TDI swap into a Cabriolet

[professor_fate]

I'm looking into swapping a TDI into a Cabriolet. The motor is from a complete car, and I'll be able to pull whatever I need from it. I know that I'll need the ECU, instrument cluster, and engine harness, but I was wondering if there were any other little bits and pieces that I'll need.

[Baron VonZeppelin]

I think they have TDI swap guides / builds / FYI / DIY stuff out the ying yang over on TDIclub.com

Intercooler and plumbing, tranny, axles, accelerator assy's, clutch pedal triggers, just about all wiring harnesses if you're doing Electrical TDI - instead of Mechanical TDI.

Fuel filter mounting, vac solenoids etc by the filter airbox
call it just everything.
Cut the car in half and bring the front half home.

[BigVWman]

Bring the front half but don't forget the gas tank! Won't help with the cabriolet but is good for resale! Read a ton of the guides. I own a 1z cabriolet 92, and a 1z 97 cabrio and they are great but its alot of work/fun in putting it together. On tdi forums g60 has sticky for builds by platform! BAsically teh cabriolet swap is just an mk1 swap gone topless with the exception of some wiring since depending on year the cabriolet is likely ce1. What year are you looking to do?

[Blocksmith]

It's an '85. We (I'm his brother  ) found a wrecked beetle donor for it on CL, and rather than buy the whole car, decided to just get the motor (and a few other bits) for half the price and just go the M route. Keepin' it simple (& cheap!). Just gotta get a Rover pump from ebay.uk now....

[chopper03]

On the rover pump do you need a adjustable pulley or is the pump mounting holes  slotted like the vw one is ?

[Blocksmith]

From what I understand you just use the pulley from the vw pump; the only modification necessary is the mounting bracket needs to be milled out a little bit for the rover nose to fit.

[chopper03]

CRSMP5
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Re: 1984 Jetta , TDI WE MUST!
« Reply #175 on: February 20, 2012, 11:28:46 PM »
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never tried dial indicator on a tdi.. i use vag-com

i gave you link a few pages back.. its like fitting a alh pump on a ahu.. then a gov mod, some throttle cable mounts/manipulations and making up the rear mount.. my inital pump timing is 118... and has no advance cable.. it is really easy... now since i could not score the ALH pully/hub set up i had the AHU pully modded like a gasser adjustable cam gear.. $100 machine shop simplicity.. which eliminated shimming the pump and such.. i actually think ill get another pully modded for my 1.6td never have to turn the pump again..
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Pretty sure that you need a adjustable pulley .

[Blocksmith]

Pretty sure that you need a adjustable pulley .

Yes indeed we do! I just went out and looked at the motor, and there's no slots to move the pump body back and forth. From CRSMP5's post, it appears that there is a difference between the AHU (not adjustable) and the ALH (adjustable) pulleys. While I was not aware of this when I pulled the motor, we ended up lucking out in that respect, as the motor is an ALH. Here's a pic of the pulley:



So, we should be good to go once we get the Rover pump and alter the brackets so it'll fit.

[CRSMP5]

its pretty much direct fit... you gotta create the rear mount.. swap the injector line pieces/valves.. and do some throttle linkage/cable mods... dont forget the gov mod.. but using the stock pully/hub and mount.. its all direct swap/fit

[Blocksmith]

So, CRSMP5, asking someone who has done it and knows that it works, I have a question for you--why is it that EVERYONE doesn't go with the rover pump? It just seems sooooo straightforward compared to the other options. From the way you describe your setup, it doesn't sound like there are ANY downsides.

[R.O.R-2.0]

So, CRSMP5, asking someone who has done it and knows that it works, I have a question for you--why is it that EVERYONE doesn't go with the rover pump? It just seems sooooo straightforward compared to the other options. From the way you describe your setup, it doesn't sound like there are ANY downsides.

its not COMMON KNOWLEDGE..

its just like me using a peugeot 10mm pump on my car as a performance pump..

works great, but nobody does it, because MOST people have no idea that peugeot used 10mm bosch VE pumps on their engine..

there are engines out there with some pretty fancy parts that make life simple.. the rover TDI pump is one of them.

i bet alot of the reason people dont use them is because its basically IMPOSSIBLE to find one on this side of the atlantic..

[CRSMP5]

the old mod myke_w had heard of it.. was on vac over in the uk.. picked one up.. let it sit on his shelf.. and somehow i became guini piggy... till me or him actually tried it.. it was a "rumor" or option per say.. but till someone with knowledge actually tried it.. it was snake oil to us..

for 100-200+shiping.. IMO worth a try.. but sadly you can only expect it as a "core" as well kinda hard to say if any good or not.... if it works great.. cheap option.. if it needs rebuilt.. ok still a option just not as cheap.. BUT imo still cheaper then 2 pumps that could be resold to build one...

no reason at all the pump he is pulling from his engine cannot be sold for 500ish.. except the hub needs to be removed.. and unless you know how to reinstall said hub will be its biggest draw back from its sale..

me i had a custom pully made for my AHU from the stock AHU one... works great and to be honest.. i want to make one for my 1.6 too... so much easier to turn the pully vs the actual pump...

p.s. i started at 118 on my pump timming.. so far no reason to change that... very happy with how it starts in 30*f with NO GLOWPLUGS and how it starts in warmer temps too..

for the gov mod i did 4 washers...

pulls like a gasser to id say 7k... but my tach is way off.. and people say diesel does not burn at that rpm... but i can say this... 195/50-15, 3rd gear, 74mph with the stock 98 tdi 02a... is pretty much redline.. thats gps not speedo..

i do not have a vnt.. but the stock 98 turbo i run at 18-21psi under that it gets wonky and surges going down the road..

[professor_fate]

Does anyone know a good way to control the VNT on an m-TDI?

[theman53]

libbydiesel is in my opinion the foremost authority in doing just that.

This is a site I have kicked around but never done anything with. They have complete program ready to go, but you have to install a bunch of electronic stuff for it all to work together.
http://dmn.kuulalaakeri.org/vnt-lda/