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Discussion Starter · #1 ·
I have just picked up a 1998 AHU complete donor, and my plans are to swap the engine and trans in to my 1981 Jetta. I understand that the newer motor will accept all the same motor mounts from the 1.6D, but the trans mount may need to be fabbed up, which isn't a big deal really. Also I understand the new motor is a drive by wire and a cable shifted transmission.. I have the entire car, so I will have practically any part necessary from the mk3 side of things.

A thought was brought to my mind.. converting the car to CE2, or using the entire harness from the 98 and put it in the 81.. both of these were brought to the front of my brain, but i know nothing of either, care to explain it to me?

I will have (hopefully if I can get it going) another car to drive while this one takes the garage spot for a while.. so I will have to rip the interior apart to make the shifter happen as I have to cut out the old one.. and this one will need to be fit in there somehow (anyone got a link as to how they have seen the cable shift adapted to an mk1?).

Also on the pedal cluster, how does this work out? (anyone cross over any good threads on this part either?) I am still on the learning curve of a lot of this stuff as to how to get the engine operating properly in the mk1. The car is in my possession so I will begin to tinker around on it and figure out the TDI diesel side of things. I mean I am not a complete invalid I have researched a bit on how the TDI's function so I am good on that part.

Also this engine has an A/c compressor and my car once had A/c.. could this be made to work out or what? I mean I guess there really is no reason why it couldn't work right? A couple fittings should hook things up nicely eh? Could I actually use the lines from the AHU engine? and run them in to the condenser in the car?

The turbo spools up niiicely its starting its spool at like 1400 and is screaming by 23-2500, I'm very excited!

I would appreciate every piece of information you have to provide! I have been doing lots of reading, but the same info twice is never a bad thing.. just makes understanding it easier Eh? :D

Thanks so much guys, wish me luck on this project!!
 

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Sounds like a cool project.
I hope you document it here even though I think this forum is the last place to ask for most of this info. :thumbup::thumbup:
 

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Around here, people make the engine an M-TDI. They lose all the electronics, and just mount an mechanical pump. Of an old volkswagen LT, i believe.
 

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Discussion Starter · #4 ·
A1 thanks man! just what I was looking for perfect. I was unaware that it was a combination of those swaps (1.8T, ABA, VR) that makes it easy to find some build threads as they are frequent swaps, and pick out all the information I need! Thank-you very much! I may very well just do a good compilation of all the info I find and make up an AHU->Mk1 thread. Yes the mk3 TDI (only came in 96 Passats and 97-98 Jetta's for mk3) were drive by wire, and ECU controlled. Which is actually a very good for the pump timing as it adjusts itself to a wide variety of timing numbers to have the best fueling and injection timing all the time. I was totally thinking of your piggy backing idea A1 but I don't think it will work quite the same way, as I think I may also need the mk3 cluster :eek: Which is awesome because it has a tach! SCORE lol I will read through a couple really in depth swap threads and combine all the information I need, thanks a bunch. Also the condenser is all that is left of my current A/C it has had the compressor taken away some time ago. The old systems are upgradable to the new stuff no? this should be totally doable really, if you could just get the fittings right to hook the new compressor up to the old condenser no? Why are you against A/C? lol I think it would be a crazy luxury on a car with crank windows and manual locks ;) :D

Mr. Shanahan, it appears a good place to ask for the info as it seems to be just a bunch of Gasser stuff all in one. I asked here mainly for the volume of people that pass through the MK1 forum, easy to get someone who knows TDI stuff as well who is just passing through eh? It worked to pull A1 in with his infinite knowledge on swaps and other assorted tomfoolery :p

Ronnie, Yeah I have read a bit on the M-TDI side of stuff, and I don't think it is a route I wish to go just yet. Maybe in the future I'd like to experiment with it. For now however a straight TDI swap seems easiest/cheapest for me, present time.

Few more questions regarding what I should keep off the donor, as the shell has to be gone A.S.A.P!


I will need;


  • Engine and Trans
  • All Engine Wiring (should I just keep the entire car wiring harness for the hell of it???)
  • Fuse-box
  • Cluster
  • Engine Harness
  • ECU
  • Axles (I think I will need inner flanges to adapt to my axles?? if I am not mistaken??)
  • Shifter cables as well as the shifter box


Anyone see anything crucial I might be missing?
 

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depends on how much of the donor car comforts you would like to keep..

i would prolly swap everything.. simplify the wiring, swap all that.. i would swap the shift box to keep it hydraulic and mount the master cylinder somewheres..

vr did the hydro master swap cuz he put the vr in .. check his thread for an idea/example of what you could do..
 

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i build an 1.9 afn tdi in a mk1 golf last year. And i fitted an corrado gearbox to it, with cables.
Took all the hydraulic stuff from the clutch-system off, and replaced the cilynder on the transmission with an mechanical part of an vw transporter ( t3). This way you can use the old clutch cable.
 

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09 CC 3.6 4mo, 98 DE Leftover car, 90 Corrado, 78 Triumph Spitfire
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MK1 TDI Projects

I have swaped a 96 Passat TDI into a 81 rabbit truck but I did not use the o2A trans but the original o2o five speed and flywheel. The 81 AC brackets, alternator and motor mounts all bolt on with minor triming to the inner timing cover shield and modification to the engine cover support bracket. The Passat's throttle potentiometer was installed by modifing its plate to fit the A1 pedal cluster. I combined the Passat's schematic to the 81 truck's schematic. Not to many of the wires are needed to get it running properly, but this is not currently using the Passat's instrument cluster.

I have another 96 Passat TDI setup I am planning to install in my 82 Rabbit truck and plan to use the 96 accessories and o2A trans so I would also like to know the best way to install the hydrolic cylinder and cable shifter as well as the transaxle mount.
 

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I have another 96 Passat TDI setup I am planning to install in my 82 Rabbit truck and plan to use the 96 accessories and o2A trans so I would also like to know the best way to install the hydrolic cylinder and cable shifter as well as the transaxle mount.
Build or buy mounts, modify your pedal/ bracket or buy the eurospeed one.
 

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eurospeed's 02a hydro clutch sucks.

Buy a welder, learn to fab your own shiz.

Some people like the clutch 02a but I HATED it. I used a eurovan and honda cable and never got it to feel good. I have a hydro clutch with an 02j and it feels great.

Your a/c might be an issue if the compressor hits the crossmember like an ABA. I know I had to do some extensive work to keep the a/c in my 1.8t rabbit but damns it's nice to have 263whp and a/c.

Diesel swap is cake especically if the car is already a diesel. DO NOT swap the entire harness just for the engine on a diesel. If all the car stuff works(lights, wipers, cluster, etc) then just splice in the engine.

I've never done a 1.9 swap but I've done a lot of other swaps and like someone mentioned already...a 1.9 is will be like mixing some other swaps so generally searching will help.

HTH,

Jason
 

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A zero-rewire* solution is to find an AAZ fuel pump and get it converted to M-TDI. There are at least two companies that will handle the conversion if you send them a core. Then it is a matter of attaching a gear and getting a belt to it. M-TDI is not likely to be as efficient as the drive by wire setup. But overall, I think the installation would be easier if the car is already diesel.

*almost zero: fan switch, glow plugs, and whatever instrumentation you want need to be sorted.
 

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thought about doing this swap myself over the winter into my cabby, but my OG motor gave out before then so i just said to hell with it ill toss in a 20vt

since you are in ontario, you may want to talk to cliff at ESS, he is just finishing up my 1.8t swap into my mk1...

yes the O2A needs a modified mount, i know where you can get one.

i didn't think ahu tdis were drive by wire but thats just me, i can take some pictures but like i said before talk to cliff at ESS because he changed my car to drive by cable as opposed to drive by wire.
:thumbup:
 

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Discussion Starter · #18 ·
Hey guys thanks for all the replies,

I know the engine can be modified to drive by cable by fitting a mechanical TDI pump to it, but i dont think its something I want to do.. as it will be just as much work as fitting the drive by wire pedal I'm sure. LOL

I have decided to keep the car for the time being, and do some off the road work on my 81 before I take this engine :D
 

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Discussion Starter · #19 ·
ok so i have a few more questions on just how deep i should go with this swap!!

A friend of mine who is pretty fluent on MK3's said that if I don't keep the antitheft part of the harness the ECU will go in to a sort of lock-down mode when the system is not disarmed when the doors are unlocked.. SO! i was thinking..

If I'm gonna do this.. I think I should really do this :beer: ;)

Maybe I should swap the FULL CE2 harness.. Right down to the cluster & power locks.. Ehh ehh?? Maybe I should even keep the dash.. for further possibilities??? That would be pretty cool to do as well down the line...

I mean it would essentially make the electrical part of the swap a ton easier.. more work, but easier work really I think. Label every thing and then run it through the 81, then meter out what does what.. one at a time eh? The only one I seeing giving trouble is the cabin fan motor and the brake lights .. How will the mk1 pedal cluster and brake switch trigger the mk3 wiring? What would be involved at swapping the whole pedal cluster over??

glx2.8 I will be pm'ng you following this post :D on that tranny mount. Also I don't think there is anyway to go about modifying the TDI drive by wire to cable other than making it an M-TDI.

The axle ends will come off the mk3 axles and go on the mk1 axles in the car correct? to get that all in order as well.. just trying to cover my bases before i get to deep on this.

thanks people! :D
 

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ok so i have a few more questions on just how deep i should go with this swap!!

A friend of mine who is pretty fluent on MK3's said that if I don't keep the antitheft part of the harness the ECU will go in to a sort of lock-down mode when the system is not disarmed when the doors are unlocked.. SO! i was thinking..

If I'm gonna do this.. I think I should really do this :beer: ;)

Maybe I should swap the FULL CE2 harness.. Right down to the cluster & power locks.. Ehh ehh?? Maybe I should even keep the dash.. for further possibilities??? That would be pretty cool to do as well down the line...

I mean it would essentially make the electrical part of the swap a ton easier.. more work, but easier work really I think. Label every thing and then run it through the 81, then meter out what does what.. one at a time eh? The only one I seeing giving trouble is the cabin fan motor and the brake lights .. How will the mk1 pedal cluster and brake switch trigger the mk3 wiring? What would be involved at swapping the whole pedal cluster over??

glx2.8 I will be pm'ng you following this post :D on that tranny mount. Also I don't think there is anyway to go about modifying the TDI drive by wire to cable other than making it an M-TDI.

The axle ends will come off the mk3 axles and go on the mk1 axles in the car correct? to get that all in order as well.. just trying to cover my bases before i get to deep on this.

thanks people! :D
looks like this project will be way over your head, good luck anyway.
 
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