Turbo7379 3 Posted April 29, 2007 I finally got around to rebuilding the 1.9 MI lump I bought last year . I am using it to replace the tired 8v in my e-reg 1.9 GTI rally car . Fitted the engine today but I can't get it to start . I can't get a spark & the only time the fuel pump gets power is for 2 seconds after you release the ignition key from the start position . The engine was running 100% in the doner 405 . I've checked the wiring between the coil , ignition module , CAS & the ecu - all ok . Tried 3 different ignition modules . Tested resistance of CAS - 520 ohms & it increases when you pass the sensor over a steel object . I was going to make up a link loom for the conversion but I couldn't find the brown multi-plugs in the 205 . Instead I used the original 205 sensor loom for the alt , starter , oil/water gauges & warning lights . From the Motronic 4.1 loom I ran 2 wires ( 76 & 2 ) inside the car & connected 76 to another 76 on a multi-plug . Wire 2 was joined onto a switched ignition feed at the radio multi-plug . I wasn't sure about wire 112 ( tacho ) so I connected it to the similiar shielded cable going to the original 8v coil . I kept the 8v engine loom intact & pulled it inside the car & unplugged the ECU & tach relay . Is there anything wrong with my wiring that would cause my problem ? Maybe the tacho wiring ? I would like to keep this set-up as it will leave it easier to refit the 8v if the 16v blows . I've read through most of the posts on MI16 wiring problems & tried out several things but still not working . Really peeved as I had booked a track day today to run the engine in & do some testing . Any advice greatly appreciated . I might remove more of the dash later to try & locate those multi-plugs . Share this post Link to post Share on other sites
jackherer 543 Posted April 29, 2007 (edited) Early 205s like yours dont have the brown multiplugs so don't take the dash out! It sounds like you've done everything right, with the possible exception of using a switched 12v from the stereo as I suspect that might be cut during cranking (and possibly confirmed by the short burst of fuel pump activity you get). Try connecting wire 2 to the switched 12v that was going to the 8v coil along with the tacho wire you used. (edit: Posted Today, 5:21am, have you been up all night working on your pug? I hope you get it sorted and maybe get some time on track ) Edited April 29, 2007 by jackherer Share this post Link to post Share on other sites
Turbo7379 3 Posted April 29, 2007 Early 205s like yours dont have the brown multiplugs so don't take the dash out! It sounds like you've done everything right, with the possible exception of using a switched 12v from the stereo as I suspect that might be cut during cranking (and possibly confirmed by the short burst of fuel pump activity you get). Try connecting wire 2 to the switched 12v that was going to the 8v coil along with the tacho wire you used. I've been working late nights all week to try & get this engine built & fitted , last night I gave up at 4.30 am ! Took a well earned rest today but curiousity got the better of me & I went & tried what you suggested - you probably heard my shouts of joy around 7 pm when the engine burst into life straight away ! Thanks for the help . The battery warning light is on now & I think the alternator is faulty as the same light was coming on the 405 at idle . Will the 8v alternator work on the 16v ? Still a lot to do yet - make up exhaust , connect water pipework , modify radiator , ect but at least the engine is running . Share this post Link to post Share on other sites
jackherer 543 Posted April 30, 2007 nice one The 8v alternator will be fine, it has one groove less on the pulley but you can either use an 8v belt or cut one groove off the 16v belt. Share this post Link to post Share on other sites
