Jetta GLI Mk2 1986 Gas to Diesel Swap 1.6D

[slavik19]

hey guys i just joined the forums.
seems like a great place
anyway i have my first swap.
got some questions/problems need some help

first of all the engine runs fine,
only when i direct the fuel line directly into a bottle fuel of diesel or something.
no air bubbles
something like this look on the side youl see the line.


next what i did was connect it to the original gas line, without removing any pumps or anything just discounted the gas CIS system and connected my fuel filter. got most of the gas out. the engine runs but poorly, gets air (bubbles) into the system, i can tell because i have a clear fuel line.
im not sure if im powering on the fuel pump or not?
how does the fuel pump work?
does it continuously pump fuel?
is it same to run it with a diesel injection pump? with a fuel filter in between off course.

wiring: very simple so far. i have 1 wire coming from the ignition coil to the injector pump. that works fine.
glow plugs, ill figure out a manual system.
oil pressure and coolant temp: ok i need help with these.
oil pressure sensor on the cylinder head on the side of the transmission?
connect the blue wire?
im just not getting any kind of signal on my speedo, how can i test it?
coolant temp sensor? which one do i need? its all different.  there is like more the  one sensor on the 2 different coolant flangs?
i just want my gauge to work on my cluster. so i can keep an eye out for the coolant and oil pressure.
which one do i need to connect to make that work?
also how can i test it?

for right now that it.



my custom non ac bracket;:
me and my dad built it out of a AC bracket, what do you think?


some pics:
messy work place
already have single round set up


mounted the 5 speed:

[8v-of-fury]

If the fuel pump runs fine from a bottle and not fine from the cars fuel lines you definitely have leaks somewhere. Either that or the main seal on your pump shaft has gone bad.

The oil pressure sensors should be the same wire as before, whichever came off the sensors on the gas motor should go to the sensors on the diesel motor.

For the coolant sensor it should be a two wire plug that would have connected to the front coolant neck of the gas motor.

When you say signal on the speedo, what do you mean exactly? there is no power at all? or just no temp gauge readings?

[slavik19]

my gas engine has something different it has 2 sensors on the front coolant flange they are diffrent kind of connectors. ill have to take a picture and it looks like the oil pressure sensor is on the front of the cylinder head on the gas engine. diesel on its on the side.

alright guys i figured it out. thanks for everyone's help.
no more air bubbles.
deleted the high pressure pump or what ever it was.
kept the in tank pump all wired up. kinda usefull. shorted the fuel pump relay and made a plug in wire for on or off.

runs okay now.

i have half of tank of gas and half a diesel.
my mistake i thought there was much less gas inthere. put five gallons in and its almost full.
what should i do?
i guess thats why it runs rough right now. but hey it runs.

hocked up the radiator and overflow tank. put water in it. how can i test to see if my water pump works?

also i took pictures of the sensors, can you guys help me figure out which is which?

pictures:


before;


after:


in tank fuel pump. now i know how it works and how the level works and all.


buy the end of the day it runs!

sensors:
Coolant temp? sender?


the one on top is oil pressure and the two on the coolant hose are more temp sensors?

[R.O.R-2.0]

that temp sensor on the front coolant neck is not a temp sensor, its a fan thermo switch. those are only found on TD cars. so that neck came off a mk1 TD..

take your temp gauge connector, and cut it off, fold the ground wire away, and put a female spade on the yellow/red wire, then hook it to either one of the TINY coolant temp senders on the SIDE coolant neck..

if you have any specific questions, let me know, i just did this swap a week ago..

[CRSMP5]

not fan thermo switch... its a ac cut off switch for if it overheats.. it kills the ac... any diesel with ac after 81 has it..

[lovinthedeez]

Five speed makes it kinda bearable, but the mk2 shell was so much comfier.  I did the same thing awhile back
http://www.vwdiesel.net/forum/index.php?topic=19324.0

[R.O.R-2.0]

damn you, i want your front clip.. 

[slavik19]

hey guys i figured everything out. well the wiring i was looking to hard. and at the wrong harness. got my oil pressure coolant temp and alternator wires hocked up and working! got all the gas out and put 5 gallons of diesel in her

Five speed makes it kinda bearable, but the mk2 shell was so much comfier.  I did the same thing awhile back
http://www.vwdiesel.net/forum/index.php?topic=19324.0

love the front grill already got a round rad support and lights like your and a cheap ebay badgelss grill.
hey how do i tell if my is a perreli edition? i have the same seats and the wolfsburg emblem on my fender sunroof small bumpers and its a 86.  no p slots tho:(
are you swapping a diesel into yours?

[R.O.R-2.0]

hey guys i figured everything out. well the wiring i was looking to hard. and at the wrong harness. got my oil pressure coolant temp and alternator wires hocked up and working! got all the gas out and put 5 gallons of diesel in her

Five speed makes it kinda bearable, but the mk2 shell was so much comfier.  I did the same thing awhile back
http://www.vwdiesel.net/forum/index.php?topic=19324.0

love the front grill already got a round rad support and lights like your and a cheap ebay badgelss grill.
hey how do i tell if my is a perreli edition? i have the same seats and the wolfsburg emblem on my fender sunroof small bumpers and its a 86.  no p slots tho:(
are you swapping a diesel into yours?

that car is ALREADY a diesel.. the swap already happened.

[slavik19]

yes justread his thread wish i found it earlier. its the same exact thing im doing

[lovinthedeez]

love the front grill already got a round rad support and lights like your and a cheap ebay badgelss grill.
hey how do i tell if my is a perreli edition? i have the same seats and the wolfsburg emblem on my fender sunroof small bumpers and its a 86.  no p slots tho:(
are you swapping a diesel into yours?

pirellis had this interior


and then it had the RD(?) hi comp. engine, along with the wheels.  pretty sure they only came in atlas grey.

liked it lots like this though...


fired the glow plugs by the push button in the dummy switch just left of the radio.  don't wanna leave
those puppies on...

[slavik19]

yeap have the same seats the RH motor but no wheels.

ill be making a trip to homedepot and napa or advance soon for the glow plug set up.

what kinda of transmission?
mine seems like its to low of gearing. first almost seems like im in second or something when starting off.

[8v-of-fury]

what kinda of transmission?
mine seems like its to low of gearing. first almost seems like im in second or something when starting off.

Can't be, all of the vw 020's are the same 3.45 first gear. Different R&P ratio, but it doesnt make too much a difference. You probably have a close ratio transmission in that car.

[slavik19]

what kinda of transmission?
mine seems like its to low of gearing. first almost seems like im in second or something when starting off.

Can't be, all of the vw 020's are the same 3.45 first gear. Different R&P ratio, but it doesnt make too much a difference. You probably have a close ratio transmission in that car.

im not sure.
lower numbers lower ratio?

i bought a ASF tranny.
ASF, AON, ACN, ACL (8v)    3.67    3.45    1.94    1.37    1.03    0.75

[8v-of-fury]

lower numbers the longer the gear, and lower too yes.