Diesel is finally running

[SJKrawler]

Finally fired up the diesel. Music to my ears. Having some fuel delivery problems, so I haven't really been able to take it on much of a test run. Shift into 3rd and it dies.
Nice idleing along in 4low, like driving a tractor.
Getting air in the fuel line somehow. First, it was a craked fuel line at the tank, so I put a new one in, but it's still getting some air. I'm thinking that the electric pump may not be pumping out enough volume. ???

Thanks KAC for helping me out with the glow relay. That saved a lot of hassle.
Anyways, got to go now and get this thing running right.

[KAC]

No problem good to hear that it is going:D

[Dirtbag]

yep thats my project for this winter, i have a 1.6 sitting in the garage, now all i need is a zuki. hey SJKrawler, what tranny combo did you use, how well does it work together. im planning on using the sammy tranny but with a machined fox flywheel and want not.

whats the biggest problems you guys faced while doing the conversion??

[SJKrawler]

I used an '86 samurai tranny with the taller 5th gear. Adapted it by using a kit from Roadless Gear. If I had known what needed to be done to adapt the tranny, I would have done it myself.
The kit uses the samurai flywheel machined to fit the vw crank. I'm using the stock clutch, aswell as the samurai starter. Both work fine. I'm surprised how well the started turns the diesel over.
Pretty much have most of the bugs are worked out, runs real nice. I just touch the key and the thing's running. Taller gears for the road would be nice. It sounds and feels fine at high revs, but I would be happy to get them down another 300-500rpm's.

[Dirtbag]

i found this site
http://www.rocky-road.com/diesel.html

but i dont see why you can't use the vw starter and alternator. the site advises for custom adaptors for the oil filter and etc...i find that weird. or maybe i haven't had a good look at the sammy's engine bay.

SJKrawler are the revs really far off?? what about going up hill how does it fair??

[SJKrawler]

I used the VW alternator on mine, but it wasn't charging enough, and a bearing was shot, so I put the samurai alt in.
The starter bolts to the transmittion not the engine, so the VW starter wont bolt up unless you make it so. I've heard the vw ring gear won't fit into the samurai bellhousing, so that's why the flywheel needs to be machined down for the samurai ring gear to be pressed on. I believe KAC had to do that with his vw flywheel.
For oil filter adapter, all you need is one off a vw fox. It's swept back, away from the engine mount and frame.
Revs, yes it's revving higher than I like for highway travel, but the VW is a tough engine. Everyone I've talked so far said it will take revs no problem. It has a governor so you can't over-rev it.
I don't know how it pulls up hills yet, I'll probably find out next week when it's on the road.

[SJKrawler]

Hey Dirtbag, where are you located?

Tried the diesel up some hills, pulls better than the 1.3. Can make it in 4th rather than 3rd.
Power comparison(acceleration) is pretty close to that of a 1.6 8v with 4-1 t-case turning 29" tires.
BTW, this diesel isn't exactly a fresh engine. The car it came out of had 500K, the engine has been rebuilt sometime in there, but I don't know what was done. Doesn't blow blue smoke so I'm happy.

Dirtbag: Is your 1.6 a N/A or turbo?

[Dirtbag]

mine is actully a 1.6 turbo, i picked up off a guy that was parting out his 83 jetta with only 119,000 man its still fresh. i have a 87 1.6TD jetta with 600,000km and its still going strong ,im located in mississauga. i would love to see your setup!

P.S im no stranger doing diesel conversions, i should show you my YJ with a 5cyc mercedes turbo diesel motor, the first run i had i passed a burried rubi and still pulled him out ..oooo...the irony.......

[SJKrawler]

I aswell would like to see your setup with the mercedes. Anything bolt up at all, or is everything completely different?
You're welcome to come see it sometime, I'm just outside of Rockton.

[Dirtbag]

hey check your pm i may have an answer to your fuel problems!

[SJKrawler]

I see that, thanks:)
The problem with the air was the fuel filter on the fuel pump was pluged. :roll: No air now.