Conversion - Mk4 Petrol - OUT, Mk3 Diesel IN

[CK0505]

OK Guys, I'm not the best mechanic in the world..... maybe I should say I'm the worst... But hey we gotta start somewhere.

My Mk4 petrol engine died, so as I have a Mk3 rust bucket with a cracking diesel engine I thought I would take the bull by the horns and convert my fuel hungry petrol Mk4.

Now, all seemed to be going well... Engine dropped in a treat. Prop matched up perfectly, engine mounts are exactly the same location.

I fabricated a mount for the power steering pump and running this off the bottom pulley (when I have found a belt to fit).

OK, so here's my problems that I hope someone can help me with......

The loom on the Mk3 and Mk4 are different. I have wired up everything that I can work out and have the following to sort.

1) Fuel Shut-off solenoid
2) Thermostart control box thingy - WHERE IS IT???? WHAT DOES IT DO??? coz I can't find it.

The round connector on the Mk4 has a lot of cables coming out that I haven't found a home for, but I assume that a lot of them were for the electronic ignition that was on the petrol engine.

Also, if I try to start the engine the Starter Relay under the bonnet trips out. There is also a brown cable form this that I can't find a home for. According to my mate Haynes, it says that this goes to earth. When it is earthed is trips the relay.

If anyone can help I would be eternally grateful as I can't afford to pay someone to do the work for me and I've lost 2 days work so far too.

Cheers

CK

[Luke]

have a read of my mk4 progress thread - i did the conversion too and theres pics of the starter relay wiring!

the fuel solenoid is a live wire feed from the ignition, and the thremostart is mechanical cable all on the engine no need to worry about it

[CK0505]

Thanks Luke, I have tried to find your post, but I guess I'm not that good at the search thing either, it returned 3020 post by you.

[MrMPuk]

http://www.fordtransit.org/forum/viewto ... highlight=

[CK0505]

Thanks for that

[Luke]

yep thats the thread but its not in there sorry, and i cant find it

but this is the pic im on about



and there's a thread explaining what i did somewhere

[CK0505]

I found the one with the above pic. AND, read the entire thread on your conversion. Nice. I'll post my progress report as soon as I get the thingy working.

I am a little confused. Did you use the starter relay from the Mk3 or bypass it and direct cable connection to the solenoid?

[Luke]

yeah what you need is the feed from the petrol starter to go to the diesel starter relay which then feeds the diesel starter soleniod

as the petrol doesnt have a starter relay as the starter is a lot smaller

[CK0505]

well that was easy......

MUST GET BRAIN CELLS TO WORK TOGETHER!!!!


Thanks Luke. I wanna go out and do it now, but as I have no power at my garage it will be a bit difficult in the dark. First thing in the morning, I'll have a crack at it.

One other thing, what about the Fuel cut-offer solenoid on the Lucas/CAV pump? Where does that wire into?

[Luke]

One other thing, what about the Fuel cut-offer solenoid on the Lucas/CAV pump? Where does that wire into?

basically any switched live so a wire from the back of the ignition column would do it (get a meter on find which is live when the key is turned) - and while your there fit a hidden switch on it for an extra security measure

[CK0505]

That was easy too. Thanks again Luke.

I've started a progress thread and will put my updates in there.

With a bit of luck I'll be up and running tomorrow.

[Gazza01]

hi mate as your petrol engine has died and your changing to deisel is there a chance you still got the gearbox converter plate as im looking for one for my project thanks Gary

[CK0505]

hi mate as your petrol engine has died and your changing to deisel is there a chance you still got the gearbox converter plate as im looking for one for my project thanks Gary

PM sent Gazza

[CK0505]

I would like to suggest a new section to the site titled...........


'DONUT OF THE MONTH'

And I propose myself as the first owner of this prestigious title for the following.

For 2 days I have been trying to work out why my engine wouldn't turn over. If you've read the above posts you will see what I was asking. Well the engine still wouldn't turn over.

It turns out that my original wiring was spot on. And, I could have saved myself 2 days of misery if.......................


I JUST TIGHTENED UP THE LIVE CABLE TO THE SOLENOID!!!!!!!!!!!

Anyway, the engine is turning over now, and after breaking and replacing one of the flowback covers on the injectors (thanks to Diplock Fuel Injection in Hailsham for helping me out with the part) the engine still won't start.

I've bled the fuel system. When cranking the engine it turns fast as if there is no fuel getting to the cylinders. Can anyone tell me how I can test to see if I've bled the system properly?

Also, where does the glow plugs get their power from? Might sound a silly question, but I have no clue.

Cheers

CK

[MrMPuk]

Well you are the one to answer if fue; is getting to the injectors as you have said above you have bleed them. When you bleed them was lots of diesel squirting out?