In NY all you have to do is check the diesel fuel fuel type box on the registration forms and your all set. Same for propane, just check the alternate fuel box. They seem to be encouraging alternate fuels here, making it easier to do these kind of swaps. Its that easy for vehicles that came with a diesel from the factory, your in a world of hurt if they never made a diesel for your vehicle.
On newer vehicles with diesels its a nightmare. A friend bought a 2008 VW diesel from a dealership in another state and drove it home. He tried to register it here. They wouldn't let him because none of the newer diesels from 2006(?) - 2008 meet the smog requirments here. They won't even let the dealerships sell them.
I agree the CARB and emmissions laws are nothing but a HUGE SCAM and a pain in the ass. Nine tines out of ten it doesn't make any sense at all, ie: the inability to replace a 15mpg guzzler with a 30mpg diesel of a newer year becuase it wont meet a visual inspection. Also the inability to alter a vehicle even if it makes it burn cleaner. I agree if it passes the sniff test what difference does it make what it looks like or what components you use. If it was really about cleaning up our air it wouldn't matter what you did to your vehicle as long as it passes the sniffer. The sniffer test should be the deciding factor and nothing else.
The preach GO GREEN save the earth, do your part. Go alternate fuel BLAH BLAH BLAH its all crap because they nail you every way they can for stepping outside the box of conformity. Go biodiesel or SVO they crucify you for failing to pay road tax on your fuel. Put a high mpg diesel in your vehicle and you can't register it anymore because it doesn't meet bogus smog laws. Tune your vehicle to get more milage and performance and you don't meet visual inspection law anymore. Its all a big fat JOKE. If politicians really cared about actual environmental impact and wanted to encourage change they would alter the laws to allow these repowers and alternative fuel uses. Its hypocritical to push for all these changes in the private and commercial sectors of our society just to prevent you from applying them in any practical way at the DMV. DMV and CARB laws need to be scrutinized and reformed immediately. Think they will ever do it? Hell no, they would rather preach from a podium how crucial it is to prevent global warming by drilling into you the need for higher efficiency, higher mpg vehicles that also burn twice as clean. At the same time completely ignoring the laws that are in place that effectively prevent you from doing anything you can to accomplish just that. Its complete insanity to imagine that a person could invent an engine and fuel system to net 60mpg and burn twice as clean as any engine is use today and still be non smog compliant on a visual inspection. That to me is the definition of ludicrous!!! Just imagine trying to register a brand new 2009 (insert vehicle of your choice) with a 50mpg carb on it. You wouldn't even get to the sniff test. Your invention could run on used motor oil and blow candy kisses out the tailpipe and you'd never be allowed on the road because the emissions system has been tampered with. Sorry, but I don't consider improvements "tampering". I don't care if the engine is from 1932 as long as it passes the sniff test it shouldn't matter what's under the hood. Its just plain insanity to me and I've been saying it for 15 years.
Sorry for the length of this post I just feel this issue is important, and needs to be adressed within government ASAP. People are being penalized for being creative and trying to help improve our environment. The laws are unjust, the system is a SCAM, and the federal and local governments need to end the hypocrisy.
"Don't tell DMV anything!!" Sadly this is the best advise and I agree 100%. Get it built and register it anyway you can. There is almost always some loophole somewhere you can take advantage of. Its just a matter of finding out when where and how to squeek your papers through. I've know guys that swap engines once a year to get the papers they need just to swap back once its legal. A real pain but sometimes its easier then bashing your head against a wall at the DMV for what seems like a eternity.
smoothoperator - To answer your question your swap may not be legal in your state and you may never be able to register your CJ for on road use with the 4bt in it. I say this because the CJ you own probably was never available from the factory with a diesel engine option. So, to put it simply you might be skewd.
Possible options:
Try and register it as a composite vehicle. They will need papers on every part that went into the truck. Engine, trans, chassis, body, axles, everything. I know a man from another state that put a CJ body on a heavily altered dodge truck chassis that came with a 6bt. He used the 4bt, but because the chassis came with a diesel and he re-bodied with the CJ the DMV allowed him to register the vehicle as a composite and issued him a new VIN for the truck. This is a complete pain in the ass to accomplish and requires a very very thorough inspection by DMV inspectors and depending on the inspector they may give you a real hard time.
Canada has alot of diesel Jeeps I believe alot of them are made by Mitsubishi and imported directly from Japan. Find out what the import laws are from Canada and see if you can get one of these. Mitsubishi bought the tooling so tubs and body parts interchange. Put your 4bt chassis under that body and you might have something easily registerd as all you would have to do is check off the diesel engine box on the reg forms and your all set. Now if your state requires underhood inspection or sniff tests for diesels this may not be a viable option.
Buy a small piece of property in a non emissions state and set up a post office box there. Register your Jeep in that state. I actually have a family member that used to do this in Maine until they started requiring emissions testing. I still register all my boats and trailers in Maine as there are no inspections for trailers and the registration fees are less then half of what they are in NY.
Buy another CJ chassis with a gas engine and register it, then put your tub on the 4bt chassis. You'd have to switch back and forth every year. I wouldn't go this route myself as its illegal smog wise and to much work to bother with.
And the last thing I can think of is call your main DMV office and get in touch with someone who is versed in your local laws on alternative fuel vehicles. Tell him you have built this vehicle and want to run SVO in it. Ask what you need to do to get it through the system as an alternative fuel vehicle. Now, you never have to run SVO or biodiesel in it if you don't want to. It just seems to me that some guys in the DMV will work with you to finagle the system a bit to push an alternative fuel vehicle through because they know the system is a joke and hypocritical. As an alternative fuel truck you might find you have better luck acquiring the information you need from these folks. This is how I found out about the laws here in NY. I called, spent an hour on the phone before I got to this older sounding gentleman at DMV in Albany NY. He told me as long as I put my 4bt in a vehicle that originally came with a diesel engine option to simply check the diesel engine box on the reg forms and take it for safety inspection. Diesels older then I think 5 years here do not require emissions tests. I also found out that if I ran propane in any of my vehicles I simply needed to check the alt fuel box and list propane, wich would in fact enable me to a rebate on my taxes for running an environmentally friendly fuel.
Its all just a mass of BS and red tape, double talk and rules with countless exceptions. You just have to find out what hoops to jump through and what people to talk to. Good luck man, your going to need alot of it.
By the way, what state do you live in?