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Mk3 Tdi into a Mk1

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Mk3 Tdi into a Mk1

Ok are you sitting comfortably ?

After 'we' found out we were having a second baby my wife decided the B*W saloon wouldn't be practical enough and I got cash and a mongerel mk1 cabrio project in part ex. and although I've always preferred my cars with RWD this one has grown on me a lot.
It is a W reg that has had a 1600 caddy diesel engine and 4 speed box fitted - now for the past 4 months I've only needed the car for local trips and the low gearing and general lack of 'puff' have not been a problem BUT I now have to do a 250 mile round trip once a fortnight for work.
Having read about the Mk3 to Mk1 diesel engine swap AND having a mate with an MOT failure '96 Tdi with very low miles could I ask a couple of  questions ?

1) Do I need anything else to do the swap that isn't on either the Mk1 or the Mk3 ?

2) Are there any particular problem areas ? Exhaust / Engine Mmgt. system ?  Driveshafts ? Engine Mounts ?

cheers

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You need to speak to Bert mate.He's done this in his mk1

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have a look on caddy fourms, its been done a lot before.

1457 gx, matalic green. 5 door.

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bert will now all this info, hes the mk1 diesel guru, :wink:

1983(Y) VW GOLF GTi

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I think the late Mk3 TDI's are harder to fit with the more complicated stuff like the ECU. This link may help :
http://www.vwgolfmk1.org.uk/modules.php?name=Forums&file=viewtopic&t=38646&highlight=tdi
If you have to keep the 1.6, fitting a 5 speed gearbox will be worth its weight in gold for more comfortable high speed cruising/long journeys/fuel economy. It's a shame the Cabrio body is that bit heavier than the hatchback aswell.

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its a bit of a female dog to get a nicly fitting intercooler and youll need sound deadening for sure as mine has none and its very loud also constant turbo whistle but really dont worry me i like the sound lol

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A (very) breif list:-
Engine
5speed gearbox
Depending on which gearbox you choose you need the mounts for it (mk1 o2o 5speed diesel box will fit the mk3 engine, or buy mounts and fit the new mk3 box)
If fitting the mk3 box the shifter cables and selector, a cable clutch conversion from a seat/ hydraulic clutch pedal conversion (I would go for the cable IMO)
If using the mk3 box also you will need 100mm late cabby driveshafts and wheel bearing housings as the earlier mk1s are only 90mm.
Wiring is the tough bit, but there are guides as to which you need on the t4 forum (quick search and you will find it I promise)
Either a petrol tall block mount for the engine or chop down the old diesel one.
The fly by wire throttle needs to be connected to either the pedal direct or the old cable.
If you get the ecu immobiliser removed you won't need the key chip and immobiliser box, but you can keep these its just more of a faff.
Have a look in my thread next week, I've just done this and aim to finish it over this weekend!
Best advice I can give you is plan time for the swap. Then plan some more lol!
Hth!
Matt

Last edit: by chortle

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