thermostatically controlled and a cheapo alum. radiator off of ebay. Intercooler was off ebay as well.
It has a 1" body lift, and a 2.5" OME sus. lift. I had to fab 1.75" lift shackles for the front to level it out after the motor was in, but I plan to change that down the road.
I have not had it on the dyno, I will after I actually do work to the motor, I plan to put a 6bt turbo on it, injectors, a thing called a "killer dowel pin" in the injection pump to crank it up, hopefully it'll blow some nice black smoke. Hoping for 400 ft/lbs torque eventually.
The axles are stock for now, can't decide what I want to do with that yet.
I got 20ish MPG driving down from PA to VA, I hope to increase that a lot with new gears, it is pretty much topped out at 75 mph because the engine governor is set at 2800 rpm, I want to change the springs in the governor to get it to 3200 rpm as well.
Yes I HATED the yellow paint, I like the sahara green much better haha, but the interior is junk.
You almost need a lift to fit it
Front suspension has to be beefed up a little
Plan to re-gear to 3.08s, almost a must
Air/air intercooler is much better than the stock water/air aftercooler mounted on the intake, and you can save 3" of height off the top of the motor if you ditch the aftercooler
No glow plugs on this motor
A big issue is clearance for the exhaust
Most the bolts on this motor are metric, I have found some good manuals I'll throw some links up to later
Got to get to work!
Jeep 1:Used to have a 93 YJ 2.5l- 3.5" Black Diamond, Chevy TBI 5.7l V8, SM 465 4 speed, 8.8 rear( 4.10, L/S), rhinoline, Mile Marker 9000, NP 231, Had to sell it due to college
Jeep 2: 89/91 YJ, 4BT Cummins, NV4500, NP 231, Old Man Emu 2.5" suspension lift, 1" body lift.....Runs and drives, but very much a project
Interned at Novak Conversions 2 summers ago
Ask me about my 4BT Cummins Motor Mounts!!