Rabbit Pickup, maxed out turbo IDI, home grown o2a swap!

[fastinradford]

Here's my baby, owned 30vws and it's the only one that's stuck around. Was off the road all winter due to other projects/time shortages; the usual.

dont mind the block heater cord stuck under the 16v lip


Uh oh, what's hiding in there!



1.6td block
1.9 aaz head
1.6 injectors/pump/lines
maxed fuel boost pin, fuel screw, max fuel screw, maxed lda tuning.
k24 @25psi
2.25" straight exhaust
EGT gauge.
puck clutch, feels as stiff as south bend.
solid, slightly lightened flywheel
02a from g60 corrado
cable shift
cable clutch conversion (eurovan actuator, crx cable, home made bracket, this seems to be a different cable from what others used.... but works awesome).
Home made mounts.

Somewhere in the neighborhood of 140-150hp. Pulls like a mother. Does 100mph in 4th no problem.







Let me know what you think?! Been dailying it since the mk4 tdi broke the rear beam!
Was my bday wish to drive the caddy on my birthday (may 19), and it turns out I HAD TO, LOL.

Can't get enough of this thing, working on some videos of the pulls....... and the smoke.

[fastinradford]

More pics, got LOTTts more, haha.

[ilovesandiego]

Bad Ass motor! More pictures of the bay and intercooler set up..

[fastinradford]

Reppin BURNT TOAST: crsmp5


Gotta love that sliding glass, with the beads, its 1/3 way to a/c

SUGGESTIONS and OPINIONS ECT WELCOME,
thanks for looking

[fastinradford]

Bad Ass motor! More pictures of the bay and intercooler set up..

Thanks!
Curious about nnything in particular?

Intercooler is unmodified toyota MR2 (the supercharged mk1, NOT mk2 turbo)


As you can see, with a little love it fits the stock core support, and there is an oem hole near one of the outlets. I have a big clamp that holds the intercooler firmly in place.
Fits behind the stock copper rad
And clears at least my belt setup.
But my engine position is custom, so I kinda set all the tolerances
But seems to fit better than anything anything custom made for a mk1, and it's all metal intercooler, no end caps, it's tough.



Air box is stock mk2 A-chassis turbo diesel. Along with turbo inlet hose. Used factory fuel lines and moved the fuel filter against the fire wall.

[ToddA1]

Ah, Frankenmotor. Where did you set the timing? I've heard of hard cold starts with these... how's yours?

What are you basing your hp numbers off of? Any ideas on torque?

What type of mileage are you pulling with that 02a?

-Todd

[fastinradford]

Ah, Frankenmotor. Where did you set the timing? I've heard of hard cold starts with these... how's yours?

Timing is set at "1.00" I had it lower and higher, it really made almost no difference. New 1.6 injectors too.

As for hard starting, all I can say is it started at -12f, plain diesel fuel, single glow, no block heater. And made heat. Fast. Temp gauge never creeps above 3/5, even on those toughest beatings.

But... it smokes white on startup. Did it today, 85f. Lol. It always smokes white on startup for 1min.

What are you basing your hp numbers off of? Any ideas on torque?

Rough estimate, it easily pulled a few 16vs mk1/2. I also ran with a guy who has a 535hp cummings, and I could beat him by a tad, so I gotta be up there. on vwdiesel.net, similar franken motors have made 150hp.

What type of mileage are you pulling with that 02a?

Same as when I had the 020 basically. bellowing smoke, full throttle runs ect. no less than 32mpg. Even steady highway, 50mpg.
Usually 39-44 mixed.

-Todd

Go frankentd, there is no real reason not to.

[fastinradford]

[richarddhoward]

Love it! Frankenmotor I love! I may need to look into the 1.9 head for mine...hmm....

Did you build the motor yourself? Or is this a swap you did someone else built?

[ak757]

love this

[fastinradford]

Love it! Frankenmotor I love! I may need to look into the 1.9 head for mine...hmm....

Did you build the motor yourself? Or is this a swap you did someone else built?

Myke_W built the motor originally for his mk2 coupe; that was until we (he) went drive by wire ahu tdi. But I have swapped out the int shaft, oil pan, turbo/manifolds, changed to a different headgasket, swapped cam and injection pumps, timing belt, belt covers, so it's a little of both of us.

When I came into possession of this truck it had 59k miles on it, 100% stock, mostly original, now has 79k, still mostly stock, or easily reversible.

[fastinradford]

love this

Thanks man, means a lot

[richarddhoward]

Do you have build up pics of this stuff?

[ToddA1]

Go frankentd, there is no real reason not to.

Hmmm... I may have to explore this. I've been amassing the parts to simply go TD; 95% there. My crank is washed out, so I may go TD and run it until it gives out, then go franken TD.... I definitely like this.

Did the 020 give out or did you want the longer legs with the 02a?

-Todd

[fastinradford]

Hmmm... I may have to explore this. I've been amassing the parts to simply go TD; 95% there. My crank is washed out, so I may go TD and run it until it gives out, then go franken TD.... I definitely like this.

Did the 020 give out or did you want the longer legs with the 02a?

-Todd

the 020 was leaking, (although "rebuilt" with a bolt kit0, then the oil galley started leaking, so if you remove the gearbox, why not convert it too. Lol. easier said than done.

Also, I had a new sachs clutch w/16v pp, and the clutch always smelled burnt, it slipped slightly at high end 3rd gear.

02a w/ puck clutch is zero slip. let go of the pedal and she locks up. it can spin the tires in the garage at idle. haha.

[fastinradford]

Do you have build up pics of this stuff?

not really, but anything you are curious about, I am more than willing to help you!

[fastinradford]

curious about cable clutch in mk1 with unmodified pedals?

It's easier than you think!

And better than your mildest dreams.

[ToddA1]

You could have also stayed with the grasshopper linkage kit to keep it even more simple.

-Todd

[richarddhoward]

I'm just curious how hard is this thing is to complete! I'd love to do one lol It'd be sweet!

[rabbitnothopper]

nice
beautiful

awesome mods

great picture project

awesome that its a 1.6TD!!

[Minty_Fresh]

truck looks sick. love turbo IDI's. but you need some new strut mounts.

[stewardc]

Very nice project here ! I love these little trucks with TDs in them. After all, "Real Trucks Don't Have Sparkplugs" !

[richarddhoward]

What head gasket are you using on this thing?

[fastinradford]

What head gasket are you using on this thing?

2 notch aaz metal gasket

[richarddhoward]

2 notch aaz metal gasket

I'm over on vwdiesel.net...researching, and researching lol this is getting interesting.

[simon_C]

this thing rocks! i love hot diesels.

[fastinradford]

this thing rocks! i love hot diesels.

thanks! you know it must be cool because nobody is criticizing my horrendous mounts!

I'm over on vwdiesel.net...researching, and researching lol this is getting interesting.

It's easier than you think. I'd suggest a k14. mine made 140hp @18psi intercooled, and was spolled by 2500rpm in every gear, high gears (3+) spools instantly (almost). k24 makes more peak power and has a higher top speed, but it is laggy. Even dumping fuel at it. With the k14, 100mph was the max in 5th, with k24, will do 100 in 4th. flows that much better. also got better mileage with the k14, despite being at 10psi cruising 70mph.

the k03 from the ahu (not 1.8t) is also a great turbo, although oil lines are custom on an idi.

[fastinradford]

Very nice project here ! I love these little trucks with TDs in them. After all, "Real Trucks Don't Have Sparkplugs" !

heck yes!

truck looks sick. love turbo IDI's. but you need some new strut mounts.

Thanks, and I know, almost everything is oem still, but truck is pretty good shape, 79k miles!
looking for brake upgrades, coils, drop plates in near future.

Also thinking about throwing the 13" caddy steelies back on it, it didnt handle corners as well, but it was a rocket in raw acceleration.
Pulled a v6 dodge ram @ 55rpm in 5th.

[richarddhoward]

thanks! you know it must be cool because nobody is criticizing my horrendous mounts!



It's easier than you think. I'd suggest a k14. mine made 140hp @18psi intercooled, and was spolled by 2500rpm in every gear, high gears (3+) spools instantly (almost). k24 makes more peak power and has a higher top speed, but it is laggy. Even dumping fuel at it. With the k14, 100mph was the max in 5th, with k14, will do 100 in 4th. flows that much better. also got better mileage with the k14, despite being at 10psi cruising 70mph.

the k03 from the ahu (not 1.8t) is also a great turbo, although oil lines are custom on an idi.

That is making me drool...I don't need to do 100 mph lol But being able to get out of my own way sounds good lol

[fastinradford]

Food for thought...

[Ziptied]

Love this thing.
for DIY mount fabrication

[ToddA1]

Would you be able to post a cold start vid?

The smoke is the only thing that's steered me away from this in the past. Some people who had done this combo hated it so much, they pulled the combo out.

-Todd

[fastinradford]

Love this thing.
for DIY mount fabrication

Thanks so much

Would you be able to post a cold start vid?

The smoke is the only thing that's steered me away from this in the past. Some people who had done this combo hated it so much, they pulled the combo out.

-Todd

Will see if I can remember this weekend.
Basically smoke on cold start is based on the MAX fuel screw....
If fueling is set low, it will bellow smoke for 1min, crank up the fuel screw (likes to idle like 1100rpm), and just a whisper of smoke.
Its a strange beast, but tough.

[ohiodub_99.5]

Nice build.

Also, if you need a mk4 rear beam I have one... Im in cincy... I'd let it go cheap

[fastinradford]

Nice build.

Also, if you need a mk4 rear beam I have one... Im in cincy... I'd let it go cheap

I appreciate it man, just picked one up from Marshals Junkyard, in circleville ohio.
$69.99 and came with calipers /brakes ect all in good shape. And they had 8 in stock

And they have a fairly good online inventory!

Was a nice 2.5hr drive in the caddy! it's nice to be able to go 75mph without pushing it.
Pre-turbo setup, this thing could hardly hold 5th up any hills.