ALH rabbit truck swap

oldpoopie · Jul 24, 2014

A buddy is hooking me up with a pretty nice rabbit truck.

Its already has been modified to run an O2J trans and clutch setup. All i had to get was a pass side motor mount.

The engine is at the machine shop now, it will be an alh, 11mm pump, R520 or pp764 (not sure yet) 17/22 turbo.
02j mk4 trans with taller 5th gear and peloquin diff.

Im planning on running the mk4 cluster, so i spent the past 3 evenings ripping apart the interior mk4 dash harness. This is whats left before final cleanup.

Also picked up this sprinter intercooler for it. (guess what, it wont fit! Went with an Air-Water setup instead)

papasmurf · Jul 25, 2014

Awesome. I can't wait to see this truck transform

burpod · Jul 25, 2014

nice

mk1 1.9 tdi is the best

GTiTDi · Jul 27, 2014

liking the looks of the sprinter intercooler!

sccaddy · Jul 29, 2014

What 5th gear are you going with on the O2J? Just refresh motor? or you going to bore it out bigger for oversize pistons? Nice intercooler. I also have a caddy in that same color.

[/URL][/IMG]

runonbeer · Jul 29, 2014

Sub'd. I used to have a yellow caddy beater 1.5. Shouldn't have sold it (glad I did).

oldpoopie · Jul 29, 2014

Nice looking truck!

The 02j came from my golf. Its got a peloquin and a .658 5th already installed.
Block is being bored out for oversize ASV pistons and rosten rods. Head is ported with a stage 2 colt cam. r520 injectors, 11mm pump.

Turbo will either be gtb2260vk or 17/22 not sure yet.

tothemax · Jul 29, 2014

That will be a FAAAAAAAAAAST caddy.. .cant wait to see it J...

oldpoopie · Jul 29, 2014

tothemax said:
That will be a FAAAAAAAAAAST caddy.. .cant wait to see it J...

Yep! Im leaning towards a 17/22 right now, for ease of tuning and city driving responsiveness.

burpod · Jul 30, 2014

when i do my scirocco i'm going to do a 2056vl i think. 17/22 is fun and very responsive, but i certainly wouldn't mind a little more. responsiveness shouldn't be an issue either way i think, given the weight.

EvilLawnGnome · Aug 2, 2014

What are you doing about the engine mounts and pedal cluster?

oldpoopie · Aug 2, 2014

Pedal cluster wil be from a cabriolet so i can run cruise. The truck has already been converted to run an O2J, so trans mount is replaced, already has rod shift kit for O2J and mechanical clutch cable kit.
http://www.clausvonessen.de/pi69/pi38/pd1332.html
http://www.clausvonessen.de/pi69/pi38/pd1698.html
http://www.clausvonessen.de/pi69/pi38/pd1780.html
http://www.ebay.co.uk/itm/MK1-Golf-...arts_Vehicles_CarParts_SM&hash=item1c410f1da2
Or
http://nothingleavesstock.com/online-store/#!/~/product/category=2903030&id=13912984

And for the belt side mount
http://nothingleavesstock.com/online-store/#!/~/product/category=2903030&id=13912974

sccaddy · Aug 2, 2014

What intake are you planning on using? Are you keeping the power steering and A/C?

whitedog · Aug 2, 2014

Interesting. Today Cousin Louise told me a friend of hers is looking to do this. Would an AHU be any easier?

whitedog · Aug 2, 2014

Belt side mount:

(not ALH unless you change the timing belt idler design. it WILL bolt up to the block and be in the correct possition, the idler is just in the way)

burpod · Aug 2, 2014

have you checked out epytec ?

i have a set of NLS mounts in my rabbit. but they are way overpriced for what they are....

in my rabbit, i just rigged up a ~1980 honda civic clutch cable and the 02b ? eurovan lever i bought a while back from 1stvw. works great. just had to make a little bracket with my drill and grinder

oldpoopie · Aug 2, 2014

Yes, AHU is easier to bolt in, but i already have an ALH.

As for the belt side mount, the lower idler roller will be eliminated, and a larger non-automatic tensioner will be used.

Intake will likely be a PD130 gearbox-side inlet manifold sourced from RyanP at darkside.

The truck is non-power steering, non-AC so those will be deleted.

Best example of what I'm trying to do is MrDave's build.
http://forums.vwvortex.com/showthread.php?778864-The-Rabbit-TDI-Project-Part-1-Introduction

oldpoopie · Aug 2, 2014

@burpod,

The truck is coming to me already converted to run the O2J, so shift linkage, cables, and motor mounts come with also, so I didn't have to go hunting for any of it.

thanks for the link though! Cool stuff there!

Im also putting in the gokraut front crossmember reinforcement bar.

burpod · Aug 3, 2014

thats a nice bar, i got one a little while back while they were on sale, as well as the X subframe bar - highly recommend that piece to really tighten things up

oldpoopie · Aug 3, 2014

Yes, I plan on getting the x bar but want to get it running first

vw_nut · Aug 4, 2014

Not having A/C makes it much easier and a lot more room for the intercooler, no need for air in your neck oof the woods here in TN it's a must for me, I'm in the process of fixing a few things while my motor is out

oldpoopie · Aug 6, 2014

Managed to score a cabriolet pedal cluster today so i can run cruise control.

Have to go back and grab the stalk parts.

Also picked up the block from being bored and the head from being freshened up.

Ill assemble the motor and measure for protrusion, then dissasemble and have it decked.

vw_nut · Aug 6, 2014

Are you gonna run cable or hydraulic clutch, mk4 hyd clutch is really nice and very easy to do

burpod · Aug 6, 2014

fwiw, it's really easy to make your own mounting bracket/holes for those switches on the stock mk1 pedal cluster. that's why i did, everything works perfect and was easy to do with simple hand tools

oldpoopie · Aug 6, 2014

Cable clutch. The truck is coming to me that way already.

vw_nut · Aug 6, 2014

Well I have arthritis in my knee and its soo nice to have the hydraulic clutch effortless to use

oldpoopie · Aug 6, 2014

Maybe someday.

turbodan62 · Aug 19, 2014

i called NLS and they did not know which manual belt tensioner to use .... i think it would be a 16 valve because the belt is wider .. did you ever order and get the right one ?? Thanks Tdan

oldpoopie · Aug 19, 2014

Not yet. Ill have to hunt a bit and find he info again.

oldpoopie · Aug 19, 2014

Ok I'm fairly sure it is the 16v tensioner part # 051109243. Im ordering one to see.

ALH rabbit truck swap

Vendor

Veteran Member

teh stallionz!!1

TDIClub Enthusiast, Macht Schnell! Vendor , w/Busi

Veteran Member

Maintenance EnthusiastVendor

Vendor

Top Post Dawg

Vendor

teh stallionz!!1

Active member

Vendor

Veteran Member

Veteran Member

Veteran Member

teh stallionz!!1

Vendor

Vendor

teh stallionz!!1

Vendor

Veteran Member

Vendor

Veteran Member

teh stallionz!!1

Vendor

Veteran Member

Vendor

Veteran Member

Vendor

Vendor