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Discussion Starter · #1 · (Edited)
Build thread: TDI Haldex Mk1 caddy

I need a pickup truck that gets good mileage and that can still tow. I currently have a 2003 ALH that I have been using as a truck and I no longer want it full of exhaust parts so I picked up some Caddy's and a 2000 jetta TDI that lost its head due to a bad timing belt job. I have been working on sorting parts for the past 7 months and am finally to a point where I can start fabricating and assembling this truck. I will need some help with the more technical aspects of this build so please chime in if you have done something similar.

Now for the pictures:








ALH block, crank and accessories weighing down my current truck.

MY 02m gear box out of a TT. Now I need the TDI ratios to swap in.

I am currently waiting on some Roston rods. When they arrive I will be taking the bottom end to the machine shop to get the cylinders bored to match the pistons and have them assemble the bottom end. In the mean time I am going to start fabricating the rear subframe for the Haldex to mount to. I want this truck to sit low so it is going to be a challange to do with out chopping away at the bed. Wish me luck.
 

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This is a cool build, the TDI 6-speed ratios you'll need are gonna be available in the european market as they had a 6-speed option on there TDI's believe its was for the later common rail engine but still the same idea. however i dont know what the R&P set up they run. you may want to check out tdi club fourms they will have all the detailed info. i know the one guys name is delvi and he has done a fwd 6-speed swap in his tdi and later swapped his ALH for a BEW (i think thats the common rail engine code). i ll check back your progress, good luck!
 

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Discussion Starter · #5 · (Edited)
Thanks

I am going to need it.

Heres my Manual Haldex controller so I can do away with the wheel position sensors. I tried to get the F-town unit but they would not respond to me. SQS gave me a good deal on this one shipped. Stand up guy if you need haldex stuff.
 

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Discussion Starter · #6 ·
Side tracked

Sorry I got a bit side tracked. I picked up a Corrado that needed some love and so it took my attention for a couple weeks. It should be finished the end of next week and then back to the truck. In the mean time my friends shop got rid of a couple cars so now the rabbit truck can go inside for some fab work.
 

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Discussion Starter · #7 ·
Motor mounts

I am looking for suggestions for my motor mounts. Since I am running the ALH diesel engine I am wondering if there might be a softer poly bushing I could use or if i should just go with a higher durometer rubber mount? I have always used poly on gas cars but am open to hearing the choir.

Anyone have experience with these: http://www.034motorsport.com/chassi...olkswagen-8l-8n-audi-18t-20l-tdi-p-13092.html
 

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Discussion Starter · #8 ·
Oh man

No advice on the motor mounts? Dang. looks like we will just have to make some. i think I will go with 70 durometer poly with some aluminum inserts.

Well I have my christmas present from my wife arriving today so I will post pics soon. :D
 

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Discussion Starter · #10 ·
Christmas came early!

They just got here and look pretty good.

I know I don't need bumpers yet but they were a good deal and I wanted carbon fiber or chrome euro bumpers and these were less then the chrome ones so I snagged them.
 

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I think Nothing Leaves Stock in PA makes motor mounts for this swap. Have you checked out TDIclub at all? A couple people have done compound turbo's on ALH's. Most go with a 17/22 but quite a few have stepped up to the 22/60 turbos. Looks like you're headed in the right direction with Rosten rods and a girdle. What pistons did you go with? Any plans on coating them and/or dropping the compression ratio? Sticking with 1.9L or are you bumping up to 2.0? What are your plans for the head/cam? What's the plan for fuel delivery? Haldex will be sweet!!
Corrado's aren't temporary distractions. ;) They'll literally rob you blind. Ask me how I know. Good luck on the build! My Dad has a caddy and I've thought for a while that it would be cool to make it a TDI.
 

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If I were you, Try the stock motor mounts for now. The stiffer they are in the TDI's the more vibration you get from the motor. The 60 durometer dog bone mount in my car made if feel like it was going to rattle apart. If you can, try to find some 50 durometer mounts. Not horribly stiff, but enough to make a difference.
 

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Discussion Starter · #14 ·
Ha

The engine is almost finished.
I went with a colt stg 2 cam, TT dual springs and ported the exhaust ports and slightly ported the intakes.

I am going to run Kerma's 1856 hybrid turbo until I can get a manifold made and compound turbos.
 

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Discussion Starter · #15 ·
I think Nothing Leaves Stock in PA makes motor mounts for this swap. Have you checked out TDIclub at all? A couple people have done compound turbo's on ALH's. Most go with a 17/22 but quite a few have stepped up to the 22/60 turbos. Looks like you're headed in the right direction with Rosten rods and a girdle. What pistons did you go with? Any plans on coating them and/or dropping the compression ratio? Sticking with 1.9L or are you bumping up to 2.0? What are your plans for the head/cam? What's the plan for fuel delivery? Haldex will be sweet!!
Corrado's aren't temporary distractions. ;) They'll literally rob you blind. Ask me how I know. Good luck on the build! My Dad has a caddy and I've thought for a while that it would be cool to make it a TDI.
From what I have found nobody makes motor mounts for this to work with the MK1. Gotta make mk4 work.

I am using pd 150 pistons. It is bored .5 over to accommodate them.

I understand the cost of owning a corrado. My friend is a corrado but and has about 6 of them laying around.
 

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Could have sworn that NLS had mounts for this swap. :confused: I'm running Kerma's 1856 and have been for almost 5 years. Great power and IMHO an excellent turbo for a daily driver that won't leave a smoke screen every time you decide to go WOT. I bought a stg 3 Colt cam but it won't fit in my head without some clearance work. I need to trade it in for a stg 2.
 
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