Swapping VW engines - Gas to Diesel?

[Sam]

I'm sure this has been covered before.

Can anyone direct me to info regarding how to convert a gas powered MkI or MkII VW to a diesel engine?

Thanks

Sam

[catlin_cava]

Get a VW diesel of your choice, and a complete wiring harness for it,

take out the gasser and the wiring harness and replace it with the diesel,
Your best bet...get a complete donor car,makes it easier to do the switching

Many of us of done this swap

[Sam]

Thanks, I do have a donor car with a good engine and interior but the body has rusted.  So this sounds fairly straight forward as long as the wiring harness swap isn't too difficult?

Do all the engine mounts line up?

Any other mods?

I've heard diesels have beefier suspensions?

What about gas tank?

Any help is greatly appreciated.

Thanks

Sam

[catlin_cava]

When I did mine I swaped tanks and lines, My engine mounts lined up, I did it with MK3's. if both cars are from the same gen its a straight forward swap.

[8v-of-fury]

Do all the engine mounts line up?
If your going from the same generation, the mounts do not differ from gas to diesel. If your going from one generation to the other, the mounting holes on the engine do not differ from gas to diesel. Meaning you can put an mk2 engine in an mk1 and vice-versa.

Any other mods?
It would be wise to keep the gasser in tank fuel pump (3-7 psi) as it will be a huge aid if you ever need to re-prime the pump in the event of a small fuel leak or other issues. You can also use the wire that would have excited your coil to operate the shut-off solenoid on the injection pump of the diesel engine.

I've heard diesels have beefier suspensions?
I have an 81 diesel jetta 4dr and an 84 gas jetta 4dr and visually all the suspension components look to be about the same size.. could be a stiffer spring for all I know. Diesel's generally weigh more, however I think the 1.6/1.9 weigh only minimally more then there gas equivalent displacement engines.

What about gas tank?
The original "gas" tank can be used as long as there is a supply and return line running from the tank to the engine bay. Now depending on what car you are converting to diesel it will already have the lines there for you. An mk1 mechanically fuel injected car with CIS will have both Supply and Return lines.

Seeing as you are choosing to swap an MkI or MkII to a diesel this will be simple as pie. With a little more information we will be able to get you happily on your way to some diesel motoring.

Can we have some information about your donor? Mk1 or Mk2? Turbo or non turbo? What year?

I think with the help of the awesome people on here this will be an easy swap! good luck!

[teftdossy]

I had to swap my gas tank and I found one from a 97 2dr Tahoe. Im using my original pump from my 93 Blazer. Does anyone have any pics or a how to on swapping these two?

[rabbitman]

I had to swap my gas tank and I found one from a 97 2dr Tahoe. Im using my original pump from my 93 Blazer. Does anyone have any pics or a how to on swapping these two?

 

[Sam]

Seeing as you are choosing to swap an MkI or MkII to a diesel this will be simple as pie. With a little more information we will be able to get you happily on your way to some diesel motoring.

Can we have some information about your donor? Mk1 or Mk2? Turbo or non turbo? What year?

I think with the help of the awesome people on here this will be an easy swap! good luck!

Hey thank you very much!!  I knew I came to the right place!   

I currently have an 89 Golf that has a NA diesel engine.  This car and engine have been so good to me it made me very upset when I noticed that my floor jack was pushing the jacking point up thru the floor!     I was more than surprised because underneath the car looked so solid.  Anyhow I won't do that again.

I'm on the hunt for a replacement car and thought that if I can swap my diesel from this car into a gasser then I have a lot more potential cars to look at.  I'm not fussy in terms of MkI or MkII.  I actually think I like the older ones better!  It's very good to get some information on this swap.  The coil wire to the fuel solenoid is a great idea.

Currently I'm still on the hunt.  I'm hoping to find a VW Rabbit pickup to put the diesel in.  My dad has one that is almost mint but he won't sell it to me despite the fact that he's WAY too big for it.  His beer belly hits the steering wheel!   

I'll continue to drive the 89 for now.  Hopefully my seat doesn't fall thru the rusty floor.  I found a nice Rabbit GTI that might keep me going until I find a caddy.

Thanks again.  If I have any more questions I know where to come. 

[GEE-BEE]

Several on the samba.com

[Sam]

What about putting a MKII dash into a MKI?

I've seen a few ads where this has been done.

Is it just a straight swap?

For some reason I always thought the MKII's were a bit wider.....

[GEE-BEE]

EARLY JETTA DASH AND CABBY DASH FIT.....

[lovinthedeez]

i converted a mk2 jetta with a mk1 rabbit motor here

http://www.vwdiesel.net/forum/index.php?topic=19324.0

its super easy.  message me with any questions if you got em

[topless96]

I converted a 1996 cabrio from gas to diesel using a 1984 1.6 td motor and transmission. My next one will be from a 1997 Passat but that has all the wire issues ( computer for pump) to sort out. The 1.6 with a Giles pump mod is great to drive even in the slightly heaver cabrio.