now that ive done an engine swap in my 91 deisel i took the engine from a 91 golf (that had an auto tranny on it) and put it inthe jetta with a 1.8 tranny from another jetta i had. changed the drive axels all the wiring gas tank pump etc.. now everything works fine but the clutch is loose... like its not hitting anything... i just replaced the clutch(fly wheel etc) and now it wont engage.. did i miss a spacer or is my rod not long enough or is it in the end of the tranny some where should i take thacap off the end and see if its the clutch push rod.. could i have pushed in the little dot on the plate on the clutch ?? some one please help me with this.. also where does the brown and blue wire from the fuelpump\sending unit go??? any schematics?? please helpp i need thcar today !!


thanx sooo muxh



www.nauticlestar@msn.com

I do remember something about there being two different length push rods.... Did you keep all the parts from the trans with the clutch parts?

well i have an automatic tranny here still but nothing else and im prettty sure the rod from that wont work with the manual . im not sure whats going on with the tranny could i have put it back together and the clutch was engaged and pushed through the dot in the plate?? reluctantly im going to take the tranny back off the engine already mounted.. i hate crawling under the car to do tranny work its soo much easier when the engines out. i want you to tell me i just have to buy a new rod and thats my only prob or its the plate.. we wwill find out today and ill let you know exactly what it is...

after the engine swap despite the tranny the car shoudl still start which it is not.. the pump is sending the gas but the ignition is not turning over. the ignition itself is from a golf and the engine wiring harness is from a jetta and the fuse box and digifant comp are from the golf. could this be an issuse? both had the same options except the golf was auto and the jetta was manual.. i dunno but im getting stressed.. its taken me two weeks to change these engine and replace the clutch etc.. to much work this must be the ultimate swap for problems .. any advice at all would help greatly. does any know what the brown and blue wire from the fuel pump is for and where it goes? gas gage?

thanks again!! markethan avid veedub enthusist

ok so now the tranny is off and there appears to be nothing wrong with anything.... the plate is still intact and everything looks normal. and i took the tranny off again for no reason ... what a piss off.. well tomorrow it goes back on. does anyone know the length of the push rod thats supposed to be used with an AUG31050 3 manual tranny? its now bolted onto a 026103373AA engine with the digifant fuel injection system... i can think of nothing else that could be wrong except for the pushrod length.. any other ideas? has no one had this problem before?? HELP!

Pop off the end plug & make sure the cross-shaft arm that pushes the rod & holds release bearing is okay.

tranny is back in and i just got back from the vw dealer ship. new release bearing and end cap $38.00.. i havent put it in yet, but i hope this solves the problemi was going to replace the lever too but they wanted $25.00 mines ok i looked and no cracks. do they make different size levers....? any who thanx again and ill let you know what happens .. markethan

You should be able to feel if there's excessive free play in the rod unit once the trans is bolted up to the engine.

I am in somewhat of the same boat, I totaled my 91 1.8 jetta and bought a 91 diesel 1.6 from a junkyard for the body. I found that even though the Transmission on the 1.8 and 1.6 are the same, the clutch and pressure plate are different between the diesel and the gas.
I'm not completely certain that I've followed what you did, but did you use the pressure plate, clutch and flywheel from the 1.8?
Doug

i took a 91 deisel jetta. and gutted it .. absolutely everything from brake to wiring harness gas tank fuel pump i mean eveything it was down to bare chasis. the i took a wiring harness and a manual tranny from a 91 1.8 gas jetta and pieced it with my engine, fuse block, ignition from my 91 1.8 golf. i have finally put it all back togetherand i drove it the otherday. im not sure what your doing witht the trannies but i do know that the drive axels on a deisel are a different size and bolt spacin then the gas.. i just took a manual and put it on my golf engine that had an automatic on it. everything said and done and a million wiring probs shes almost ready to go i just have to replace the brake lines on the back and shes ready for the road.. its sounds good considering i left the deisel exhaust on that has no cat and one muffler but it wont pass etest with it like that.. i did replace the clutch backplate flywheel bolts and disc but not the fly wheel or the pressure plate . it turns out my problem all along was the clutch release bearing and my clutch cable... as soon as i put in the new cable it engaged properly and i took it around the block for the first time despite teh bit of black smoke... which was from me spinning the tires it fucking flew.... im happy the whole process took me by myself close to two weeks and only so far has cost me about $200. plus what the brakes are going to cost me. im getting happy and i will be even more when its on the road. i have alot of plans for this car.. ciao.

also where does the brown and blue wire from the fuelpump\sending unit go??? any schematics?? please helpp i need thcar today !!


The wiring harness going to the fuel tank for the diesel and gas are different. I exchanged them. The harness goes from the trunk through the interior (drivers side) and connects to the blinkers, fuel sending unit, fuel pump, emergency brake engaged light, and trunk light.
The wire from the fuel pump should be routed with the fuel lines up through the opening in the trunk for the fuel tank. The sending unit for the gas fuel tank has 4 connections instead of 2 for the diesel. You have to use the sending unit from the gas fuel tank.
I can help with the schematics if you need, but it's really just a matter of switching the harnesses.

Doug

I got delayed while writing my last. Sorry it didn't account for your reply to my first. I'm completely restoring my Jetta. Fortunately, both vehicles were the same year and model. It made the wiring much easier. I had to buy a new exhaust system, it cost a couple hundred from carquest, but it bolted right in. I didn't have to replace the catalytic converter. I tore the car completely apart and literally wirebrushed every nut and bolt. New rings, bearings, seals, the works. I still am working on the interior and then need to paint the exterior.
Doug