Ok...first things first...lets keep the "models" straight...
The mk1 convertible through late 92-early 93 (yes, they do exist...) right before the switch over the the "MK3" floor pan for the car is properly referred to as the "Cabriolet"
The MK3 (93-99?) and MKIV looking versions are referred to as the "Cabrio".
Sorry, its an MK1 thing.
Second. Please don't let motor mounts or anything like that scare you off. There are "good" things too and the mounts are a very little part of the battle.
For instance...on my Mk1 mTDI swap, this is what my passenger side motor mount ended up looking like...SIMPLE...made from the much heavy duty (especially than the stock MK1 gasser motor mount) integral Mk1 diesel motor mount/injection pump mount. Cut to the profile of the block, some grinding and presto. This will work on the 1z/AHU setups with a little work and a bit of cutting the the timing belt backing plate ... Easy.
If you aren't going to use a 1z/AHU motor...there is another p side mount variation out there as well that utilizes the available bolt holes on the p side of the block (2 that are in the same location as the rabbit mount originally) and wraps around the back of the block to utilize a couple other available mounting holes back there to fully secure the ALH engine for a Mk1 style p side motor mount.
These are popular with the 1.8T mk1 swaps as well. MrDave did one for his TDI mk1 caddy conversion...the thread probably can be found here somewhere and def. over on the VW Vortex.
As for the other mounts... the Mk1 front mount can be made to work easily with either the use of a 020 tranny (like what is already in your mk1...a linkage operated/cable clutch tranny) or the 02a/j TDI trannies (found in MKIII TDI cars and MKIV's). However, if you do it right, you'll use the actual TDI tranny (02a/j) and need to buy (WRDUSA has them) or have someone make you, or fab yourself a set of tranny mounts for the d side and lower rear tranny mount. Stock Mk1 mounts will not work for this.
Here is a pic of the WRD mounts and a link...
http://wrdusa.com/Merchant2/merchant.mvc?Screen=PROD&Store_Code=WRD&Product_Code=010A180
Other option as some have done...weld in the MKII/III style mounts into the Mk1 ...thats a whole new thread.
For dealing with the 02a's cable acutation for shifting and the clutch operation...
The cable box assembly can be pretty easily installed in the mk1 with some removal of the original shifting linkage setup, etc. and some customization. It shouldn't be too bad. I'm doing this myself this winter.
The clutch...you can either reinforce the firewall, install the complete TDI mk3/b4 pedal assembly (or MKIV) and run a wet clutch (hydraulic)...or you can avoid having to swap out pedal assembly for the most part and go with the european style cable acutated clutch assembly...
More on that...but I'm getting tired.
If you go eTDI...either way with either pedal assembly...as already mentioned...you'll have the eTDI "go pedal" to worry about...but its been done. If you go mTDI, or mechanical...and run the cable acutated clutch...then you don't even have to swap out the pedal assemblies at all...the stock rabbit one can be used!
I've even heard...seen, maybe it was on here. Supposedly someone in german or across the pond is now selling a CONVERSION KIT for the 02a/j style trannies that allows the transmission to be controlled via the old style linkages instead of the cable box.
I'll personally be going with the cable box though...haven't seen this for myself yet (this 02a/j linkage conversion kit)
Lets see...what else.
Late cabriolets (late 88-early93 before transition) SHOULD run Digifant 8v gasser motors. The Digifant systems ran CE2 wiring which should make the installation of the TDI electronics and harness (if thats the route you go) alot easier. CE2 is so nice to work with IMHO.
Exhaust/dp...
Well...that depends as well. If you go with the stock TDI configurations for the turbos (either the early 1z/AHU setup with the GT15 series turbo or the ALH with its VNT15) you'll have to come up with a custom dp setup to connect to your current exhaust system. If your not already running an aftermarket exhaust of 2.5" or so...I'd recommend doing an entire exhaust to get the most out of the TDI once installed.
If you opt for mechanical versions (mTDI) or a eTDI setup for a wastegated turbo...then you can simplfy the exhaust/dp slightly by using the exhaust manifold and a wastegated turbo from an IDI 1.6 TD (either a t3 garrett or a KKK K24 ....both are .42 A/R cold .36 hot) and go that route...easily capable of 18-20psi or so with very little lag. There are other "custom" options out there as well. The older TD configuration of the turbo brings the turbo up "higher" on the motor, and if you want to use the stock cast turbo outlet dp from the TD application, and already have an "aftermarket" exhaust still utilizing the toilet bowl style manifold connection...you can get away with replacing quite a bit less.
Of course...there is ALOT more to consider than this... but creating an Mk1 Cabriolet TDI would be unique...and fun to drive I imagine than the heavier Mk3 (and personally...less desirable aesthetically) based cabrio.
With any swap...it takes time, planning and weighing several options. Like I said...alot more to consider, but the road to doing this isn't "dark" nor super challenging...
Anyways...good luck!
If your interested in the mTDI setup or reading more about the swap into an MK1 (using the 1z/AHU motor...) here is my thread...
http://forums.tdiclub.com/showthread.php?t=129127
ALH...def. have to check out MrDave's swap into his caddy...and that was eTDI ...over on
www.vwvortex.com
Here is a connection to the "mount" portion of MrDave's thread...it also contains links to the rest of his swap and contains alot of great information!
http://forums.vwvortex.com/zerothread?id=789621
Good places to start and gather info...among a host of others out there now!
Joe
