1.6D Swap

[8v-of-fury]

dont worry about the water seperator. People generally remove theirs anyhow..

Any mk1, mk2, or mk3 fuel filter will work. I personally prefer the latter two as they have a built-in fuel preheater system.

[lovinthedeez]

thought I'd throw some pics out there for you; a few things that I ran into doing this swap (except mine was mk1->mk2)

try to find a non a/c alternator bracket.  here it is sans alt.



diesel nozzle restrictor.  used a sharp wood chisel and it came out in two big pieces


you'll need the diesel accelerator cable or find a way to splice the diesel one onto the gasser one.  the ends are different


for the glow plugs, I highly suggest vince's pimp your glow plugs idea


pics are from my swap thread
http://www.vwdiesel.net/forum/index.php?topic=19324.0
I also have an extra mk1 fuel filter flange if ya end up needing it...good luck

[Mark(The Miser)UK]

diesel nozzle restrictor.  used a sharp wood chisel and it came out in two big pieces

Hi
I was just wondering why your injector hole looks  like something out of Ghostbusters.  Even forgetting that 'ceramic' finish, I can't quite make out your heatshield ledge. Mine is below for comparison
Perhaps it's a trick of the camera perspective

[veector]

thanks for clearing up a few things, im definitely considering the pimped glowplugs, PO upgraded to the conical short cycle glows.

[8v-of-fury]

You may or may not need a different throttle cable. All of my volkswagens have the same throttle end.. And if its the same clip over ball type throttle cable that was on the mk1 CIS then it can be made to work ridiculously easy. Put a picture up of your pumps throttle and your throttle cable end.

[veector]

The throttle cable is good, same ball and clip type as all mk1s.

After playing around with some manifolds and having both of them crack at the flange during handling , i think il stick with the orig 4/1 manifold that came with it.

what would be a good size exhaust to run? I've got a Liestritz muffler kicking around id prob throw on the end

[8v-of-fury]

I personally have a 2" straight through exhaust with a cherry bomb between the downpipe and shifter in my tunnel... It goes over the axle and out the side behind my drivers tire.. Its not ANY louder than a 1.6D with an exhaust. As I have another to compare too.. However some will say there will be a ridiculous drone, where? I have yet to experience it. I drove this thing right off the manifold and it wasn't even that bad...

As long as its a sealed exhaust system and it exits out the back, you won't have a drone. The drone comes from trapped exhaust note circulating around inder the car.. Ie. A poorly built exhaust system.

[lovinthedeez]

diesel nozzle restrictor.  used a sharp wood chisel and it came out in two big pieces

Hi
I was just wondering why your injector hole looks  like something out of Ghostbusters.  Even forgetting that 'ceramic' finish, I can't quite make out your heatshield ledge. Mine is below for comparison
Perhaps it's a trick of the camera perspective

no, I think its a trick of looking at the fuel filler neck and not the injector hole in the head.  Don't know how they do it in the UK, but they put a restrictor on the gas cars that won't let you accidently put diesel in your car.

[veector]

Okay thanks Jer, i'l be taking it to my exhaust guy, he works wonders, all custom and veryyy reasonably priced.

thanks again to everyone for the help, I remember why I like it here way more than poortex

[dl_sledding]

diesel nozzle restrictor.  used a sharp wood chisel and it came out in two big pieces

Hi
I was just wondering why your injector hole looks  like something out of Ghostbusters.  Even forgetting that 'ceramic' finish, I can't quite make out your heatshield ledge. Mine is below for comparison
Perhaps it's a trick of the camera perspective

Ummm...

I might be a little dense here and missing the joke.. But the first pic is not of an injector location, but the filler for the fuel tank. "Nozzle" like in "Fill 'er up", not injector nozzle.  Like, it's 2" wide, compared to 1/2" for the injector...

[Mark(The Miser)UK]

Holy sh**e, wow what a plonker I am.  I thought that messed up lug on the side was a fused glowplug I must stop these 3AM posts!
I'd be tempted to run away from this forum in shame,  however, I can take being wrong, unlike some

"I might be a little dense here and missing the joke.. But the first pic is not of an injector location, but the filler for the fuel tank. "Nozzle" like in "Fill 'er up", not injector nozzle.  Like, it's 2" wide, compared to 1/2" for the injector..." So how come my picture is bigger than yours?

[dl_sledding]

"I might be a little dense here and missing the joke.. But the first pic is not of an injector location, but the filler for the fuel tank. "Nozzle" like in "Fill 'er up", not injector nozzle.  Like, it's 2" wide, compared to 1/2" for the injector..." So how come my picture is bigger than yours?

LOL...

http://www.mcescher.com/Gallery/recogn-bmp/LW439.jpg
http://www.mcescher.com/Gallery/recogn-bmp/LW435.jpg

and my fav

http://www.mcescher.com/Gallery/back-bmp/LW389.jpg

It's all in the PERSPECTIVE, grasshopper!   

Alex

[Mark(The Miser)UK]

"I might be a little dense here and missing the joke.. But the first pic is not of an injector location, but the filler for the fuel tank. "Nozzle" like in "Fill 'er up", not injector nozzle.  Like, it's 2" wide, compared to 1/2" for the injector..." So how come my picture is bigger than yours?

LOL...

http://www.mcescher.com/Gallery/recogn-bmp/LW439.jpg
http://www.mcescher.com/Gallery/recogn-bmp/LW435.jpg

and my fav

http://www.mcescher.com/Gallery/back-bmp/LW389.jpg

It's all in the PERSPECTIVE, grasshopper!   

Alex

I like the last one too, but I still can't see the fuel cap, or injector hole for that matter

[veector]

Got a bunch more work done, its running now, upgraded to the auto TDI starter and it fires up first crank without glows or the advance cable.  Picked up a mk4 filter/separator which should be going on soon with some new fuel lines, tank is now drained too.

Gonna wire up a few gauges and bolt on my manifold