Author Topic: my 86 pirelli 4 door gas to diesel build  (Read 40312 times)

Reply #15April 22, 2009, 07:33:47 am

lovinthedeez

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my 86 pirelli 4 door gas to diesel build
« Reply #15 on: April 22, 2009, 07:33:47 am »
didn't much done tonight.  introduced the diesel to a new friend.  hello ms. ACN.

checked to make sure that the rear motor mount lined up.  Need to clean up those threads a little.  what was the first vehicle to use those threaded holes as a mount?  it just blows my mind that there are provisions for a motor mount that wasn't utilized until four years after the motor was built.  
my buddy helping me out, reminding me to pick up dropped messes and such.  
location:  ashland, oregon US

Reply #16April 22, 2009, 09:37:27 am

Rabbit on Roids

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my 86 pirelli 4 door gas to diesel build
« Reply #16 on: April 22, 2009, 09:37:27 am »
all i know, is that ive had a buncha OLD OLD 1.5 engines.. and they all have the provision. im pretty sure the engine in my car right now is from a 77 or 78

btw... that is a really good alt. mount.. i had just about every style i thought there was, then i came across one of those mounts. i havent bent or cracked it yet. the pressed steel ones are a joke.

Reply #17April 24, 2009, 08:55:42 pm

lovinthedeez

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my 86 pirelli 4 door gas to diesel build
« Reply #17 on: April 24, 2009, 08:55:42 pm »
so I got a bunch of work done in the past couple of days.  I got the motor in,and bearing its own weight.  I had to cut the mk1 motor mount off to make clearance.  


put on the front core and subframe with new grade eight hardware, which the p/o was kinda enough to either not have or if it was it was finger tight; thanks.  

then I got to work and back together the linkages and hoses, as well as the manifolds



got to the diesel nozzle restrictor and took care of that real quick with a chisel.  came out in two big pieces.


I tore out the cis main pump, and will remove the gasser sending unit after I drain the tank. I still have to figure out how the rewire the three prong plug from the jetta to the two wire diesel sender.  bought new fuel line to run new ones from the tank to the filter, and from the pump back to the tank.  


still have to drain the tank, and put in the diesel sending unit and wire it
run new fuel lines
wire the alternator and starter
install new glow plug harness
intall cold start cable
connect diesel acc.  cable end to the gasser one
make a home for the fuel filter under the hood

the list is getting shorter and shorter, and there and pretty much no more parts left on the floor
location:  ashland, oregon US

Reply #18April 27, 2009, 07:35:41 am

lovinthedeez

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my 86 pirelli 4 door gas to diesel build
« Reply #18 on: April 27, 2009, 07:35:41 am »
so i'm stuck on the wiring on this thing.  I know that I need the red/black wire that feeds into the coil to run to my injection pump.  when I have the key on, that wire only reads 2 volts or so.  Is it just because the motor isn't cranking.  also, i can't seem to find the wire to energize the solenoid to the starter.  this thing is an electrical nightmare, all the hack jobs.  I think I want to make a box of switches to run everything.  it would go something like.
wire a main power switch to the ignition (so you can't steal it)
then it would be like a helicopter
main power on
glow plugs ignited
turn on the 12v switched to the ip
then push button start
then vrooom....well more like putt putt put puttt

gonna tow it home tonite, because the motor is bolted in, and ready to roll.  It will be much easier having it at the house to trouble shoot.  It's so close i can smell the diesel.   so excited
location:  ashland, oregon US

Reply #19April 27, 2009, 07:51:39 am

53 willys

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my 86 pirelli 4 door gas to diesel build
« Reply #19 on: April 27, 2009, 07:51:39 am »
I found my solenoid switched power inside by the fuse box....make sure it stays 12v while cranking too.



almost there...and looking good.




BTW I'm using the gasser "intank pump" and sending unit in mine...works great long as the gasser pump is running...if the pump is off the IP cant suck through it....then you dont have to rewire anything. :wink:

Reply #20April 29, 2009, 11:09:31 pm

lovinthedeez

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« Reply #20 on: April 29, 2009, 11:09:31 pm »
got the car home tonight.  now i can finish up the wiring, and this thing should be golden.  my poor little bunny.  won't someone come save him
$9.27 and a six pack.....how do ya go wrong......
location:  ashland, oregon US

Reply #21April 30, 2009, 08:31:09 am

Rabbit on Roids

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my 86 pirelli 4 door gas to diesel build
« Reply #21 on: April 30, 2009, 08:31:09 am »
still 9.27 and a six pack? and it still doesnt come with the front clip? or is that including the clip now too? only reason i havent gotten back to you on that thing is because i havent fixed my trailer yet, has bad brakes on one axle.

Reply #22April 30, 2009, 10:55:51 am

lovinthedeez

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my 86 pirelli 4 door gas to diesel build
« Reply #22 on: April 30, 2009, 10:55:51 am »
i'm gonna put the late westy fenders back on it.  all it will need is a grill and markers for late westy, or put on another set of round fenders and keep the early westy.  i told everyone who wanted body pieces that i wasn't cutting it up.  I don't have the heart to really start parting it out yet.  the only thing thats missing from it so far is the motor, the headlights, and the k-bar.  I thought it would be a problem for it to sit where it is at, but apparently not, so its just kinda sitting at the moment.  why don't turbo diesels fall from the heavens in southern oregon like they do in ontario?
location:  ashland, oregon US

Reply #23May 01, 2009, 12:14:57 pm

lovinthedeez

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my 86 pirelli 4 door gas to diesel build
« Reply #23 on: May 01, 2009, 12:14:57 pm »
needed to take a little break after i found the timing jumped, for reasons not to be said, and i heard a little clicking when trying to start it using the og starter wire.  i feel so dumb not turning it before i tried to start it, but, oh well.  I retimed it, rotated it three times by hand, with good compression it seemed all the way through.  gonna finish the swap, and if worse comes to worst, a different head.  i guess we'll see.  in the downtime, I removed the rest of the gasser stuff, including the knock box, ecu, and its wiring harness, and coil.

nice uncluttered rain tray......needs a good cleaning


I'm left with my starter wire, my coil wire, my temp and oil plus a few other wires, and all my lights still work.  i'm stuck at the water temp wires on the end of the head.  i have to go through the bently and figure out what goes where.

gotta cut the diesel end off of my rabbit cable and connect it to the old gasser one

still gotta make a new lead for my the alternator plug.  two B+ wired to a single lug to the starter solenoid.  D+ to the exciter wire

still gotta:
install the fuel filter under the hood, run new lines
install new pimped out glow glug harness.
bleed system, its getting close.......
hopefully i didn't wreck the head
it kinda looks like it belongs there.....look at all that room

 the wire I believe I need to hook up to my stop solenoid; the red/black that went to the coil that is sitting just above the vacuum pump in the last pic, can anyone confirm?
location:  ashland, oregon US

Reply #24May 04, 2009, 09:20:37 am

lovinthedeez

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my 86 pirelli 4 door gas to diesel build
« Reply #24 on: May 04, 2009, 09:20:37 am »
haven't gotten much done since its been raining the past few days.  been wild goose chasing the coil feed that i think i cut when removing the cis.  I think that the red/black wire I was looking at is the tach wire, which is why i was only seeing two volts.  I'm kinda stumped on something so easy.  Think I'm gonna run a 12v switch for the ip, I think.   went and got a new tube flaring kit to use the old cis to/fro lines as much as I can, and use viton for whats left over.  also got a siphon pump to get the rest of the gas out of the tank.  Need to get this done, pronto......... :P
location:  ashland, oregon US

Reply #25May 04, 2009, 09:26:56 am

Rabbit on Roids

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my 86 pirelli 4 door gas to diesel build
« Reply #25 on: May 04, 2009, 09:26:56 am »
thats the coil negative you got there.. i would just find some keyed power somewhere under the dash and just T off of that. the IP takes under an amp to energize the solenoid. and for some reason i think the coil positive wire is part of the CIS loom if i remember correctly. im pretty sure thats how my old 85 golf was.

Reply #26May 07, 2009, 05:48:44 pm

lovinthedeez

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my 86 pirelli 4 door gas to diesel build
« Reply #26 on: May 07, 2009, 05:48:44 pm »
so i was able to put some time into the project today.  plumbed up the fuel system, which involved changing out to the diesel sender, and installing new lines running from the sender to the old cis that run in front of the main pump.  I still need to get some kind of clear inline filter in between the filter and pump so i can see any air bubbles in the line.  went to wire up the ip when i found the p/os jimmy rigged something wired up in the 50 terminal of the ignition switch.  i think its the fuel pumps, because i found the hot wire under the hood.  here is that removed...its a relay for who knows what

looks much nicer now.  and found my black wire to run my ip

slowly chipping away.  working on mounting the glow plug fuse box, and wiring it up to a switch in the cabin.  
still have to
wire up the fuel level guage at the sender.
bleed it
check timing real quick
turn it by hand a couple times.
start
location:  ashland, oregon US

Reply #27May 07, 2009, 08:11:33 pm

lovinthedeez

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my 86 pirelli 4 door gas to diesel build
« Reply #27 on: May 07, 2009, 08:11:33 pm »
come more pics from today
fuel filter needs to be lowered just a little, but has plenty of room for adjustment.

took off the hard lines, and took off the the bus bar and starting wiring up the plugs with the 10 guage now you see it

now you don't, that's where the fuse box and solenoid will be, where the wires come out of the loom against the driver side strut tower.

got the cold start cable all hooked up while i was in there as well as the fuel cutoff solenoid, ran back into the cabin

got all the hard lines back on it. left it for the night.  

this is taking so much longer than i thought.  being back on a good weather schedule sucks....
location:  ashland, oregon US

Reply #28May 08, 2009, 09:17:42 am

8v-of-fury

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my 86 pirelli 4 door gas to diesel build
« Reply #28 on: May 08, 2009, 09:17:42 am »
LOOOOOOKING GOOOOOOOOOD

I can't wait to start my own diesel swap! I've been waiting for good weather since October! :) I'm so excited, and I just can't fight it! lmao...  :oops:

Reply #29May 21, 2009, 06:34:18 pm

lovinthedeez

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Re: my 86 pirelli 4 door gas to diesel build
« Reply #29 on: May 21, 2009, 06:34:18 pm »
well......lots has happened since.  the car runs, drives, great; but has some serious electrical issues due to me removing lots of extraneous wiring.  i have an uncut full harness on the way, so it shouldn't be too bad, I think.  the p/o did some serious rewiring, and I figured the best thing was to remove and replace with the right stuff.  so I got some pics to add.  all in all, the swap itself was super easy.  i've learned a bit, but not looking forward to rewiring the car, but anyhow.....some last pics and a couple of videos


installed the new glow fuse box and the solenoid.  the lug missing the cable is going to the starter lug


the donor rabbit found a new home:  my friend a co worker who has a post hurricane katrina diesel with a wrecked up shell, and all kinds of electrical problems.  gonna swap out everything from his car into my shell.  traded it for two cases of sierra nevada :P


a couple of videos of me trying to start it for the first time.  i got so excited that it started right up, i expected it to idle by itself after only 15 seconds, so thats why i had to post the second video.  the acn tranny is great for the motor, it just takes a little getting used to
http://www.youtube.com/watch?v=dgwDCUWgs3Y&eurl=http%3A%2F%2Fforums.vwvortex.com%2Fzerothread%3Fid%3D4387069&feature=player_embedded
http://www.youtube.com/watch?v=1Y0ntOKK5fE&eurl=http%3A%2F%2Fforums.vwvortex.com%2Fzerothread%3Fid%3D4387069&feature=player_embedded
location:  ashland, oregon US