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Posted by: jsayre914 Apr 5 2009, 06:04 PM

I got my engine in the mail few days ago. I got a complete 1.8 w l-jet. I dropped out my 2.0 w/ d-jet, figured it would be a semi-quick swap...

I then realized i was missing the resistor pack, and dual relay (djet does not use these) and now i will be recieving those two very important pieces tuesday. So my next question is....

am i forgetting anything eles??

i think my 2.0 fuel pump is the same right, and i havent started hooking up the wiring yet, but seems like the plug to the relay board is the same looking. I got the ss heats and bursch exhaust, along with basic tune up stuff.

i really cant afford to have the project held up anymore, you guys have any insight or advise? anyone do this recently?

Posted by: jim_hoyland Apr 5 2009, 06:34 PM

You need the 1.8 ignition harness-----

Posted by: jsayre914 Apr 5 2009, 08:31 PM

where do i find that, how will i know if i got it?

Posted by: jim_hoyland Apr 5 2009, 09:09 PM

Well, the 1.8 ignition harness has more wires. Starting at the 12 pin connector at the relay board: 1 big yellow to solanoid and 2 grey wires to the tranny ( same as a 2.0 ), then a black wire to the + coil and a black/purple wire to - coil ( tach ), the back + wire will double back ( call it black 2 ), and a green/red for the oil light;
than the eand of the harness ( this is going into one side of your double relay) has a yellow, black/red, black2, and brown ( ground).

You also need the 1.8 FI harness. Here's a pic of my dual relay mount on the left, the box on the right is a fused distribution block i added ( not necessary )






Attached image(s)

Posted by: SirAndy Apr 5 2009, 09:16 PM

It's the same size, but don't just assume all the wires are in the same location!

There were some changes over the years in the location of some of the wires on that connector.

I'd open it up and compare each wire location to your old plug!
Andy

Posted by: jim_hoyland Apr 5 2009, 10:17 PM

Where the casing meets the 12 pin connector, you will see a 2 -5 inch yellow wire with a female spade terminal. This is unique to the 1.8 ignition harness and a give-away.

Posted by: type47 Apr 6 2009, 07:31 AM

On your new 1.8 engine, do you have wires connected to the fuel injectors? If so, isn't that the 1.8 L-jet harness? That harness should have white plugs for the dual relay and the resistor pack since those parts, especially the resistor pack, are part of the wiring that sends signals to the fuel injectors. I think the other end of that wiring harness plugs into the relay board.

Posted by: jim_hoyland Apr 6 2009, 07:38 AM

Two harnesses:
1. Brain to injectors, cold start, AAR, AFM and right side of dual relay, plus a wire to the - side of the coil

2. Relay board to starter, BU switch; coil, oil lght, left side of dual relay

Posted by: type47 Apr 6 2009, 07:42 AM

Listen to Jim H. I'm in NY and my 1.8 is in VA so my comments are from (a weak) memory. All my references are at home in VA.

Posted by: jsayre914 Apr 6 2009, 07:43 AM

Yes, i have the 1.8 harness, and jeff just let ne know that the extra yellow wire is for the fuel pump controll and needs to go into the relay board, he said there is a picture in the world somewhere he will find and post for me.

sorry for confusion

next questions

is there some bracket that holds the air box, or does it just sit on top, i do not see a bracket like the 2.0 application.

do i need to use the charcoal cannistor. or can i delete it?

Posted by: jim_hoyland Apr 6 2009, 07:48 AM

The canister will not affect operation.

Airbox, you mean the part that contains the air filter and attached to the AFM ( Air Flow Meter) ? The bottom part of the box is held down with a wing nut; it sits on a flat piece of metal. The top is help to the base with 5 clips. The front of the AFM attached to the throttle body boot ( a critical part, check for cracks)

Posted by: jim_hoyland Apr 6 2009, 08:04 AM

Pin Outs on the 12 pin Connector, Odd # are on the left, even are right; 1 is located at front left, 12 is at back-right:
1. Green/red stripe - oil
2. Grey/ brown - bu light switch
3. Empty
4. Grey/brown - bu light switch
5. Black/purple stripe- tach
6. Yellow - starter
7. Black - coil
8. Empty
9 Empty
10. Green jumper to 11
11. Green jumper to 10
12. Black/red for fuel pump

Posted by: Cevan Apr 6 2009, 10:18 AM

Yes, you need a bracket. It's held in with 3 bolts. The bracket has a threaded bolt that sticks up. The bottom half of the airbox is bolted to this bracket.

Posted by: jsayre914 Apr 6 2009, 10:28 AM

anybody got a picture of the bracket, installed preferred

Posted by: type47 Apr 6 2009, 03:43 PM

Maybe someone will get one soon. For me, Wednesday afternoon at the earliest. I have a bracket removed and another bracket installed and can get pix of both/either.

Posted by: jsayre914 Apr 6 2009, 04:25 PM

can i run her a few days untill i get the bracket?? just dont turn too fast right

Posted by: type47 Apr 6 2009, 06:36 PM

I don't think it would hurt to run it. Seems to me the important thing would be the connections to the AFM are leak free. It might flop around a little but I think it would be drivable. Maybe you could wire tie it down to make it a little more secure.

Posted by: jim_hoyland Apr 7 2009, 07:15 AM

Support the bottom too, should be OK.

Posted by: gothspeed Apr 7 2009, 07:48 AM

Am I missing something here ? ........... what is the reason for going through all this trouble? I thought a 2.0 was a tad more desireable? .......... or is it because of the fuel injection?

Posted by: type47 Apr 7 2009, 08:27 AM

I think his 2.0 needs a rebuild and wants to install another engine to still be able to drive the car.

Posted by: gothspeed Apr 7 2009, 12:02 PM

Makes some sense now.

Posted by: type47 Apr 8 2009, 08:35 PM

pix of bracket top and underneath. I looked all through the PET and could not find a part number.

Posted by: jsayre914 Apr 9 2009, 01:51 PM

i was so close to diagnosing the alternator problems...

then the smell of smoke, from the alternator area. looks like the ignition was on for too long, and somthing in the harness sizzled.

looks like i just met murphy.