converting a 1991 Jetta GLI to a 1.6 TD????? - page 1 - IDI Engine - VWDiesel.net The IDI, TDI, and mTDI source.

• converting a 1991 Jetta GLI to a 1.6 TD????? by 53 willys on 02 Aug, 2008 11:20
• So what would a guy need for a conversion like this??
  seems like it would be really easy right?
  I have been looking ALL over the place and can not find ANYBODY who has converted a gasser to a 1.6td..do you all have any links to a conversion like this?
  what about...
  the motor mounts are the same?
  the TD's only need a 12v source to run?
  trannys are the same or atleast interchangeable??
  what about the gasser wiring harness vs the diesel??
  can I just hack out what I dont need on the gas harness
  what about check engine lights
  what about the diesel instrument cluster/ will I need to change my cluster?
  
  thanks for ANY help or info you guys or gals have
  Mark
• #1 by Turbinepowered on 02 Aug, 2008 11:52
• Lots of folks have swapped gas engines for diesels in the VW world. For a Mk1 or Mk2, prior to the more involved computerized controls, it's as simple as removing the gasoline engine, putting the diesel engine in, bolting it up, and doing a bit of plumbing and wire-sorting.
  
  You will need a single switched 12v source for the injection pump's fuel stop solenoid; use terminal 15 from the coil for this purpose, as it's on at the appropriate times.
  
  If you have CIS of any ilk, remove the high pressure pump, accumulator and filter assembly from the underside of the car. Run new fuel hoses from the fuel tank pickup to the hard lines running under the car. You'll install a new fuel filter mount and filter under the hood of the car.
  
  If you would like, you can use the CIS in-tank low pressure pump as a "lift" pump, but you will need to devise some way to lower its delivery pressure to within 5psi. Any higher and you could possibly alter the injection pump's internal timing. If you don't want to mess with this, delete the in-tank pump and run a diesel fuel tank pickup.
  
  You can open up the wiring harness and cut out all that you aren't using, but I'd recommend just tying it back unless you really want to get involved in a project. Without the computer the connectors won't do anything, so it's not really a big deal.
  
  You'll need to wire up a sub-harness for the glow plugs. I'd suggest using the Vince Waldon's Pimped Glow Plugs method, it's nice, its easy, and he explains it quite well.
• #2 by 53 willys on 02 Aug, 2008 12:14
• thanks for the GREAT info!! that helps a ton!
  
  newbie question???
  what is CIS?
  and ilk??
  
  could I get rid of ALL the fuel pumps and just use this pump/air separator/filterhttp://www.pureflowtechnologies.com/AirDog.htm
  then I could have an all in one unit.
  or should I just get this pump and run it to the stock filter and then to the IP??http://www.pureflowtechnologies.com/Raptor.htm
  or just source a stock diesel set-up??
• #3 by Turbinepowered on 02 Aug, 2008 12:19
• Quote from: "53 willys"

  thanks for the GREAT info!! that helps a ton!
  
  newbie question???
  what is CIS?
  and ilk??

  
  
  CIS is the mechanical fuel injection setup used by VW through the Mid/Late 70s, the 80s and into the very, very early 90s. With a '91, you might have Digifant, which I have no experience with. Others will need to chime in on that topic.
  
  If you open your hood and you have what look like 4 braided stainless lines running from a boxish thing with your airfilter to the cylinder head at the intake manifold, you have CIS of some type.
  
  Ilk is just a synonym for type.
  
  
  Sourcing a stock diesel setup would be the simplest solution for your fuel system. Fuel pick up and filter mount.
  
  The VW diesel doesn't need a lift pump, it's there more for convenience: filling the fresh fuel filter, putting a little positive pressure on the line to prevent air from being pulled in, that sort of deal. The vane pump inside the IP is strong enough to pull fuel from the tank without issues.
• #4 by 53 willys on 02 Aug, 2008 12:26
• thanks for your help buddy!
  
  I am getting real excited about this conversion! should be pretty easy.(famous last words LOL)
  
  
  what about the radiator?? should I source one from another VW diesel or get some other brand or??
• #5 by Turbinepowered on 02 Aug, 2008 12:28
• Quote from: "53 willys"

  thanks for your help buddy!
  
  I am getting real excited about this conversion! should be pretty easy.(famous last words LOL)
  
  
  what about the radiator?? should I source one from another VW diesel or get some other brand or??

  
  
  On that one I'm not sure. I had a Dasher diesel radiator on hand when I converted my Fox wagon, so I went ahead and swapped. You'll have to ask around and see what other folks are doing for radiators. They seemed to be the same core size, so I don't know if it was necessary or not in my case.
• #6 by theman53 on 02 Aug, 2008 12:40
• I know a guy who has done this to alot of vw trucks. He told me that there is something to do with the a/c and non a/c radiators are a little different, but he uses whatever is in there. I believe and I could be wrong, but the gas with a/c is the same as the diesel radiators. The gas non a/c is different. If I remember correctly he said the gas non a/c didn't return to the resivior from the top....Like I said IIRC and if he was correct in the first place.
  At any rate for the function of cooling I do know that he said either one has always worked for him.
• #7 by 53 willys on 02 Aug, 2008 13:12
• so I will probably want to freshen this IDI engine up some before I install it...I do plan to turn this baby up for some more HP...what mods should I do to the engine before I reinstall it??
  I was going to do FULL ARP's on everything
  mains
  rod bolts
  headstuds
  oil pump bolts
  ring gearbolts??
  what else should I do??
• #8 by Turbinepowered on 02 Aug, 2008 13:37
• Make sure that your refreshment includes all of the various gaskets and seals. For some, like the rear crank main seal, this is the best time to do it. Front crank seal, intermediate and cam shaft seals, might want to think about upgrading to the rubber cam cover gasket.
  
  New head gasket, obviously.
  
  Dunno if you'll actually need the full ARP setup, though. Seems most folks do fine on the stock stuff, just upgrading to headstuds rather than the stock headbolts.
• #9 by Vincent Waldon on 02 Aug, 2008 13:40
• Before you go any farther you really need to get a Bentley service manual and read the engine chapter, a couple of times.
  
  
  
  
  With the basics behind you the next step is to read read read, here and www.vwdieselparts.com.
  
  That way you'll benefit from many different perspectives and can pick a course of action... there's no right or wrong to this stuff and a couple of responses to a single post will only give you a fraction.  You'll find that your two questions have been asked and answered many times... from many different perspectives.
• #10 by Turbinepowered on 02 Aug, 2008 13:48
• *Saves another Bentley/Moses picture.*
• #11 by 53 willys on 02 Aug, 2008 14:17
• thanks for the tips guys!!
  where is the best place to get a Bentley service manual??
  do you guys think I should do a 1.9 TDI with a mechanical pump???
• #12 by theman53 on 02 Aug, 2008 14:33
• Now you're in a completely different relm.
  calling jimfoo on the M-TDI stuff and a couple others that have them is your best bet.
• #13 by zukgod1 on 02 Aug, 2008 15:32
• You can borrow my Bentley until you find one 53 willys,
  
  That book has everything you need to know about that car..
  
  Good stuff man..
  
  As per our phone conversation I think you should stick with the 1.6, for no other reason than costs. Finding a good 1.9 for a reasonable price will be hard.
  
  Off we go..!!!!
  
   :twisted:
• #14 by 53 willys on 02 Aug, 2008 15:51
• Quote from: "zukgod1"

  You can borrow my Bentley until you find one 53 willys,
  
  That book has everything you need to know about that car..
  
  Good stuff man..
  
  As per our phone conversation I think you should stick with the 1.6, for no other reason than costs. Finding a good 1.9 for a reasonable price will be hard.
  
  Off we go..!!!!
  
   :twisted:

  
  thanks Dan I am super stoked!!
  yeah I have been looking around for the 1.9's and they are WAAAY to expensive IMO
  I think I will stick to the 1.6