The Diesel Cabriolet Project

[Brom]

Thanks for the encouragement. Diesels out and sitting in the back of the other car ready to drive down tomorrow. I have access to a garage in canberra and will take my own tools and probably hire a lift rather than mess around with jacks and two engines. I've been reading up on these swaps on the US websites which all say my 5 speed won't really suit the diesel engine so i'll probably keep the 4 speed for the moment being.

I'll list all the parts up here when i get back and know what won't be needed. unless your in Canberra and want me to bring it down. Also roofrack was sold last week and is now on a beetle up the coast.

Change your strut bearings as well, the ones in the pic are shot..

No idea how you picked this up from the photo's. I wouldnt know what to look for so i'll take your word for it.

Hugh

[Mischa]

Thanks for the encouragement. Diesels out and sitting in the back of the other car ready to drive down tomorrow. I have access to a garage in canberra and will take my own tools and probably hire a lift rather than mess around with jacks and two engines. I've been reading up on these swaps on the US websites which all say my 5 speed won't really suit the diesel engine so i'll probably keep the 4 speed for the moment being.

I'll list all the parts up here when i get back and know what won't be needed. unless your in Canberra and want me to bring it down. Also roofrack was sold last week and is now on a beetle up the coast.



No idea how you picked this up from the photo's. I wouldnt know what to look for so i'll take your word for it.

Hugh

hugh mate you've got a pm

[Brom]

The Diesel's in. Mostly plumbed and waiting on electricals. A pretty stress free swap starting this morning in 2 degree weather.

But one big problem! Going to reattach the drive shafts and they won't reach. So i measured each gearbox and surely enough the 4 speed is shorter across the transaxle than the 5 speed leaving about a 10mm gap on either shaft.

I didnt bring the diesel drive shafts with me, would they fix this. My guess is not. I've noticed just now in the manuals the cabrio's front track is 1404mm compared to the diesels 1390mm. Thoug mk1's with fuel injection were 1404. But are they 4 or 5 speed?

So can anybody tell me my options? Shafts from another car, spacers, pulling the spline out of the other end, or drop the box again and throw on the 5 speed? I'm stuck.

[gldgti]

mate, the 5-speed in the diesel will be FINE. i had a 5 speed on my old diesel, and my dad does now aswell. its a perfect swap, dont worry about what those yanks say - they like to cruise at 4000rpm.

use the cab box and you'll be fine.

[Golf Loon]

Yup. I told you to use the 5 speed. Whack it in and it will be great.

[Brom]

Yeah I should have listened. Anway a reasonably painless swap.

What are your suggestions for fuel lines from the metal lines on the left of the engine bay through to the filter on the right side. Do I need carb., EFI, or special diesel line. I really doubt the pressure is that great from the mechanical pump unit as the supply line from the filter to the pump isnt even hose clamped. I'm going to run the lines around the engine bay rather than move the metal lines as eventually i will put a fuel heater along this hose.

I'm also struggling to source the screw end fittings for the metal lines. Seems to be an uncommon size?

Also all parts I don't want are now up for offers. Add in 'for sale'. PM if your after anything.

[Golf Loon]

I`d use the efi lines and cut the ends off and connect your diesel rubber hoses. And use the 5 speed, dont listen to the Americans.

[Brom]

Thanks Loon, the 5 speed's in. We'll see how it goes.
Also just finished the fuel lines. Kept the metal lines to the wrong side of the bay and then put efi rubber lines around the bay and clamped them on tight. I think it will be fine seeing as it didn't seem to be under extreme pressure before. But if it doesnt work out i'll get some one to crimp the fittings on.

I'm halfway through wiring. I've done the GP line and fuse, Stop solenoid off the coil, and oil pressure switch. Now i'm trying to work out where the thermostat wiring leads to in the cabriolet. I don't have a good wiring diagram. And also where the 'ON' lead goes from the ignition switch.

Also a lame question. How do dashboard lights work? I have the GP indication lamp positive wire to connect to a light. But for neg/earth can i just use the chassis or is there a common earth for the dash i'm yet to uncover?

[Brom]

Actually I think i've been going about this the wrong way. I can almost drop in the GP relay in place of the fuel pump relay after looking at some diagrams.

But i still can't work out what i should do with the thermostat's wiring. Or even if i'm looking at the right wires. Pic to follow.

[Brom]

Are either of these the thermostat wiring?

On the diesel it's just two clips on the left side of the engine at the coolant hose connection. So i'm not sure what i should be connecting up really???