Mk3 Gasser to Diesel swap - IDI Engine - VWDiesel.net The IDI, TDI, and mTDI source.

• Mk3 Gasser to Diesel swap by failure on 18 Dec, 2009 03:45
• My Diesel's being held together with duct tape what is needed from the body to swap it into a gasser?
  
  Motor 
  fuel tank?
  pump advance cable
  speedo
   
  What electrical will i need?
  
  What do i have to yank out of the gasser?
• #1 by akrallysport on 18 Dec, 2009 08:54
• Which engine are planning on replacing it with? 1.9TD (AAZ) or the 1.9TDI?
  
  *edit: Mind you, you have posted in the IDI forums, so that should be a no brainer...
• #2 by failure on 18 Dec, 2009 09:10
• yup the AAZ
• #3 by akrallysport on 18 Dec, 2009 09:25
• What I'm using for my swap (because I had a complete mk3 TD donor car):
  - tank
  - fuel/diesel lines and filters
  - engine (I hope)
  - transmission (clutch disc has different splines from a gasser, and different 4th/5th ratios)
  - exhaust downpipe to cat (cat-back is the same for both gas and diesel if you keep it stock)
  - instrument cluster
  - throttle/pump cable (throttle pedal shouldn't need to be changed unless you want cruise control... I'll find out about this over the break as I do some research)
  - cold start cable
  - engine bay wiring harness
  
  If you're doing a mk3 to mk3 swap, most of the wiring should just be plug and play. The harness makes it easier, but most guys mod them anyways for glow plug wiring mods, etc.
  
  As far as yanking the old gasser stuff out... the entire EFI system and cluster can come out. This is also where you make the decision regarding keeping A/C.
• #4 by failure on 18 Dec, 2009 09:35
• Thanks for the info, whats the glow blug mod all about?
• #5 by akrallysport on 18 Dec, 2009 09:47
• http://vincewaldon.com/index.php?option=com_content&task=view&id=30&Itemid=28
  
  I'm going to try a cleaner version of that setup.
  
  Forgot to mention, you can transfer the extra socket/clips on the fusebox, or you can transfer the whole thing over.
• #6 by rodpaslow on 18 Dec, 2009 14:23
• I'm planning the same swap with a 1.6 TD into a 96 gasser.  I have a couple of questions
  1. are the motor & tranny mounts essentially the same as the MK2, or the Mk3 gas will work with the diesel?
  2. Will the serpentine assy work with the injector pump, or will it interfere it?
  3. Tranny ratio, I have an extra .75 fifth, will it be fine as long as I change 5th?
  
  thanks for any help!
• #7 by RabbitJockey on 18 Dec, 2009 15:45
• usually mk3s have pretty tall transmissions, theres really nothing wrong with using a short geared one tho.  a gasoline tank works fine, i know on mk1s its actually the same tank i have no idea about mk2 and mk3s tho
• #8 by akrallysport on 18 Dec, 2009 16:11
• The tank itself should be the same in a mk3 (maybe a few vents?), so an alternative would be to swap the in-tank pump with just the fuel level sender unit. Or keep the pump, but I'm not sure how long it will last.
  
  As for the engine mounts, you should be able to use all of the mk3 mounts. Referring to my Bentley service manuals the major difference between diesel transmissions (1.6TD vs AAZ) is the final drive ratio... 3.94:1 vs 3.67:1 respectively. If you can provide us with a transmission code, I'm sure someone can verify the ratios.