Jeep Wrangler JK BHW 2.0 TDI Swap

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Joel451

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Joined
Aug 3, 2020
Location
Oliver Springs, Tn
TDI
2004 Passat 2.0
believe its the same pump, pulled it out of a mid 2000 volvo S40. Also pulled out a similar pump from a mazda 3 although the high pressure port is smaller. Nice thing about the volvo pump is the vw high pressure line screws right in. Pump is heavier than I was expecting so it will require a sturdy bracket for support.
 
iwannajettatdi

iwannajettatdi

Veteran Member
Joined
Jun 17, 2003
Location
Salem, OR
TDI
2015 Brilliant Black Audi Q5 3.0TDI, 2014 Tempest Blue metallic Jetta Sportwagen TDI, 2002 Blue Eurovan Weekender BHW TDI
Straypoet said:
Good feeling to have it actually in the vehicle! what PS pump are you using? I am planning to go with the volvo EPAS pump. Curious what you ended up with?
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If you havent already figure out your setup, I used a Mini Cooper electric/hydraulic PS pump initially in my Eurovan swap because of how low the stock pump hung. Easy wiring, power, ground, and an 'on' signal I stole from the alternator light wire to excite the electronics. A Eurovan is way heavier than the Mini, and I never had an issue with it. Food for thought.
 
d0u8l3m

d0u8l3m

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Joined
Jun 16, 2014
Location
Connecticut
TDI
B5.5 Passat
I watched the engine mount video and was going to ask if you weren't planning on using AC l, but went back and saw your comment about an overhead system? What's that all about, you got a small heat pump working off a battery backup? Nice progress so far!
 
S

Straypoet

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Joined
Jun 17, 2020
Location
Florida
TDI
BHW 2.0, soon to be in my Wrangler.
d0u8l3m said:
I watched the engine mount video and was going to ask if you weren't planning on using AC l, but went back and saw your comment about an overhead system? What's that all about, you got a small heat pump working off a battery backup? Nice progress so far!
Click to expand...
As far as engine accessories, I will only have one. That is a 48v Etorque generator that I have from a 2019 RAM 1500, which will power basically everything else I need via 48v, or 12v stepped down. (AC, Power Steering, Etc.)

I will power the AC compressor off of the 48v house batteries, yes.
I plan to mount the system overhead, (above the center console)
Should be able to direct the cool air forward or backward, or split depending on need.

My plan is to be able to temp control using the solar array and the 10KWHR+ lithium pack that I plan to have.

If all goes well, I would be able to sleep in AC all night long using the stored power onboard. We will see......
Thank you!
 
d0u8l3m

d0u8l3m

Veteran Member
Joined
Jun 16, 2014
Location
Connecticut
TDI
B5.5 Passat
That's badass, I have about 26KWh worth of K2 26650s lifepo4 cells that I'm building 48V battery modules out of for my house with a 12k growatt solar inverter/charger to run off and about 14kW of solar (growatt can handle 7k and a seperate mppt for the other 7).

I was planning on building up an enclosed trailer to act as the mobile power station with all the equipment rather than keeping the batteries in the house/garage, and running the feed to a generator transfer panel or a separate panel all together for stuff that I don't want to run off the grid.

I had no idea those RAMs had 48V generators that's amazing that were at that point in tech, I might have to look into that, as I can think of a ton of applications having a constant 48v off an engine. Is it 48v output even at idle or do you need to be at a certain RPM? You could even run one of those little electric turbos (the legit ones not the ebay ones) and maybe setup a PID to maintain a minimum boost pressure to minimize boost lag.
 
S

Straypoet

Veteran Member
Joined
Jun 17, 2020
Location
Florida
TDI
BHW 2.0, soon to be in my Wrangler.
d0u8l3m said:
I had no idea those RAMs had 48V generators that's amazing that were at that point in tech, I might have to look into that, as I can think of a ton of applications having a constant 48v off an engine. Is it 48v output even at idle or do you need to be at a certain RPM? You could even run one of those little electric turbos (the legit ones not the ebay ones) and maybe setup a PID to maintain a minimum boost pressure to minimize boost lag.
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Yep, I didn't know that either until looking around for a BSG to put into my project. I originally thought I would use the one that is on the 2.0 wrangler, but the RAM one is air cooled. It is basically just a 12kw generator that can also be used as a starter or to assist the engine with a little bit more torque.

It would put out a regulated voltage over 48v (would need more than 48v to charge the 48v system), but obviously the amperage would depend on how much power the engine puts into it.

Using that system to power an electric turbo is a cool idea.

I have always wondered what the real breakdown of how much power one loses by the parasitic backpressure losses caused by a turbo powered by the exhaust. I wonder if the power loss would be less by using a generator and then powering the turbo that way. Still a loss; the energy to compress the air charge has to come from somewhere, but it could be more efficient, and not having to worry about spool-up time, could make it even better. I expect I will have several years of fun enhancements on this project. :)
 
d0u8l3m

d0u8l3m

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Joined
Jun 16, 2014
Location
Connecticut
TDI
B5.5 Passat
I'm going to have to dust off my machines and drives and power electronics books at some point and look more into this in the future. I used to work for a genset company and the project I was working on was a unique application where we regulated engine speed based off the DC generator voltage output and it was adjustable from 12-75V. I always wondered using that system in an electric swap to charge the battery like Chevy does in the Volt rather than as a propulsion. Those little single cylinders don't use much fuel, and with a decent size generator I'm sure it wouldn't take too long to charge the batteries if you have all the wiring beefed up.

But staying in the ICE world yeah it will be a cool comparison to see, my truck will have full accessories so ill definitely be doing some comparisons.
 
S

Straypoet

Veteran Member
Joined
Jun 17, 2020
Location
Florida
TDI
BHW 2.0, soon to be in my Wrangler.
iwannajettatdi said:
If you havent already figure out your setup, I used a Mini Cooper electric/hydraulic PS pump initially in my Eurovan swap because of how low the stock pump hung. Easy wiring, power, ground, and an 'on' signal I stole from the alternator light wire to excite the electronics. A Eurovan is way heavier than the Mini, and I never had an issue with it. Food for thought.
Click to expand...
Thank you for the reply.
Do you happen to know what the amperage draw on the mini pump is?
I like how simple it is.

Also, is it loud? I am wondering if it is brushless or not? I assume it is.
 
S

Straypoet

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Joined
Jun 17, 2020
Location
Florida
TDI
BHW 2.0, soon to be in my Wrangler.
S

Straypoet

Veteran Member
Joined
Jun 17, 2020
Location
Florida
TDI
BHW 2.0, soon to be in my Wrangler.
I uploaded the next video.

JK130 Part 13, New Bumper, N75 Valve, Wiring Seats bolted Down


I have bought both bumpers. They are made by RIVAL, and are very nice... Though way too expensive. $1900 for the pair
Bought airbox $100, Seat Platforms $150, Battery $300, Wiring, and disconnect Switch, terminal boxes etc. $100
Also bought an EPAS pump from a Volvo $100 for the power steering conversion.
About $2,650 in the last few weeks. Ouch.
 
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