Advice on TDI to Rabbit swap

[fungus]

I've been looking for a VW TDI for some time (mostly for the fuel economy), but it's been tough. Most are prim and proper, and even ones with high mileage are $$$.

A fella that I've gotten in touch with has done a swap of a 1.9 TDI (supposedly with around 80,000mi) into an '81 diesel Rabbit pickup.

Nothing could give me jollies more than a Rabbit pickup with the balls of a TDI; however, what should I watch for as indicators of a poor swap?

He's used the stock Rabbit 5-speed (FN-15-104), which should have similar ratios due to it being a stock diesel... However, I can only assume it has "shorter" gearing due to the fact that it used to have a wimpy little 1.6 N/A diesel in it stock.

Any idea if a 5-speed from a TDI of some sort could be adapted easily to give the taller gearing (if it is an issue)? Don't get me wrong, I drive 55 everywhere I go to keep RPM's low and save on fuel (hypermiling)... I would like to be more comfortable on the interstate soon, however, since I'll be making a long ass commute twice a week due to the new job.

Advice on signs of wear on the engine are appreciated as well.

Thanks folks.

[Timbo]

I remember the rabbit diesel's were 4 speed and geared more like a bug but that was the 80 models. Probably changed a lot since so I'm no help. Just do like Johnny Cash and build it "one piece at at time".
Tim

[chopper03]

Fungus, Here is a site with more information on VW TDI than
anywhere in the world. It also has a lot of info on TDI swaps into
MK1 bodys.

http://www.vwdiesel.net/forum/


As a side note I have a 1980 VW pickup that I am going to sell
It has a blown up 1.6 diesel in it now with a pretty fair body and rough interior and a clean title.

[bugdust]

A perfect daily-driver for me would be a crewcab Caddy TDi.

[Spink]

A mate and i replaced our 1.6d engines with 1.9 engines in our campers. They where both T25's (T3). He went for a AAZ (Turbo) and i stayed with non turbo (1Y). I know theses aren't TDI but the bell housings are exactly the same. My camper had a 5 speed box and my mates had a 4 speed. My van was slow and i mean slow. i got excited when i reached 60mph eventually (down hill). My mates on the other had was perfect. He's cruise past me at 70mph no probs and the engine wasn't rev'ing it's nutts off.

I don't know if thats of any use to you, i just thought i'd let you know my experience with the different boxes.

[vdubjim]

Lots on vwvortex. Im collecting parts for that as we speak.
here are some pics ive collected.
Trans will swap with some brackets. Small amount of wiring.

http://public.fotki.com/vdubjim/my_cars-1/82-caddy/

[fungus]

Thanks fellas. I'll let you know if it is good.

[fungus]

Originally Posted by Timbo

Just do like Johnny Cash and build it "one piece at at time".
Tim

I'd entertained the thought.

[HeidelbergJohn4.0]

TDIClub.com has a forum for TDI conversions.

http://forums.tdiclub.com/forumdisplay.php?f=63