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Any one done gas to diesel? by br549 on 26 Apr, 2008 23:20
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Found a nice MkII GLI in need of an engine (16v is gone). The Recaros arn't too bad, and the body has n't any major kinks. Whats needed in the fuel system to make it work?
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#1 by jtanguay on 27 Apr, 2008 00:10
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Quote from: "br549"
Whats needed in the fuel system to make it work?
some diesel? :wink: :lol: but seriously... the fuel pump will push out probably 60 psi, which is way too much. so you need to either bypass it, or find a way to make use of it (dr. diesel has has made a system to bleed the pressure back to the tank) and then you just need to make a bracket for a diesel fuel filter, and then do some minor fuel line work. -
#2 by TedV on 27 Apr, 2008 07:41
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what he said, and a diesel fuel filter. In the Scirocco, I replaced my high pressure CIS pump with a low pressure lift pump from NAPA.
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#3 by Quantum TD on 27 Apr, 2008 09:11
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Or just cut out all the cis/motronic crap and put in a diesel sending unit and some straight hoses. The stock MK 11 diesel didnt' have any inline pump, and it pulled from the top of the tank.
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#4 by Ziptar on 27 Apr, 2008 18:30
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I have .
I had a complete donor and swapped wiring, fuel system, exhaust, and engine. I wanted to completely get rid of the Gasser DigiFart II wiring and plumbing.
If you don't have a donor it's simple enough. The mounts and transaxle bolt right up, cooling can be pieced together and you'll have to weld up some exhaust. Use the 12V from the Coil wire and hook it to the fuel cut off solenoid on the IP.
For the fuel system ditch the fuel pumps, get a diesel sender or you give yours a liftpumpendectomy with some hose and either remove it entirely or bypass it.
For a cheap, easy, and effective diesel fuel filter get a Perma-Cool Fuel Filter and Water Separator Kit from Summit for $40. and some 5/16" x 1/2" NPT hose barbs. You can bolt the filter head to the firewall / inner fender. Best part is when it comes time to change out the filter, the head is threaded the same as Caterpillar Filter Number 1R-0750, One of CATs 2 micron "Advanced Efficiency" Fuel Filters.
Cat dealers generally get $12-$16 for them so cheap easy replacements and nice clean fuel to boot. CAT uses those filters on everything up to D9s and D10s, It never had a problem keeping up with my little Ol' TDI even when it was sucking VegOil. :wink:
IDI Diesel VW swaps have got to be the easiest out there. -
#5 by zukgod1 on 27 Apr, 2008 21:36
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Quote from: "Ziptar"
I have .
I had a complete donor and swapped wiring, fuel system, exhaust, and engine. I wanted to completely get rid of the Gasser DigiFart II wiring and plumbing.
If you don't have a donor it's simple enough. The mounts and transaxle bolt right up, cooling can be pieced together and you'll have to weld up some exhaust. Use the 12V from the Coil wire and hook it to the fuel cut off solenoid on the IP.
For the fuel system ditch the fuel pumps, get a diesel sender or you give yours a liftpumpendectomy with some hose and either remove it entirely or bypass it.
For a cheap, easy, and effective diesel fuel filter get a Perma-Cool Fuel Filter and Water Separator Kit from Summit for $40. and some 5/16" x 1/2" NPT hose barbs. You can bolt the filter head to the firewall / inner fender. Best part is when it comes time to change out the filter, the head is threaded the same as Caterpillar Filter Number 1R-0750, One of CATs 2 micron "Advanced Efficiency" Fuel Filters.
Cat dealers generally get $12-$16 for them so cheap easy replacements and nice clean fuel to boot. CAT uses those filters on everything up to D9s and D10s, It never had a problem keeping up with my little Ol' TDI even when it was sucking VegOil. :wink:
IDI Diesel VW swaps have got to be the easiest out there.
That's some good info there ziptar..!!
Saving links and buying that filter mount right now..
Damn VW filters are $20.00 ea so I figure that 2 micron filter will do WAY better than the stocker and when it comes time to replace as you mentioned the CAT filters are cheap.. -
#6 by Ziptar on 28 Apr, 2008 03:23
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Your Welcome. It's something I came up with back when I was rigging up a VegOil Kit for my TDI.
The main reason why you want the CAT Advanced Efficiency Filters is they Filter Down to 2 Micron, block water, and handle frozen/gelled fuel better.
Permacool makes 3 filter heads that use the 1-14 Thread (which is what CAT uses on some filters).
Perma-Cool 88864 High Flow Filter Head (3/4" NPT Inlet / Outlet)
Perma-Cool 81794 High Performance Filter Head (Dual 1/2" NPT Inlet / Outlet)
Perma-Cool 81074 Universal Fuel Filter/Water Separator Kit
The CAT filters Thread up to the Permacool Filter heads Perfectly.
I have used / experimented with different Perma-Cool Heads and CAT Filters with my Vegoil Setups.
The 1R-0750 Filter should flow plenty big enough for any VW 4cyl Diesel but, if you want to go nuts get a 1R-0749 Filter ($16.00 at a CAT Dealer), it's huge, so make sure you have got room for it. It also works with the Permacool head. I had one on the Permacool #88864 High Flow Filter Head on my Vegoil Prefilter.
The two micron filters are used usually as secondary filters on newer and larger rigs and there is usually a higher micron rating water separator / filter before the two micron. Like a 175-2949 that is a traditional water separator with drain. You could get two Perma-Cool heads and have yourself a very inexpensive twin stage fuel filter setup.
For the past couple of years though CAT has been subbing the 1R-0749 and 1R-0750 for higher micron rating filters like 1R-0712 (10 micron) that are the only fuel filter used on older rigs. So they can be used in single and are the only filter on much of the smaller equipment CAT makes.
I have seen allot of debate on different diesel sites that other manufactures X-ref filters aren't as good as CAT's. At $11.00 and $16.00 a pop for the Original CAT's I'll stick with them but, a while back I did make up a Cat Filter X-ref in case I ever needed a filter quick in the middle of nowhere.
Caterpillar Primary Filter/Water Separator 175-2949 (threads 1-14 UNS-2B )
Fleetguard FS19683
Donaldson P551743
Baldwin BF1268, BF1214
Fram PCS5063
Wix 33005
Luber-Finer LFF8030
ACDelco TP1002
NAPA FIL3005
Purolator F60026
Hastings FF864
Caterpillar Secondary Filter 1R-0749 (2 Microns) (threads 1-14 UNS-2B )
Fleetguard FF5319
Donaldson P551311
Baldwin BF7587 (BF614, Standard Version, BF7633, Short Version)
Wix 33674
Luber-Finer LFF2749 (High efficiency version of LFF5823B)
ACDelco TP1322
Fram P8335
NAPA FIL3674
Purolator F75185
Hastings FF1056 (FF1007, Standard Version FF1079, Short Version)
Caterpillar Filter 1R-0750 (2 micron) (threads 1-14 UNS-2B )
Fleetguard FF5320
Donaldson P551313
Baldwin BF7633 (BF7587, Long Version)
Wix 33528
Luber-Finer LFF3347
ACDelco TP1326
Fram P8334
Purolator F65213
NAPA FIL3528
Hastings FF1079 (FF1056, Long Version)
It is nice cheap setup especially when you see other diesel owners like the TDI Guys paying $115 for A Lubrication Specialist Cat 2 Micron Fuel Filter System or the Durmax guys shelling out $200 for a Nicktane. I owned a Lube Specialists setup for a brief time, it worked well but, was a serious PITA to change filters on. Had to have two strap wrenches, lots of grunt, and some luck to change it in the car without pulling everything out. The PermaCool works so much better I think.
I am not 100% sure on the CAT Filter price, my brother used to work on the rental side of a CAT Dealer, he used to buy them for me at cost I paid ~$9.00 for them, I looked a while back and it seems like $12-$16.
Oh, and another handy CAT Item now that I think of it. He also used to pickup CAT's S.O.S Oil Analysis Kit for me for ~$10.00 I think. Those are great, fill the little sample jar with some oil as you change, put it in it's little bag and padded envelope and mail it. A week or so later you get a report back about how you engine is doing.
I need to start doing those again.