Wiring/electrics 1.6 To 1.9 Conversion!

[Lucky Gti 0]

OK, to start with I bought a newer 1.9 engine for my 1.6 gti, so have different dizzy and coil. I did get the loom with it, but the guy who took it out didn't label it all up and there are way way too many connectors that don't seem to go anywhere! I've spent hours looking at the haynes book of lies, and have connectors with the same numbers on which doesn't exactly help! so my question is:

 

Can i go back to the 1.6 loom, fit the 1.6 dizzy and coil to the 1.9 head and fit carbs so I don't need the ECU (I do have the 1.9 one though) or is having the newer engine just going to be a nightmare anyway?

 

I have managed to wire some stuff up where i think it goes, but the starter motor kicks in before the final turn of the key! Any help would be appreciated, as I left the garage earlier thinking bad thoughts involving breaking and ebay!!!

[gti-si 0]

There really isn't that much difference. You could fit the 1.6 coil, amp, ECU and dizzy to the 1.9 engine and it will run fine, aslong as all the parts are either 1.6 or 1.9 it's fine, it tends to screw things up if you mix parts. I wouldn't be so rash as to ditch the management because you can't figure out thew wiring yet. Some twin webbers will ofcourse be an upgrade though

 

The wiring on them apart from the dizzy and coil should be pretty mcuh the same and shoudln't be too difficult atall. If you take a few pics of what you've connected and what you cant fatham out, sure we can help you out...

 

It looks complicated but is very simple...

[Lucky Gti 0]

Ok. Thought the 1.6 ECU wouldn't work with the AFM etc from the 1.9 or would i need to refit the whole throttle body, afm and filter from the 1.6 as well? Thanks for the info though, I'll keep trying!

[steve@cornwall 100]

I would have used the existing loom and coil, anyway. Simply ditch the manifold mounted coil and connect everything up as it was before. Use the later 1.9 dissy, you will need to modify the king lead to fit the earlier coil, just snip off the end that clips onto the "nipple" of the newer coil leaving the brass collar around the lead (it may also need compressing to fit properly in the coil)

 

If you can remember where all the original stuff went, this may be the easiest way for you

[GLPoomobile 958]

I think 2 things need clarification here.

 

1 - What age is your car? As Ph1 GTIs have a different loom

2 - What age is the donor engine etc? It could be a late CAT equipped 1.9 running Motronic. Does is have an AFM?

 

Either way, you can swap the lump in as is and use the original loom and use the 1.6 AFM, ECU, dizzy, and injectors (I know it works on 'normal' 1.9s, not sure about the late CAT equipped engines though).

[gti-si 0]

Sorry, yes, you will also need the 1.6 AFM...you won't need to touch the throttle body. As steve says, much easier to just use your old loom and coil, didnt think of that

[pug_ham 244 3 Cars]

Steve, all 205's have an AFM, motronic or not.

 

You shouldn't need to change any of the wiring to run the later 1.9 engine in your car, just swap the ecu & afm for the 1.9 GTi ones you got with the later engine as long as they aren't from a Motronic cat equipped car.

 

Check your ecu number, if it is the top one of the list below it should plug straight in & work from the wiring in your car now. If its the lower one you'll be better to find one with the top number

 

Bosch LE Jetronic ecu is 0 280 000 359 & AFM 0 280 202 109.

 

Bosch Motronic 1.3 ecu is 0 261 200 160 & AFM 0 280 202 202.

 

Graham.

[Lucky Gti 0]

Right, to answer a couple of questions, its an 89 F reg 1.6 gti. I'm not sure what age the new engine is! Impulse ebay purchase!!!!!!!! the connections on the ECUs are different, so I'll need to check the numbers, but that makes me think that it probably is from a CAT equipped engine! Knew I should have paid more attention to the 'How to' guides......... So to clarify then, I could go back to the old loom, throw in the 1.6 AFM and ECU,(or use the 1.9 AFM with the earlier Jetronic 1.9 ECU keep the dizzy, but put it back on the old coil, with a slightly 'tweaked' HT connection. I'm leaning this way, as at least the old loom is still all labeled up!

 

Thanks guys, lots to check on, which I will be doing tomorrow night!! I'll let you know how I get on!

[welshpug 1,661]

did you get a complete wiring loom with the engine? i.e is the ECU plug attached to it?

 

a picture of the new engine and loom may be easier for you to explain the problem, but if the NEW ECU doesn't fit the car's original ECU plug there's something not right (dont think 2 row Cat equipped Motronic ECU's fit the Jetronic plug)

[Lucky Gti 0]

Yes, I did get the complete loom, but as you say the new ECU doesn't fit the old loom. I'm looking at an older type ECU at the moment (Bidding on one actually) using Grahams numbers so I'm going to put the old loom back in, and try it with the new (but old type) ECU! Then we shall see! Thanks for all your replies guys, I'm now over the breaking and eBay obstacle!

[Masekwm 2]

Strangely my 86 Phase 1 loom happily accepted what I believe is a late ECU, which is also available for sale in the for sale section.

Edited May 22, 2008 by Masekwm

[pug_ham 244 3 Cars]

Strangely my 86 Phase 1 loom happily accepted what I believe is a late ECU, which is also available for sale in the for sale section.

A cat equipped car's ecy would not fit the standard 205 jetronic loom, the M1.3 ecu is a three row one so none of the pins would line up imo.

 

Even if they did it'd never work due to the missing CAS.

 

Graham.

[Lucky Gti 0]

No, the two i have now are completely different, which was why i asked for the ecu and loom when i bought it! I'm guessing that there are still bit's missing, including of course the CAT?

[pug_ham 244 3 Cars]

You don't need the cat for it to run.

 

As long as your car ws made before CAT's were compulsory it will be tested on the vehicle or engine age / year of manufacter, whichever is the oldest.

 

As long as the emissions are below the MOT limit for your car it shuld pass without any problems.

 

Graham.