Club 80-90 Forums

let me know if i've missed out anything my heads all over the shop trying to be sure i've checked everything!!!


thats how i felt but if you have done the basics it will soon let you know if you have .....without doing any damage...have fun

rt the exhaust on today & forgot where a few wires go :O/

more importently i'm not getting a glow plug light & i dont thing they are heating up

also i'm struggling to get the fuel lines filled with diesel? any tips?

the engine is turning over on the starter ok!
red ignition light is on!

now for the wires i cant remebr where to connect
what colour wire is meant to connect to each oil sender? one on the head one on the filter housing

also on the alternator i have the big fat red one on the post with the 13mm bolt & there is a blue wire which i think is the battery light on the dash to show if your alternator cable snaps/comes loose!
a thin red wire with a spade connector which i have no clue where that go's????????

other than the above everthing is as it should be!

i have some pics to upload which i'm in the process of before my dinner

eager & nervous now

if there is anyone in or near coventry that is good with diesels that could come & give me a hand before the weekend that would be superb! gotta try to get to vanfest this year

now the wire in the pic below with the blue connector on is the one that connects to the fuel solinoid, have i got it on the right one or is it the one my finger is pointing at???


cant remeber where these go?



or this red one, the blue one i'm not 100% on either


i've ordered the throttle levers from brickwerks to save some time & effort, normally i'd make somthing to work but time is off the essence!!! hope simon gets the to me quick stticks, he's been top with other orders!

No no, I think the one you have it on is a sensor Wrong statement (E D I T), it is the other one you are pointing at. As I said earlier with the ig switch on touch the wire on and off the solenoid and you will hear it click in and out...senders wont click. The wire with the rubber shroud goes on the back of the head ? ! I am off work tomorrow so I will note all the colours and where they go and get back to you.

cheers pete super super appreciated! sooooo close but yet so far n all that hey

other than the fuel solinoid & glow plugs i dont need the other bits to make it run but obviously i'd like to hook them up & have them working, esspecially the temp gauge on the dash & oil pressure light on the dash also!

its all go apart from the motor at te moment LOL

AHA, you are right with the fuel cut solenoid thats the one
I have a Yellowy colour wire.............back of head on the sensor that is screwed directly into the head.
Yellow with red stripe..............on the double hose connector between No.3 & 4 injectors.
Green with a black stripe...............to oil filter

Now then, do you have one left over blue with a white stripe ? There are 2 connectors on the back of the head, one screwed directly into the head (yellow as above) and one on a hose connector. This one works the glowplug relay and tells the relay that the engine is cold so switch on glowplugs and if engine is warm it tells the relay that glowplugs are not needed.
I have left this one disconnected because she did not start too well when the engine was warm without the glowplugs and subsequently my engine starts every time with glowplugs and has not been a problem.

Hope this all makes sense mate.

right i'm confused i dont have 2 connectors on the back of my cylinder head???

have you used the original 1.7ky wiring loom pete???? or have you joined the 1y loom on?

i only have the wires in the pics above which ran the 1.7ky motor??????

i'm super confused now!!!!!!!!!! See i just dont seem to understand wiring whatsoever


i have my vacuum pump non-return valve setup all sorted so...................its just a case or sorting the wiring to get it to start now!


Idefo need a step by step guide on this bit folks maybe somthing i can print out!

i'm off to hoax out my bentley manual to at least know what colour wires went where on the 1.7ky

Are you saying that you only have 2 wires ???

I used the 1.7 loom with no changes, where they came from on the 1.7 is where they went on the 1Y.
All you really need to start her is the solenoid wire...........YOU GOT THAT SORTED !!
Oil Pressure Switch...........For the dash warning light
Engine/water temp.........For the dash moving temperature gauge.


I fitted the hose connector at the back of the head from the 1.7 as it had another sensor on it where the 1.9 did not.

If you only have 2 wires ? ? then one will be oil pressure switch and the other "moving temperature gauge" if you have three wires and you have identified the moving temp gauge then one of the spare 2 will be oil pressure switch. Dont look at them as a bunch of wires as they are individual and by identifying them one at a time it will become clear.
Turn on the ignition and touch one of your 2 wires to a good earth and see if the gauge moves if it doesn,t then try the other one. The one that does not move the temperature gauge will be oil pressure switch.
Once you have sorted the temperature gauge thats the solenoid and temperature sorted. All you need to start her is the solenoid and you have that.

yellow with red is temp gauge

Thanks for that Aiden. There you go then the blue one must be oil pressure.
On my Alternator I have three wires, Fat red on the bolted terminal and a small spaded blue (charge light on dash) and a small red with a larger spade so you cant get them the wrong way round. Nearly there mate, keep at it.

Right the the 1y has actally ran today! & revved! woohoo! yep it does have white smoke & runs a bit jiggery when cold at the moment but when it warmed up a little it had black smoke & not blue which is a good sign "i think" the black smoke did clear a bit so once its up n driving it'll sort itself out a bit!

basicly because i am fckin clueless on diesels! i gave a ring to the one to only!

MERCDOCTOR on here, which is marcus! he came & gave me a BIG hand on the wiring & what go's where & done lots of fiddling with bleeding the fuel into the pump & other bits n bobs

suffice to say i have two probloms

1. i'm not etting the glowplug light
2. the fuel filter type i have is wrong for the 1y- my filter has a valve in the return line which stops the motor running/circulating fuel or somthng or other!

so i have a small list of parts to get & fit such as the earlier type fuel filter setup with no valve in the return side!
glow plug relay
oil senders both types
i need to pick up a cuople of spare alternator belts anyway!

So "NO DOUBT" i'll be ringing MERCDOCTOR again to give me a hand whn i've fitted & fiddled with the bits above!
She wont be rdriving for vanfest i dont think but as soon as it starts with the glowplug lighting up i'll d a video!

more pics to come of the mods i've made, let me find the cable!

Big thanks to marcus the mercdoctor so far! he's a legend!

Really pleased for you mate. When I first started mine there was black smoke (bum nipping time) and all it was was the exhaust was full of old oil from the knackered 1.7
Oh dear I have the fuel filter with the valve on the return side

& me pete! i'm getting there slowely but surely! help online from ya good self & weldore, colinthefox, aiden & in person marcus MERCDOCTOR!

TOP chaps!

there are a few issues to sort but nature of the beast n all that is'nt it1 a little of the desparation to get it done has gone now as at least the motor runs!


a question:

i've use the 1.7 dipstick on my 1.91y & filled the motor with 4.5lters of oil, i also filled the oil fitler as much as i could without it spilling all over the shop!
but.............the oil level is only just at the bottom of the dipstick not on the max/correct level!!!!

now when i put the 1.7 pump in & the 1.7 dipstick the dipstick tube sits level with the oil pickup so do i just need to top up to the correct level as the 1y motor was VERY well drained of oil or do i trim the 1.7 dipstick?

i'm thinking op up to the level which i think is only a pint between the lowest & max level so mine would need a pint & a half, does that make sence

what ya reckon? obviously i dont want the motor starved of oil or overfilled!

cheers again!

Dont make your oil level match the dipstick, overfilling is not good. Lots on here have done this conversion and 4.5lts is it. If your dipstick is too long you can trim it and make a new full mark. If it is too short you cant make the dipstick longer but you can make the tube shorter. Books have almost been written about the dipstick (think I saw the video ) I warmed and removed the tube top plastic bit and cut down the tube and put the plastic bit back. If your "correct" oil level is say 20mm lower than the dipstick full mark then you need to cut 20mm off the tube.

i have used the 1.7ky dipstick pete, the bottom of the dipstick is level with the oil pickup pipe when installed so my theory is that as the oil pickup & dipstick are in the same position in the 1.7 sump i may just need to top up a bit! what d'ya reckon

i have'nt used the 1y dipstick!

or did the 1.7 dipstick in its 1.7 motor sit lower than the oil pickup pipe???? i should have looked/checked!