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TDI Conversions Discussions on converting non TDIs into TDIS. More general items can be answered better in other sections. This is ideal for issues that don't have an overlap and are very special to swaping engines.

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Old May 10th, 2010, 18:06   #1
vw_nut
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Default My 1Z TDI Rabbit Truck Conversion

I thought i would start my build thread for my TDI Mk-1 Pickup..I got a complete 97 passat donor car.I am gonna do the full swap, I want the cluster so i am putting in the corrado dash and i also put the corrado steering column in also., I am currently working on the engine bay with some sheet metal work, i put the heater box from the passat in to free up my rain tray to put my resivor tank for the air to water intercooler i am putting in,getting the heater box to work was a challenge but it fits also i put the cabriolet core support in for the round headlight conversion, here is a few pics of the engine bay , more will follow as i get the engine bay ready to prime and paint










Last edited by vw_nut; November 2nd, 2011 at 20:17.
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Old May 15th, 2010, 18:01   #2
vw_nut
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Default welding all done

Well last night we finished the welding on the bay, today i worked on grinding on the welds cleaning things up, i test fitted the heater box after the welding and it fits nicely, i worked on cleaning the engine up today and i need to take the transmission off and paint it so thats next, i plan on having the engine bay primed and painted this next week, i have a little more gringing to do and i won't know till i get the engine in to see if my cuttaway for the compressor but it should be fine


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Old May 22nd, 2010, 18:41   #3
vw_nut
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Default Bay got Primed

Its been going slow, i know, but work has me just slammed lately but i got the bay primmed today


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Old June 1st, 2010, 18:41   #4
vw_nut
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Default Bay Painted

Well finially i got a day where we could get the Bay painted....I painted it a gray hammertone... Im now ready to put it all back together...ill have to put the engine in and intercooler piping in before i finish doing the wiring so i know just where its all gonna fit im trying to streamline it but its gonna be busy in there

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Old June 2nd, 2010, 21:31   #5
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Looks good. Should be a fun project. Are you keeping the engine mostly stock? Would probably be plenty for the Rabbit Truck.
Jon
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Old June 3rd, 2010, 12:28   #6
G60ING
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Nice swap.
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Old June 3rd, 2010, 14:52   #7
vw_nut
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Thanks Frank and Jon I will hopefully get the new tierods on and put the rack in and drop the motor in.....I plan on Leaving it stock till I get it on the road but it wont stay stock for long
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Old June 3rd, 2010, 15:38   #8
G60ING
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How are you installing the motor? Without the a/c compressor and then install it after its in?

I like how the crossmember looks with the a/c clearancing.
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Old June 3rd, 2010, 16:19   #9
vw_nut
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I will install it after the motor is in so I wont mess the paint up and if i remember right i have to to get it in and the long bolts are a pain getting back in

Last edited by vw_nut; June 3rd, 2010 at 18:45.
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Old June 6th, 2010, 03:22   #10
vw_nut
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Today i worked on the steering rack, got the new bushings in the a-arms, put the brake booster on, i got the timing belt on, intake cleaned and put back on, the motor is ready to go in, i will have to drill a hole in the frame for the bolt for the air conditioner compressor, i will do that when the motor is in, work is busy so in these times i have to take it when it comes, i hope to have it in tomorrow night
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Old June 6th, 2010, 05:29   #11
therabbittree
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Nice!.. kep up the pictures.. I will be doing my '84 jetta coupe same swap .. I to want to add a/c to a non ac car ..i will be watching yours closely.
thanks
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Old June 7th, 2010, 18:02   #12
vw_nut
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Well today i put the motor in, started working on the intercooler piping, i have to get some reducers for connecting the intercooler to the piping, i think its gonna fit well, the A/C Compressor fits well as you can see in the pics, have to trim up the heat shield on the firewall but it will work nice, I have a few holes to drill for the headlight wiring and the P.S resivor, gonna look online for some A/C fittings, anyone have a clue as to where i can find them?


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Old June 19th, 2010, 20:12   #13
vw_nut
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Well today i got the PS Resivour and line put in today and connected, i got all the front end parts , the new wheel bearings pressed in, new ball joints, a-arms, tie-rods and got them in, the intercooler radiator and A/C condensor put in, i had to angle the A/C condensor a little and i decided to put the intercooler radiator in front of the A/C condensor it puts a little angle on the radiator but it looks like it will all work fine

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Old June 19th, 2010, 20:28   #14
rackaracka
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Looking great!
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Old June 21st, 2010, 15:05   #15
xseadogx
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Default Awesome work

Really, Nice work, I have wanted to do the TDI swap to a rabbit truck for some time now. It is actually why I joined this forum. Keep up the great work and info Thanks
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