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    VWVortex


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    Thread: Mk1 TDI swap

    1. 05-24-2012 08:55 PM #1
      My friend Alex is a mechanic and we are going to put a 2002 TDI in my Mk 1 Caddy. I am new to this forum and not quite sure how this whole thing is going to work so here we go. My 1.6 recently gave up on me and I decided it was time to put in the TDI. He is a VW mechanic so he is somewhat well versed in this arena but he said I need to learn as much as possible and we thought this would be a good start to see if any of you have done this sort of swap and if you had any advise, be it good or bad, that you could share with us. I will be posting problems we encounter along the way and let you know our progress. Wish me luck!

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      05-26-2012 03:29 AM #2
      I don't know **** about this...other then I'd like to do one myself! Lol I think the first step is...will it fit, and where are you going to put all the BS electronics that come with it?
      1980 Diesel 4 door Rabbit L - yellow one
      1981 Diesel 4 door Rabbit - tan one
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    3. Member Rockerchick's Avatar
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      05-26-2012 09:23 AM #3
      Take a search over in the mk1 forum. Its been done quite a few times.
      Quote Originally Posted by TM87 View Post
      VW-making mechanics out of owners since 1957.
      The project - '84 Jetta 1.6TD, 186k+, fully rebuilt, Giles IP and injectors, 2.5" custom exhaust, 51mpg
      Hers - '03 BMP 20thAE GTI, 130k, 3" 42DD turbo back, Unitronic Stage 2
      His - '01 Jetta TDI, 135k. Now has 3 pedals, as it should!

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      05-26-2012 11:49 AM #4
      There are a couple in there. They look rather complicated. But very doable. I'd just expect to spend...a lot...of money
      1980 Diesel 4 door Rabbit L - yellow one
      1981 Diesel 4 door Rabbit - tan one
      One or both soon to be among the living...

    5. Member snowyroads's Avatar
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      05-26-2012 02:26 PM #5
      From what i've heard, If you dont have a complete donor car. Its wayy to complicated. You'll need the motor, ECU, Probably a new cluster and wiring harness. Its "drive by wire" so the whole pedal assembly too. The clutch is hydraulic operation. You'd need the tdi shift linkage too probably. And im thinking you'd need a different engine mount set-up. Probably a carriage like a vr6 swap needs.

      basically everything engine and transmission related, not to mention the drive axles are larger from the old cars. So something would have to be done with your wheel yokes. Or i think you can swap in the 90mm bits into the diff flanges.


      Mk1daily on here told me about the tdi Top end franken motor which would be much easier. You'd need the injection pump, and head from a TDI, as well as the gas pedal stuff but the transmission and block stay in the car.
      Diesel>Sex

    6. 05-26-2012 06:54 PM #6
      IIRC the key and steering column are matched to the ECU, so you need that too.

      CRSMP5 would know for sure...but he got banned for telling someone to stop being a *** and he will not re register under a new name. He is on the GTD forum though.
      I like 1.6l and 1.9l Diesels

    7. Member FalconFixer's Avatar
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      05-27-2012 12:45 PM #7
      ive got a '96 1Z in my caddy. i had the whole car so it wasnt that bad. youll need to aquire tranny mounts for starters, side and rear, or make a set, the other 2 you can snag from your stock motor. i made mine, you can find them for sale at a few places, but they are spendy ($300+). for axles, i used a set out of a 90's cabrio, has the 100mm cups, but still the right length and bolts up to mk1 hubs. i used the wiring from the donor and weeded out the stuff i didnt need (power windows, power locks, etc.) thats the main stuff, once you have that, itll slide right in. you should have an 02J tranny, that makes it easy. get the parts for a 5 speed Eurovan, itll make it a cable tranny instead of a hydraulic unit. the only thing youll have to do is thread the end of the van cable to take the mk1 plastic end. thats all i can think of at the moment, its early! also, check out TDIclub.com, lots of info there about your specific swap, lots of people put them in toyotas and suzukis.

      Last edited by FalconFixer; 05-27-2012 at 03:16 PM.
      Quote Originally Posted by wantacad View Post
      It's always been stated that VW's were "big kid Lego's" You were that one kid that took a exacto knife and super glue to his projects huh?
      ...............__
      .......____l l_\__
      O0o l_@__l_@_l

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      05-27-2012 05:58 PM #8
      Damn I'd love one! That looks good man
      1980 Diesel 4 door Rabbit L - yellow one
      1981 Diesel 4 door Rabbit - tan one
      One or both soon to be among the living...

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      05-27-2012 07:51 PM #9
      Quote Originally Posted by FalconFixer View Post
      ive got a '96 1Z in my caddy.

      That looks great! What did you do for a dash set up?

      -Todd

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      05-28-2012 08:37 AM #10
      Quote Originally Posted by richarddhoward View Post
      I don't know **** about this...other then I'd like to do one myself! Lol I think the first step is...will it fit, and where are you going to put all the BS electronics that come with it?
      Get rid of most of the electronics and run a mechanical setup instead. So much easier.. Any ALH can easily be converted over.

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      05-28-2012 12:09 PM #11
      Quote Originally Posted by MXTHOR3 View Post
      Get rid of most of the electronics and run a mechanical setup instead. So much easier.. Any ALH can easily be converted over.
      The wiring doesn't intimidate me at all. But I've wired quite a few things lol I'm also certified in diesel, so I've done quite a bit. But good to know for anyone that is doing this swap
      1980 Diesel 4 door Rabbit L - yellow one
      1981 Diesel 4 door Rabbit - tan one
      One or both soon to be among the living...

    12. Member FalconFixer's Avatar
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      06-02-2012 11:15 PM #12
      Quote Originally Posted by ToddA1 View Post
      That looks great! What did you do for a dash set up?

      -Todd
      dremel and some custom mounts for the passat cluster, stock mk1 dash.
      Quote Originally Posted by wantacad View Post
      It's always been stated that VW's were "big kid Lego's" You were that one kid that took a exacto knife and super glue to his projects huh?
      ...............__
      .......____l l_\__
      O0o l_@__l_@_l

    13. Member bengone1's Avatar
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      06-02-2012 11:50 PM #13
      Keep the electronics and get an immobilizer delete with a tune. Then use what ever dash and key you want.
      Malone tuning services available- Contact Ben at MaloneTuningVA@gmail.com
      http://malonetuning.com

      MK4, B5, B5.5 remote window control recoding available and VCDS MK5/6. SKC retrieval, Cluster matching, IMMO programming/delete.

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      06-07-2012 12:06 AM #14
      Hey look up lagomorph he's done the swap and there's a couple others. I'm about to have a tdi out of a 99 beetle swapped into my scirocco. I'd do it myself but working out of state 9 months of the year at 72-84 hours of the week won't allow me the time to do it myself....
      Rocco's getting a TDI!!!

    15. Member jpskate8's Avatar
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      08-01-2012 02:21 PM #15
      Hey could you give me a little more info on the mounts yo had to make for your MK! tdi swap?

      Thanks for your time

      Josh

    16. Member candela's Avatar
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      09-02-2012 02:41 AM #16
      nice swap, falcon.... what kind of mileage are you getting out of that thing?

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