So there is tons of talk here and there about the swap but no definitive thread on what all is needed to complete this, and I just want to make sure I understand all the parts I need to acquire before pulling the old 1.6 N/A out of my 81 rabbit.
I will be starting with a complete AAZ & 5 speed transmission from an MK3.
From what i understand, the AAZ & 5 speed trans from an MK3 is a direct bolt in. The sensors from the 1.6 N/A need to be swapped over to the AAZ, but aside from that everything else should mate up without issue. A down pipe should be used from an MK2 turbo diesel. (?)
The transmission output shafts will be 100MM, so to fix the 90mm half shaft -> 100 mm output shafts I need to use caddy steering knuckles & axles and this should fix the problem (?)
I have also been told EMPI 100mm half shafts will bolt in without modification and will not rub? (I am not even sure where the stock 100mm shafts rub, so can't tell if this is true or not). Also not sure if the stock clutch cable will work or if they used a hydraulic setup on the MK3's? Stock speed-o cable will work as well?
There also seems to be an issue with the stock crank pulley bolt used on the AAZ so a new bolt should be used prior to install (?)
Is there anything else I am missing? My move is going quicker then I thought so I am hoping to start accruing parts here shortly. Because this is my daily driver the swap needs to go as straight forward as possible for the least amount of downtime on the car. Any insight greatly appreciated, if I can have everything ready to go then the swap will be happening a lot sooner then planned.
go look in the FAQ section. the search button up there in the upper right corner is your friend!
millions of people have done AAZ swaps here. its in the FAQ section. its really easy to swap a AAZ in a MK1
you will need to use your engine and gear box mounts, if your car was originally a diesel you can use your diesel pump mount i believe which is part of the engine mount. or if its a petrol to start with you can modify your pump mount to fit with the petrol engine mount by chopping a bit off.
drive shaft wise you can just take the 90mm parts off your drive shafts (its just a case of removing a clip and knocking the CV joint off) and swap them with the 100mm ones from the mk3 if you still have them, if not any other 100mm joints from a mk2 16v or mk3 golf (think all the big blocks had 100mm shafts on the mk3) will fit.
I'd love to try that combination in my 81 Rabbit 1.6 T/D to see how much different it would be on the mountains, should be a torquey little beast
what year and model is the AAZ going into?
I will be starting with a complete AAZ & 5 speed transmission from a Mk3.
From what i understand, the AAZ & 5 speed trans from a Mk3 is a direct bolt in. The sensors from the 1.6 N/A need to be swapped over to the AAZ, but aside from that everything else should mate up without issue. A down pipe should be used from a Mk2 turbo diesel. (?)
It's "a Mark 3," not "an em kay 3". Ha ha.
I'm excited about your swap. I've been watching this car since you got it. I wish I had a garage; I'd find a donor car, too, and use you for inspiration. I guess this slow little 1.6 is inspiration enough. What are you going to do with your old engine? Convert it into a blender?
Good luck, post lots of pics, and don't get frustrated.
I will be starting with a complete AAZ & 5 speed transmission from a Mk3.
From what i understand, the AAZ & 5 speed trans from a Mk3 is a direct bolt in. The sensors from the 1.6 N/A need to be swapped over to the AAZ, but aside from that everything else should mate up without issue. A down pipe should be used from a Mk2 turbo diesel. (?)
It's "a Mark 3," not "an em kay 3". Ha ha.
I'm excited about your swap. I've been watching this car since you got it. I wish I had a garage; I'd find a donor car, too, and use you for inspiration. I guess this slow little 1.6 is inspiration enough. What are you going to do with your old engine? Convert it into a blender?
Good luck, post lots of pics, and don't get frustrated.
@ mark 3..
I am keeping my patience pretty good with the ol' girl. Just taking my time and trying to not let everything add up at once. So far it's sheer simplicity has made it more of a joy to work on then my past several cars (All audi quattro's ranging from 84-96).
The old motor I am unsure of. Almost 250k so I doubt many would want to purchase it. Maybe I'll convert my riding mower...
