Hold my hand through an mtdi build

[ienjoysnails]

Hi.  if its ok with everyone i'd like to ask a few questions regarding my mtdi project.  

car is a 1979 rabbit originally 1.5 diesel, however was swapped out to 1.6 diesel at a point if that matters.



i've procured an engine already.  it is a bone stock euro 1z tdi motor from a passat with 100x miles.  trans will be a euro mk3 chc code 020 diesel trans.  i got the trans free with the motor so decided for now to stick with rod shift instead of converting over to the newer passat 02j cable shift trans.  the pump will be modded to mechanical by giles.  i decided to swallow the $1400 cost of his mod rather than try wiring it up because i was able to buy the motor for very cheap.  also in my area it is very hard to find tdi parts cars.


 

anyway i don't want to make this into a build thread, but if people have any questions on certain specifics once i get mine done feel free to contact me and i'll try to help.  i'm very much a noob so this is a complete exercise in learning whatever i can about diesels and cars in general by doing.

and the questions begin..

i've notice other tdi swappers using the mk2/3/4 fuel filter setup.  does the flow rate differ from say my mk1 diesel fuel filter setup.  i'd like to retain it since its there.  probably move it out of the way of the intake, but at least keep it.  ??

my current glow plug set -  if i'm not mistaken there is a fast and slow relay setup. i have the fast.  wiring this relay/fuse glow plug setup into the tdi glowplug harness, would this work?  the harness has two small wires coming from it that plug into the wiring harness block.  couldn't i cut them and wire my wiring into this?

i have to ask giles regarding this but i've read that with mechancial pump setups and tdis you have to go with bigger injectors bc the smaller ones don't open with the lower pressure.  is this true?  i've seen lift pumps running a couple psi to the pump to help out, but they weren't giles pumps, they were aaz pumps.  just curious about his?

thats all for now.  more to come i know

[dodger21]

I argued a bit on TDI Club about a pusher/lift pump with a VE pump.

I had a Cummins 6BT that I put a Walbro 392 on it and regulated it to 16psi with no ill effects. In fact, smoke through the RPM band lessened and high RPM's it still pulled hard. I only sucked it down to 10psi at WOT through the 5/16" lines. I also seemed to have gained 1-1.5mpg but that was negated by my right foot.

Some Cummins guys argue anything more than 18psi will push out the front seal and red-locktite the seal in. I also know personally 2 guys pushing more than that. One has a Cummins, the other is a 1.6D VW... Both were still on stock seals.

The VW guy claimed to have gotten 4-5mpg more.

When I can afford the money, I will be putting one on my car and pushing 10psi regulated.

[drrtybyl]

i've notice other tdi swappers using the mk2/3/4 fuel filter setup.  does the flow rate differ from say my mk1 diesel fuel filter setup.  i'd like to retain it since its there.  probably move it out of the way of the intake, but at least keep it.  ??

The money will flow out of your wallet at a much faster rate every time you replace a mk2/3/4 filter vs. a mk1: I want to say they are like twice as much?  And using a mk1 filter shouldn't be an issue.

Welcome to the forum -- nice car -- always good to see mk1s getting resurrected.  I embarked on the same swap way too long ago and have finally started to finish it up.  

Are you fitting the Passat crossmember or hacking up your own passenger side engine mount?

[ienjoysnails]

yea hacked up a diesel mount.  i just need a clutch plate and i can bolt the trans to engine and bolt engine in car.  i read through your thread and its giving me some inspiration to get a move on it. 

apreciate the fuel filter answer.  puts my mind at ease. now just need to figure out glowplugs.. thanks

[R.O.R-2.0]

welcome to the most awesome diesel forum!

Im Glegor (from VwVortex) who was helping you over there..

glad to see you are one of us now.. 

[8v-of-fury]

GP should be easy to get working.

The TDI (being more efficient then an IDI) hardly uses the glowplugs.. actually I think they are only activated below 40F. Sure the light in the original mk3 dash comes on each start, they never actually fire the gps.

Leave ALL your stock wiring in place and just hook the TDI buss bar for the plugs up to your original buss bar feed. They are the same style 12v plug, pull the same amps, everything should be groovy. Just when its above 50F out just go right to start, you wont have to wait on the run position for the plugs to do their thing. In between 40-50 give them 5-8sec and below that let your gp controller do its full cycle what ever that may be.

Congrats on the a1 tdi swap. I too am currently mid swap on a full E-TDI to an 81 Good luck

[ienjoysnails]

yay got my glow plug answer i was looking for!  thanks 8v.  thats what i was figuring but i know so little i doubt myself alot!

hey glegor!  yea as soon as i saw vwdiesel reopened registration i figured i should join the best.  if you didn't read my vortex forum i dissaembled my 1.6 and found out it needed a rebuild of the bottom end and alot of headwork.  then cheap tdi came along and it was an easy choice. hard to believe only a few months back i couldn't even tell you if my engine was actually a 1.6 or 1.5.  hah