Swapping a TD in a gas model

[bevboyy]

I have a freshly rebuilt 1.6TD with trans. I just clinched a deal for a mk2 jetta with a "supposed" non working 8v gas engine. Shell is in very good shape.

My question (s) to the group are as follows:

1) Wiring - what can I ditch (besides the obvious), what to keep?

2) Glow plug wiring - from any of you who may have done what I am about to do, how did you rig this up? Relay obviously must be used, but I would find it most helpful if I got a few pointers in this general direction...:-)

3) Alternators - should be same for both diesel and gas - right?

4) Can I keep the PS pump and re-use it with the TD?

5) Fuel tank filler - how did yawll get around this?

Peace!

J.C.

[houseofdiesel]

Best bet for the gas tank is to replace the whole thing with a diesel one, not very hard to do either and remove all the fuel pump gas crap
Glow plug relay just build your own using a solenoid for the Ford or Chev diesel (Uap/Napa $50), stronger and easy to wire up. You could plug and play a factory one if you have a 1990 up (CE2 wiring), if not you would have to install the complete wiring which is more work and long wires that rob power to the glow plugs. All you need otherwise if the coil power wire for injection pump, the rest is easy.
Power steering pump exactly the same, alternator and mounting different. Get the bracket and alternator off a diesel 1.6, matters if a/c or not also.

[BlackTieTD]

i'd suggest getting a bentley manual especially for the wiring diagrams. might as well, you'll need it eventually.

[burn_your_money]

check the how-to on www.dubnetworks.net there is a gas to diesel swap in a mk2

[Ziptar]

I am doing a swap as well, not simple though. A buddy of mine is giving me a really nice 89 Carat he has owned since new with an 8V with a blown head. I am putting a TDI-M In it. I think it's got a 2Y tranny which should be fine for a TDI swap but, maybe I'll try to find a 4S, or an A3 TDI Trans but, i don't know if I want to do the Hydraulic clutch swap.

Diesel to gas swap can be done simply, just as everyone stated, the thread burn_your_money linked pretty much covers it.

I am taking the more complicated route, I want to swap it over to true diesel stuff.  I am going to swap out the CE1 Digi harness with a CE2 Diesel Harness.

burn_your_money has hooked me up with just about all the A2 diesel stuff I need. The complete CE2 Harness, a CE2 Diesel gauge cluster with tach, TD Air box and plumbing, Fuel Tank Sender, and an AAZ Injection Pump. It started arriving last week.

I will get a diesel tank locally, and I still need to chase down a 1Z or AHU engine, an A2 GTD Intercooler Setup, Intercooled AAZ Intake manifold, AAZ Exhaust manifold, K14 turbo, and down pipe.

It'll be more work and take more time but, I plan on keeping the Jetta until I die, so it's worth it. The car has been sitting in his garage for 3 years now so it will have to be gone through anyway, brakes, suspension, etc.  Might as well make it as factory as possible while I am at it. So after all that time I'll have a fairly "new" car for about $5,000 I figure.

I plan on using all the TDI engine accessories when I put the engine in, that'll take some adapting of the A/C hoses and changing out of the A2 A/C stuff to R134 but, again shouldn't be too tough.

The GM Controllers are pretty easy to hookup, below is a diagram I had for putting the later GM type into my 79 Chevy Olds Diesel, 8 cylinders but same Idea for 4, it's enough to get you started.

The GM 60G Glow Plugs are self limiting and can be used with this controller if you add a 1K Ohm resistor to the wire from "C" on the controller to the glow plugs, so that being the case should be true for VW self limiting plugs as well.

Get a Bentley for sure, the wiring diagrams are great and really detailed. Keep us posted.

[bevboyy]

Awesome info gents!  

I got a 1992 Jetta for the shell, so it is CE2 - a lot easier!

I have it figured out,  The Mk2 Jetta filler neck is larger, so I should be able to drain the tank, remove the inline pump keeping the in tank pump as a lifter pump to help out my TD IP.

Just have to locate a good solid lifter head to replace the warped on in the TD. :roll:

[burn_your_money]

I have a solid lifter TD head sitting on my work bench that I'll sell