MK1 rabbit + ALH > Daily Driven Swap

Hello All
Figured id share...
I swapped an ALH code TDI from a 2004 beetle Into a MK1 Chassis (GTI)
Found the car local
Had the swap from a part out beetle
Had the 02A from a previous project
Figured id get it going and sorted NOW before the snow starts

^^^^^
1.9L ALH in mk1 rabbit

^^ The car I bought (He kept the stupid wheels!!!)

^ The transplant as removed from the beetle (2004)

^^ middle of the wiring process

^^ ALL stock stuff
Super short serp belt
Removes power steering + AC.

The Following is a parts list
ENGINE:
ALH engine management
121 Pin EDC15
^^ Rocket chip imo. egr. isv. delete .. Plus stg2+
DBW pedal welded to fire wall
12V "smart" glow plug relay system (Late)
China intercooler + piping
Dual speed fan setup (NEVER RUNS!!!)
Electric helper fuel pump + Pump~duse fuel cooler
innovate WI-FI hot spot generator and IPone as digital dash............

Mechanical:
CTN > 02A
^^ Has 02J tower + cables w/box + pin ends
Scirocco 16V axles
NLS internal water pump mount kit (Modified for ALH)
Manual Clutch Cable Conversion (Eurovan)
billet 02J FW. vr6 clutch disk + psi. plate (South Bend)
China intercooler + plumbing
02A starter
5Lug swapped for 11.3" front rotors (Redrilled drivers edition VR6!!)
rear disk swap to 10.1" vented
Manual inline proportioning valves

CHASSIS:
Manual steering rack
Stock Rabbit Sway bars F+R
BFI front frame bracket
FK silverline PLUS coil overs
Rebuilt EARLY rabbit Front strut mounts
85% of a poly Kit

Future Plans.....
Block Heater
Coolant heater
"Turbo Timer"
After run coolant pump
Relayed "High beams"



Future Mods....
VNT upgrade
Most likely 17something
NOT looking for crazy > Dont want to do rods

EGR delete pipe at intake manifold
PD intake mani
Turbo inlet piping


Injector upgrade
Bosio's if possible
520's would be killer

Automatic pump + lines

Ill say I have built MANY swap cars
Never a diesel and I dont know why........

This thing is FUN FUN!!!

Nice car, thanks for posting!

Some time when I have more space, I'd love to have something small like that to complement my TDI powered bus.

Love it, I'm Jealous. With that light body you should get some serious MPGs

Awesome swap! Nice choice of parts! I recently heard about a clean mk1 GTI shell nearby that I might have to pick up for when my mk3 Jetta TDI finally rusts through!

igiveup said:

Love it, I'm Jealous. With that light body you should get some serious MPGs

Click to expand...

Thats what I was hoping for
However I cant seam to keep my foot out of it.......


I have a bit of "tuning" to do still....
Was reading on engine temps VS mpgs by swapping thermostats.
I think i may add an inline variable resistor to the coolant temp signal
See if it gets me anywhere...

Nice.. I will be shopping for an ALH. I have the prefect MK1

Nice looking rabbit! I'm doing a similar swap in a MK1. Still compiling parts to work together.

Love the project. The innovate option is one I've long planned for my track car. Keep the pictures coming!

short serpentine belt

Nice work! Cool car! Can you post some of the specifics about the serpentine belt you used to delete the power steering and AC. What length? Also, it appears the serpentine belt you are using is not like the stock ribbed version, but has knobs instead. Are you concerned about that at all?

I'm also not using power steering and AC in my swap (BMW 2002). Our cars are both lightweight, yours will probably be around 2000 lbs and I expect my 02 to be around 2300 lbs. I'd love to hear more about your mileage numbers and performance when you have the tuning more sorted.

couttsdesign said:

Also, it appears the serpentine belt you are using is not like the stock ribbed version, but has knobs instead. Are you concerned about that at all?

Click to expand...

That is a GoodYear Gator back serpentine belt....Nothing wrong with that..

Supposedly Quieter...

Just ordered some new goods......

Cam followers X8 (INA - Oe)
Along with new valve springs + stem seals
Included a cam front seal and tandem pump gasket
Fuel filter + Aftermarket CAT water catch

I found it odd that I could NOT order the valve cover gasket independently
NOT willing to buy a complete valve cover unless it leaks


I have also been shopping for "Heaters"
I want an OIL heating system
NOT the huge box for the inline coolant type.
I cant seam to find much that is ALH specific
(Time to start looking at tractor parts!!!)

Im about to try the old trick of swapping valve springs WITHOUT removing the cylinder head...
Adding compressed air into the cylinder holding valve shut...
This is done via the glow-plug hole...

At the same time Im planning the tbelt/wpump job
Also new followers, gaskets, seals and such.

Using my innovate WIFI generator
I was monitoring boost levels on the highway
I noticed a 20-25mph head wind requires about 1.5-2psi of additional boost to maintain my normal cruze speed of 68...

300 miles of driving her this weekend
3 People + gear in the car

Avg 58 mpgs at 72 on highway on low-pro" 15's
Avg 37 in the hills >> Thrashing on it while consistently pulling away from a modified 225TT...

Makes the work worth the effort!!!!

That's good to hear! I wondered how mine might do with lo-pro 15's. Alllriight! Gets me more motivated.

sccaddy said:

I wondered how mine might do with lo-pro 15's. Alllriight!.

Click to expand...

Its ALL about the gearing
My CTN 02A trans has been modified
3.16R&P > .681 5th....

Well
I figured I owed the site/thread an update.
(Even tho I feel as Im talking to my self in here.......)

I broke it.....
Was pushing 27-ish psi with manual controller..
Had a bit more 5th gear fun then normal
Post highway pull I had what sounded like a "BELL" inside
Seeing as I did just replace the lifters
I was thinking I may have collapsed one...
Replaced them a SECOND time and "bell" noise was same/same....

Digging in further I split the OG head gasket
Removed the complete valve train
Found #1 exhaust valve LOOSE inside the guide........


I have since rebuilt the cylinder head
X8 new guides
X8 new valves
X8 new stem seals
X16 new valve springs (Dual HD kit from TT)
X8Seats&retainers
Cam from FEBI for now... (I want a colt)
Gaskets/seals and such
ARP studs + and a 2 hole gasket

Once I get it bolted up and running again
Ill be back with some updates....

Sounds good. I like your project. I think some day I'd like to have a TDI-rabbit as a small car for days I don't need to be driving around the (larger) TDI powered bus

What size tires you running? I have an MK1 I'm TDI'in

v8 coupe said:

What size tires you running? I have an MK1 I'm TDI'in

Click to expand...

Had 195-50-15 on X8" wide wheels
Under driven condition

currently have it on some HUGE snows
195-75-15 they rub fender
Its also on topped out FK coils and a 2""lift kit"