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My 1Z TDI Rabbit Truck Conversion

vw_nut

Veteran Member
Joined
Jun 22, 2005
Location
Beechgrove, TN, 37018
TDI
, 1981 VW pickup TDI Conversion, , 2000 Golf TDI,1985 Cabriolet 16V,2006 jetta
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









 
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vw_nut

Veteran Member
Joined
Jun 22, 2005
Location
Beechgrove, TN, 37018
TDI
, 1981 VW pickup TDI Conversion, , 2000 Golf TDI,1985 Cabriolet 16V,2006 jetta
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


 

vw_nut

Veteran Member
Joined
Jun 22, 2005
Location
Beechgrove, TN, 37018
TDI
, 1981 VW pickup TDI Conversion, , 2000 Golf TDI,1985 Cabriolet 16V,2006 jetta
Bay got Primed

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


 

vw_nut

Veteran Member
Joined
Jun 22, 2005
Location
Beechgrove, TN, 37018
TDI
, 1981 VW pickup TDI Conversion, , 2000 Golf TDI,1985 Cabriolet 16V,2006 jetta
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

 

jjordan11

Veteran Member
Joined
Jan 5, 2008
Location
Lehi, UT
TDI
1988 Audi 80 quattro PD130, 1982 Westfalia TDI
Looks good. Should be a fun project. Are you keeping the engine mostly stock? Would probably be plenty for the Rabbit Truck.
Jon
 

G60ING

Top Post Dawg
Joined
Aug 5, 2001
Location
Alexandria, VA
TDI
No TDIs Currently, I have an R36 Corrado. I've had an ALH Corrado swap, AHU Corrado swap and 2003 TDI Jetta
Nice swap.
 

vw_nut

Veteran Member
Joined
Jun 22, 2005
Location
Beechgrove, TN, 37018
TDI
, 1981 VW pickup TDI Conversion, , 2000 Golf TDI,1985 Cabriolet 16V,2006 jetta
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
 

G60ING

Top Post Dawg
Joined
Aug 5, 2001
Location
Alexandria, VA
TDI
No TDIs Currently, I have an R36 Corrado. I've had an ALH Corrado swap, AHU Corrado swap and 2003 TDI Jetta
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.
 

vw_nut

Veteran Member
Joined
Jun 22, 2005
Location
Beechgrove, TN, 37018
TDI
, 1981 VW pickup TDI Conversion, , 2000 Golf TDI,1985 Cabriolet 16V,2006 jetta
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
 
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vw_nut

Veteran Member
Joined
Jun 22, 2005
Location
Beechgrove, TN, 37018
TDI
, 1981 VW pickup TDI Conversion, , 2000 Golf TDI,1985 Cabriolet 16V,2006 jetta
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
 

therabbittree

Veteran Member
Joined
Feb 20, 1999
Location
Red Hook, NY USA
TDI
B4 passat, 2000 Golf, 2003 Allroad tdi
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
Deo
 

vw_nut

Veteran Member
Joined
Jun 22, 2005
Location
Beechgrove, TN, 37018
TDI
, 1981 VW pickup TDI Conversion, , 2000 Golf TDI,1985 Cabriolet 16V,2006 jetta
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?


 

vw_nut

Veteran Member
Joined
Jun 22, 2005
Location
Beechgrove, TN, 37018
TDI
, 1981 VW pickup TDI Conversion, , 2000 Golf TDI,1985 Cabriolet 16V,2006 jetta
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

 

xseadogx

New member
Joined
Apr 2, 2010
Location
PHX AZ
TDI
not yet
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
 

dieselherb1

Veteran Member
Joined
Oct 25, 2008
Location
Va.
TDI
06 MK5,09 Mk5 CR,03 Mk4,96,2-97 B4s,98 A3,2000 A4,4 Caddies( 2-1.6TD,1.6,TDI) Chevys 6.2,6.5,6.5TD
Corrado dash into a Rabbit? Passat heater/evap. cores in a Rabbit?
 

vw_nut

Veteran Member
Joined
Jun 22, 2005
Location
Beechgrove, TN, 37018
TDI
, 1981 VW pickup TDI Conversion, , 2000 Golf TDI,1985 Cabriolet 16V,2006 jetta
Yes dieselherb I wanted to keep the cluster and make it look factory and not have to cut up my dash to get it in ill have pictures hopefully this next week with it in. I'm also going hydraulic clutch which I almost have that all done also I think this next week it will be done
 

G60ING

Top Post Dawg
Joined
Aug 5, 2001
Location
Alexandria, VA
TDI
No TDIs Currently, I have an R36 Corrado. I've had an ALH Corrado swap, AHU Corrado swap and 2003 TDI Jetta
Nice. I might eventually build something similar so please take pics of the dash swap and HVAC install.
 

vw_nut

Veteran Member
Joined
Jun 22, 2005
Location
Beechgrove, TN, 37018
TDI
, 1981 VW pickup TDI Conversion, , 2000 Golf TDI,1985 Cabriolet 16V,2006 jetta
I will Frank I'm working 7 days a week right now trying to keep up with work, I'm not complaining just no time to work on truck
 

G60ING

Top Post Dawg
Joined
Aug 5, 2001
Location
Alexandria, VA
TDI
No TDIs Currently, I have an R36 Corrado. I've had an ALH Corrado swap, AHU Corrado swap and 2003 TDI Jetta
I fully understand that. Spring time is my crazy work season where all family and car projects get put on hold.
 

vw_nut

Veteran Member
Joined
Jun 22, 2005
Location
Beechgrove, TN, 37018
TDI
, 1981 VW pickup TDI Conversion, , 2000 Golf TDI,1985 Cabriolet 16V,2006 jetta
Well i have been working 7 days a week for the last 5 weeks with only 1 sunday off, and its been 100 to 106 with the heat index so it make it tought to work in the heat then come home and work in a oven of a shop so i have been rounding up parts, i have most of the A/C lines and have it pretty much all figured out what i have to do for that, and i am having the lower radiator pipe made at my local shop, i have to have some tig work done on the A/C lines and some shortened, i got both new axles in and have to grease them up and put them on, i am getting the back brakes changed to disk and the rear springs and beam powdercoated i havent got it off yet but hopefully this weekend i can, its all a very tight fit no room for much, im glad i am putting the battery under the truck cause it wont fit upfront
 
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vw_nut

Veteran Member
Joined
Jun 22, 2005
Location
Beechgrove, TN, 37018
TDI
, 1981 VW pickup TDI Conversion, , 2000 Golf TDI,1985 Cabriolet 16V,2006 jetta
This is one of the lines i have to rework, i talked to a guy who tig welds and hes gonna look at it, monday im gonna go to a Hose and belt place in nashville and see if i can find another fitting thats straight
 
8

8v-of-fury

Guest
I am actually looking in to a 1Z/AHU in to an 81, this thread has been helpful :)
 

vw_nut

Veteran Member
Joined
Jun 22, 2005
Location
Beechgrove, TN, 37018
TDI
, 1981 VW pickup TDI Conversion, , 2000 Golf TDI,1985 Cabriolet 16V,2006 jetta
well not much done to the truck this week, i have had sinus problems and my weekend was on the couch, i have made progress on the A/C Lines i hope to have them back this week along with the lower radiator hose, i got the leaf springs blasted and the rear beam, im getting the rear disks ready to put back on and finish the brakes.. will see were suppose to be in the high 90's again this week
 

vw_nut

Veteran Member
Joined
Jun 22, 2005
Location
Beechgrove, TN, 37018
TDI
, 1981 VW pickup TDI Conversion, , 2000 Golf TDI,1985 Cabriolet 16V,2006 jetta
Well with over 100 heat index for the last 2 weeks im over my sinus infection but its been miserable to work in the shop so i have let it sit i waiting for my A/C lines to be finished up so i can pick them up this week and hopefully my axle beam also i think its suppose to cool down a little this week
 

dieselherb1

Veteran Member
Joined
Oct 25, 2008
Location
Va.
TDI
06 MK5,09 Mk5 CR,03 Mk4,96,2-97 B4s,98 A3,2000 A4,4 Caddies( 2-1.6TD,1.6,TDI) Chevys 6.2,6.5,6.5TD
Not sure if I asked but what type of trans-eng mounts are you using(bought, homemade?) And clutch(cable hydra?) Pedal assem. from ? if you are using hydraulic.
 
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