In a hidden warehouse on some farmland outside of metropolitan Detroit, a group of engineers from the oldest family in 4x4s assembled a secret project in an effort to bring a special product to market. The plan was simple, the timeline short, and the result spectacular. Here is the inside scoop on how some rogue Jeep-lovin' Mopar guys stuffed a military diesel into a Jeep TJ in hopes that you'll do the same someday soon.
From the outside it looks...
From the outside it looks like your average built TJ Unlimited with 35-inch BFGs, 3-inch Black Diamond suspension, and an AEV Highline hood and fender kit. Under the hood it's another story. Actually, it's this story.
It all started when the engineers in the Mopar Performance Parts unit realized that the 2.8L I-4 diesel engines being built for the Egyptian military could also be a great small diesel crate engine. The version used here would perform better than the 120hp and 240-lb-ft of torque version used in the '03-'05 Jeep Liberty diesel and could be easily fitted into a '97-'06 TJ Wrangler, then those owners looking for something different and fuel-efficient just might be willing to do the swap. Thus a few months before the big Easter Jeep Safari in Moab, a plan was hatched to pull one of these diesels from a military Jeep test mule and stuff it into an '05 TJ Unlimited. We got some behind-the-closed-doors photos of the install. We also got a chance to drive the finished vehicle and are waiting impatiently to get our hands on a crate engine of our own.
Your 2 Cents
Do you think Mopar should go ahead with this crate-engine program? Remember, it doesn't only have to go in a Jeep; it could fit in any 4x4 that a small torquey four-cylinder would help motivate and would do so efficiently. If you support the effort, send your comments to the following e-mail, and let them know you're ready and willing: moparpr@jrthompson.com. Make sure you reference the story in 4-Wheel & Off-Road magazine in your e-mail!
 The project started with two...  The project started with two Jeeps: a military long-wheelbase TJ known inside Chrysler as the T1, and a TJ Unlimited Rubicon. The T1 came with the 2.8L common-rail diesel packing 120 hp and 240 lb-ft of torque and a five-speed manual transmission. The Rubicon had a 4.0L straight-six and a six-speed manual. The first job was to pull the engines from both Jeeps. |  The fenders and tub were removed...  The fenders and tub were removed from the TJ chassis. Original plans were to bolt the 2.8L diesel to the TJ's NSG370 six-speed manual, but because this engine has an integral bellhousing, the T1 NV3550 transmission was used instead. The NV3550 was available in '00-'04 TJs, and our sources believe the earlier AX-15 five-speed would also bolt to the diesel. |  The gas and diesel engines...  The gas and diesel engines have different motor mounts and new frame brackets were required, so the framerails were ground clean. Notice the complete engine, transmission, and transfer-case assembly waiting to go in the chassis. Behind the NV3550 is the Rubicon 241-OR transfer case with the 4:1 low-range gearset. The transfer case was moved slightly in the chassis and driveshaft modifications were required, but final versions would ideally not require any changes |
 Since time was short, the...  Since time was short, the original diesel engine mounts were cut from the T1 chassis and welded to the TJ chassis. If a complete kit becomes available for the swap, we expect new motor mounts would be included as well as the complete fuel system, radiator, and intercooler. All these steps are being assessed to determine if the swap is viable and at what cost. |  With the drivetrain installed,...  With the drivetrain installed, the body was slowly lowered back onto the frame. The engine clears the firewall, and because the T1 uses the same front sheetmetal as the TJ, the mil-spec radiator and intercooler were used. |  Since time was short, the...  Since time was short, the original diesel engine mounts were cut from the T1 chassis and welded to the TJ chassis. If a complete kit becomes available for the swap, we expect new motor mounts would be included as well as the complete fuel system, radiator, and intercooler. All these steps are being assessed to determine if the swap is viable and at what cost. |
The only hint of the new engine is the green diesel fuel cap and a subtle combustion clatter coming from under the hood. Final pricing hasn't been determined yet for this crate engine (Mopar still calls this entire effort "a research project"), but we would like to see it around $7,500 for the crate engine alone (Hemi crate engines are $8K to $11K) and $11,000 for a complete kit. We feel the kit should include everything from fuel and cooling system down to clutch and flywheel bolts. It should also be available from any Chrysler, Jeep, or Dodge dealership offering Mopar parts, making it easy for anyone to source.