Author Topic: 96 MK3 Diesel Build (Read 4753 times)

catlin_cava · « **on:** September 06, 2008, 12:54:07 pm »

As you may know by now i was building a 96 MK3 gas into a 1.9TD. Well today was the test day and it works...however to get it started i have to run a wire from the connection near the throttle body to teh + battery post...and i have to take the wire out to shut it off...Anyone have any sugestion about that???And Man i'm happy i did the swap...alot more power heheheh :twisted: ...oh and only my odometer, tach, and speedo work...no other gauges...why???Thanks for all you guys help on this.

Catlin

gigaz2 · « **Reply #1 on:** September 06, 2008, 01:06:27 pm »

you need to route a fused wire from the keyed positive that comes from the key.

make a list of what doesn't work, its easier to address

catlin_cava · « **Reply #2 on:** September 06, 2008, 04:42:55 pm »

Ok this is what works...
-speedo
-tach
-odometer
-sunroof hehehe

what doesn;t work
-fuel gauge
-heat gauge
-car wont start unless there is a wire from the fuel cut off to the battery
-most of the lights in the gauge cluster
-an anoying beeping sound when all my fluids are fine. :evil:

Its almost done...

gigaz2 · « **Reply #3 on:** September 06, 2008, 05:05:23 pm »

all wiring problems, do you have a chiltons or a bentleys manual?
they show both wiring versions, you can compare and rewire.

the fuel one is the easiest, then the senders, you might have swapped the wires.
what dash are you using?

flapjack · « **Reply #4 on:** September 06, 2008, 08:08:59 pm »

For the fuel solenoid on the injection pump: unplug the coil, find which wire has 12v and run it to the fuel solenoid.

Fuel gauge: did you do anything to the intank pump / float ?

Annoying beep: the gas engine sensors are for different pressures. The TD sensor that goes on the oil cooler should be for 1.4 bar, the one on the TD head I think is the same as the gas one, I don't remember

My temp gage didn't work with the TD sensor, I had to put the gas sensor back in.

catlin_cava · « **Reply #5 on:** September 07, 2008, 07:14:57 am »

I have the Hans Repair Guide, I'm using all the front hiring harness and Fuse panel/dash form the TD. I have the Diesel tank and sending unit in the tank...i think the temp gauge might be because i didn;t let the car warm up much...i'll try it later. For teh fuel Gauge i have clipped the wires for teh Gas sending unit and connected the wires for teh diesel tank matching the wires...maybe it didn;t wrk?

catlin_cava · « **Reply #6 on:** September 10, 2008, 07:25:17 am »

OK so i found the problem....there is a little Black box thats connected in the dash behind the light switch that controls the GP's and Fuel system...oops....I actually called for help on it the local VW Specialty shop help me with that...I hope it works

zukgod1 · « **Reply #7 on:** September 10, 2008, 07:35:51 am »

Quote from: "catlin_cava"

I have the Hans Repair Guide,

Theres one problem

Quote from: "catlin_cava"

I'm using all the front hiring harness and Fuse panel/dash form the TD. I have the Diesel tank and sending unit in the tank...i think the temp gauge might be because i didn;t let the car warm up much...i'll try it later. For teh fuel Gauge i have clipped the wires for teh Gas sending unit and connected the wires for teh diesel tank matching the wires...maybe it didn;t wrk?

The sender is different from gas to diesel. reads different oms anyway which would cause the gauge to not function correctly.

catlin_cava · « **Reply #8 on:** September 10, 2008, 07:44:56 am »

I realized the manual was use less....my sister has the bentley but thats in Halifax...I used the float unit on the diesel in my car.

catlin_cava · « **Reply #9 on:** September 13, 2008, 04:46:15 pm »

http://ca.youtube.com/watch?v=o8yj4arCNa0 ... thats it today its idling a bit high

djarka · « **Reply #10 on:** September 13, 2008, 11:27:19 pm »

What cluster are you using? The TD cluster that came from the TD engine?

catlin_cava · « **Reply #11 on:** September 14, 2008, 06:31:28 pm »

Yea I'm using the TD Cluster...would my gassers cluster work better???heres all the issues i;m having, my tach and speedo work...sometimes, If i pull the hand brake up they go off, there is beeping and the oil is fine...once again the hand brake stops it...The anti theft is set off and the starter doesn't want to turn...I have to jump start the car everytime...and lastly...I HAVE A MAJOR SHORT...it drains the battery in the matter of 3 hours...

Catlin

Vincent Waldon · « **Reply #12 on:** September 14, 2008, 06:48:53 pm »

Tach in the gasser cluster won't work with a diesel without some mods.

The fact that the handbrake affects electrical equipment is the classic sign of one or more major ground issues... the handbrake cable is adding a parasitic ground when the cable is tightened.

Buzzer means the potential of low oil pressure (*not* fluid level) but the fact that you have a bunch of electrical issues suggests it's a false alarm. I say "suggests" meaning: it could also really mean your engine has no oil pressure.... a mechanical oil pressure gauge will tell the story.

A three hour drain is a pretty big leak... the classic way to troubleshoot this is to rig an ammeter in series with the battery and then pull fuses one by one until the current drain goes away.

catlin_cava · « **Reply #13 on:** September 14, 2008, 07:09:37 pm »

There is oil pressure, I pulled the oil cap off to check there was oil splashig in the valve cover...

What about the car not starting? yesterday the starter was working then the battery went completly dead and it stopped starting...

and for the major electrical...its going to a shop to be fixed...i don;t understand wirring...

djarka · « **Reply #14 on:** September 14, 2008, 08:16:39 pm »

Quote from: "catlin_cava"

What about the car not starting? yesterday the starter was working then the battery went completly dead and it stopped starting...

I am thinking maybe alternator isn't keeping the charge up for you. For diesels, once when you start the car, everything runs off the alternator (except for things like lights, music , etc is off the battery).

As for the cluster, I was wondering because if you mix different harnesses together, then I heard it doesn't work. Like if you use the Jetta's harness, you have to use a Jetta cluster for it (so in this case, the same harness that the TD cluster came from). I heard the gas ones would work but things like the tach and such would be way off. It's best to use a TD cluster just because it has your indicators (ie. glow plugs and such).