MK1 Jetta Coupe ALH TDI Syncro Swap

I'm pretty bad at build threads and keeping updates but since I've already completed most of this and have been driving the car this summer I think I can handle posting my project.
I've owned the MK1 for the last 7 years and has gone from a 1.6td to a stock ALH TDI and now to a ALH TDI with a GT2256v and Syncro AWD.
This is one of the earliest pics I have of it, was pretty rough when I got it


After fixing pretty much everything to do with the body and driving it as a 1.6TD I felt the car needed a bit more go so I started collecting TDI parts.

At first I was going to swap in all MK4 wiring and computer but after looking up other build threads and performance upgrades for the AHU TDI I figured out I could simply swap connectors on the AHU harness and get a chip to run the VNT turbo. Malone made the tune I used which was basically to run a stock AHU with a VNT turbo but without a maf or egr. It still amazes me how similar AHU and ALH are.

I drove it with a 1.9AAZ Transmission for a summer, I really should have had a better clutch but ended up swapping in a MK3 TDI Trans that winter.
Last year I had a lot of issues, mainly 2 failed turbo's and one run away engine that put a rod through the block. It was my fault to trust turbo's that I didn't know the history on but it's in the past now.





I did end up putting in another engine and drove it for the rest of the year but I still felt the car needed more go, but whats the point of more go if you'll just spin?
Comparison of the VNT15 to the GT2256, I used a cast VW turbo manifold from a 1.6td and a friend fabbed up and adapter to match the up the turbo to the manifold but I cant find a picture of it.

To fit in the Syncro drivetrain I welded in a B3 Passat tunnel, raised up the steering rack 2 inches, shortened the middle section of the Passat driveshaft and shortened the passenger side axel shaft. I also had to make my own mounts for the rear passat beam, not exactly a direct swap.

As for the engine I ended up building another as I dropped a valve. It's a stock ALH bottom end with head studs, 11mm pump, .216 nozzles, no EGR or MAF, ALH N75, custom intake,FMIC, VR/G60 clutch/flywheel, Stock G60 Syncro trans and a GT2256v turbo running 30lbs. The car works great and I haven't had any issues except for destroying a rear diff and my clutch slips sometimes under boost.





And this is how it currently sits, It's really fun to drive and I love the fact I can just jump in it and go for a drive without an issue




Now I'm likely forgetting something but if you have any questions please just ask.

Nice work

AWD. Every potent TDI powered swap needs it. If it's anything but dry warm weather my mk2 just sits and spins...

So much want!

Thanks guys, it's really been all about making something different and I love diesels. There is just something about a diesel that can surprise most gassers. Here's a couple links to some not so great videos of it.

Video of it driving

http://m.youtube.com/watch?v=gfEY_5wzKR0

Short in car clip

http://m.youtube.com/watch?v=rRQD3VTViwY

And of the boost gauge, my gauage only goes to 25 but I run 30 so it blows past the 25 mark. It makes me laugh.

http://m.youtube.com/watch?v=IJGQggfpI3M

Oh man. Got excited when I saw your location being Canada and no front plate... Then saw the NS plate Awesome project!

Battery in the trunk ?
Iam ruuning a 1/0 cable to a bmw remote jumper term, using the battery mount area for a ram-air airbox filter location and the a small box for the phillips hid's componets
Mine is still in paint , complete paint, no doors or engine ( mk1 coupe )
Why no breather catch can on valve cover..
GB

Yeah I have the battery moved to the trunk, my intercooler piping kinda took up the space. As for the lack of catch can, it wasn't something I thought about

Where's your intake filter ?

Iam going to run a soft flex duct to my Ram-Air airfilter airbox
I mfg these :http://www.csobeech.com/GeeBee-HeatDuct.html
flexiable and smooth bore
Using a gb1756vk with a darkside tubular top mount exhaust manifold
TT Tuning is making the 2.5 downpipe

GB

GEE-BEE said:

Using a gb1756vk with a darkside tubular top mount exhaust manifold

Click to expand...

Pics?

I dont have an intake on it, i just run a screen on the turbo. It's not ideal but I dont daily the car and since the sunroof hates rain i dont drive it when it rains either. It will take some magic to get a nice intake mounted up since there is so much stuff in a little engine bay.

Had a little fun with the mk1 the other day before putting it away in my friends garage for the cold season

http://m.youtube.com/watch?v=wiek3wXjat0if

That is awesome!