Wiring Diagrams to aid 1.9TD into 1.6D Caddy swap - IDI Engine - VWDiesel.net The IDI, TDI, and mTDI source.

• Wiring Diagrams to aid 1.9TD into 1.6D Caddy swap by markb on 29 May, 2007 16:58
• Hey all,
  
  Good to finally post something here, hope all are well.
  
  I have acquired a 1988 1.6D Caddy Pick-up (with a slightly leaky/smokey engine) and a 1.9TD engine and reading some of the excellent posts on here from Bert among others i want to revive the old girl.
  
  My only previous experience has been with beetles (and some Subaru stuff - again, think heart transplant ), so i am quite new to this car tinkering mullarkey, but i love it!
  
  Right, my question is:
  
  There is a round multi-plug connector on the TD engine and I am slightly unsure if/how to wire up some of the wires. I can see what i believe to be the fuel cut-off solenoid (think i can leave this unplugged as i am going to be upping boost/fuel) oil pressure switch, glow plug wires and possibly something going to the fuel injection pump there are others, but of the top of my head i cant remember 'em.
  
  Can anyone provide any info on wiring diagrams/give me some tips as to how to wire this beast in?
  
  I will post some pics of the engine/associated plug tomorrow at work USB does not work on this PC.
  
  I'm afraid i cannont give much info on where the engine came from/what year as the scrap yard had already removed it and did not seem to know much about it - but if anyone can point me in the direction of numbers/identifying features i will try and provide as much info as possible.
  
  Help convert this petrol head to the oil burning ways!
  
  Cheers,
  Mark B.
• #1 by BlackTieTD on 29 May, 2007 17:18
• hi markb.
  
  good idea sounds like fun.
  
  the short answer is that the bentley manual has everything you asked for and more. the wiring diagrams in the manual will explain what does what, and the sub-systems are explained in detail throughout the manual. personally i try to get a bentley for whatever car it is i'm working on, so that's my advice to you.
  
  however, thats a pretty simple swap and from the photos we can probably tell you what goes where.
• #2 by markb on 29 May, 2007 17:45
• Hey,
  
  I have read countless posts about Bentley manuals, but have never seen any in the UK, is that the equivalent of our Haynes manuals?
  
  Anyways, i will get on google and find me one!
  
  I hope you can tell me where stuff goes too! Stay tuned for the pics tomorrow morning  :wink:
  
  Mark B.
• #3 by Audi80 on 29 May, 2007 17:52
• Why don´t you use old wiring from 1,6?
• #4 by markb on 29 May, 2007 18:14
• I hope to use as much as I can, but the question is what can/can't i re-use? there is more on the 1.9 turbo than the 1.6 non-turbo...
  
  Cheers,
  Mark B.
• #5 by burn_your_money on 29 May, 2007 18:19
• The Bentley is much different then the Haynes. I can take pictures of my mk1 bentley for you if you'd like but you honestly don't need it for this swap but you still should buy it, it is invaluable
  
  If you are using the mk1 tranny and starter then what you need to do is remove the coolant flanges from the 1.6 and put them onto the 1.9 head. Oil pressure switches might need to be changed but I think they are the same.
  In the truck you will most likely have slow glow plugs. Find a fast glow plug relay from a mk2 and you can use the 1.9 glow plugs.
  
  The alternator connections are different but all the wires are the same color. If you J-yard motor didn't come with an alternator you can swap out the serp setup on the 1.9 and install the v-belt setup from the 1.6
• #6 by markb on 29 May, 2007 18:42
• excellent info, cheers!
  
  At some point in the caddy's life it has had a 5 speed box put in it, but i think it is still a mk1 box.
  
  The motor didn't come with an alternator so the 1.6non turbo pulley/alternator etc can be swapped onto this engine then?! awesome, saves me getting a new alternator!
  
  Now on the hunt for a mk2 glow plug relay!
  
  Mark B.
• #7 by RabbitJockey on 29 May, 2007 19:12
• there is only like what 4-5 wires, and only one to make it run, the rest are all sensors... you shouldn't have an problems.
• #8 by Audi80 on 30 May, 2007 02:40
• 1 wire to pump, 1 to glow plugs, 3 to alternator, 2 to starter and a couple of sensors. Take the sensors from 1,6. Thats about it
• #9 by markb on 30 May, 2007 07:30
• Right, i have finally got around to getting the pics sorted. I dont know how to post pics here, so i uploaded them to photobucket and they can be found at this link:
  
  http://s182.photobucket.com/albums/x91/markb_1303/
  
  Thanks for everyone's help on this!
  
  Any more thoughts/ideas/comments/things i should be aware of now you can all see the engine in question?
  
  Mark B.
• #10 by bert on 30 May, 2007 14:12
• Mark,just read your Pm mate,the engine is exactly the same as mine was,its an easy swap,just dump all the electrics,and like others have said,do what i did,just use the alloy water flanges with the mk1 sensors,there better than the plastic ones anyway,or just bring your camera and come see mine in the flesh,i will take you for a razz  :twisted:
  Bert