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Thread: Mk1 Caddy - AHU Build

  1. #21
    Join Date
    Dec 2007
    Location
    Bristol
    Posts
    644
    Does anyone know the part numbers for a shorter belt and pulley to delete the mk3 PAS pump?

  2. #22
    Join Date
    May 2018
    Location
    United States
    Posts
    7
    Nice Caddy you have there

  3. #23
    Join Date
    Dec 2007
    Location
    Bristol
    Posts
    644
    The caddy has progressed a bit now.

    The 1.6 petrol has come out, generally that was not too much of a battle thankfully.

    The 1.9TDi AHU engine was stripped down out of the donor. Sad times, it's been such a reliable workhorse:
    2018.08.11 - Engine Swap 01.jpg


    The engine out and back cover exposed before it was cut to expose the holes for the new mk1 engine mount:
    2018.08.11 - Engine Swap 02.jpg


    Removed the the PAS pump, belt, pulley etc, new cambelt kit, back cover trimmed to fit the new mk1 engine mount:
    2018.08.11 - Engine Swap 03.jpg


    Trimmed the plastic cover around the mk1 engine mount:
    2018.08.11 - Engine Swap 04.jpg


    Fitted the O2A gearbox conversion mount to the back, bit fiddly finding some suitable allen key bolts as it was so tight to the gearbox (though later found a bag of bolts in the box of goodies that came from Retrofication that I think were for this purpose - whoops):
    2018.08.11 - Engine Swap 05.jpg
    2018.08.11 - Engine Swap 06.jpg


    In the engine went, generally quite smoothly:
    2018.08.11 - Engine Swap 07.jpg


    Found a problem that the oil filter was much larger on the mk3, and it left no space to be able to get it out in the future. The engine was lifted up again and the mk1 oil filter was put on what was smaller:
    2018.08.11 - Engine Swap 08.jpg


    Other mk1 conversion gearbox mount, generally a great kit:
    2018.08.11 - Engine Swap 09.jpg


    Mk3 hose trimmed to get the heater matrix pipework to fit in the mk1:
    2018.08.11 - Engine Swap 10.jpg


    Petrol taken out the mk1, and diesel replaced:
    2018.08.11 - Engine Swap 11.jpg


    More trimming of the mk3 hoses to connect to the mk1 reservoir:
    2018.08.11 - Engine Swap 12.jpg


    Various bit of other bits connected up, and this is how it sits at the moment.
    2018.08.11 - Engine Swap 13.jpg


    Used the retrofication kit ready for the hydro clutch. The how to guide was very useful:
    2018.08.11 - Engine Swap 14.jpg


    Couple of questions you guys might know?...

    There seems to be two options for the coolant reservoir pipe - is one better that the other? Or just take a pick and black off the other?
    2018.08.11 - Engine Swap 17 (Coolant Pipe).jpg


    I'd like to use the original intercooler pipework to keep it looking like a factory install - this leads both pipes to the right of the radiator, and I have bought an intercooler that will suit. There isn't much space though between the radiator and battery to get the pipes past? Has anyone welded in a new battery tray at 90 degrees to create more space? Someone else I met was using a much smaller battery from a Suzuki Jimny on an AAZ conversion which was starting up ok?
    2018.08.11 - Engine Swap 15 (Intercooler & Bat).JPG


    What route have been taken their O2A cables back? Is it better through the firewall, or beneath?
    2018.08.11 - Engine Swap 16 O2A Cable Route.jpg


    Still a way to go, but the mk3 is now scrapped and more space freed up...

  4. #24
    Join Date
    Dec 2007
    Location
    Bristol
    Posts
    644
    Quote Originally Posted by hgiblin View Post
    Does anyone know the part numbers for a shorter belt and pulley to delete the mk3 PAS pump?
    For others benefit... turned out different belts are not needed.

  5. #25
    Join Date
    Mar 2015
    Location
    United States
    Posts
    10
    I ran my shifter cables, through the floor and over the steering rack.
    IMG_3963.jpg
    IMG_4555.jpg
    I'm still getting the truck sorted but it seems to work well.

  6. #26
    Join Date
    Dec 2007
    Location
    Bristol
    Posts
    644
    Quote Originally Posted by SeanDiesel View Post
    I ran my shifter cables, through the floor and over the steering rack.
    I'm still getting the truck sorted but it seems to work well.
    This looks smart. Can a mk1 centre console fit over that?

  7. #27
    Join Date
    Dec 2007
    Location
    Bristol
    Posts
    644
    Happy New Year's all.

    So bit of an update...

    My friends been doing the clever bit with the wiring... it's getting there and a lot been stripped from the loom now.
    2018.12.31 - Wiring Progress.jpg

    There is a problem with the driveshafts though - I have bought new from the retrofication, but the boot is clashing with the strut, and on the passenger side when the nut is tightened it all locks up solid? Anyone else experienced these issues?? Any ideas?

    2018.12.31 - Clash with CV and Strut.jpg

    Any help with questions above appreciated too.

  8. #28
    You need to tickle the hubs with a grinder to allow clearance for the bigger cv's. There's a thread on it in the how to section of the forum.

    http://www.vwcaddy.com/showthread.php?42579

  9. #29
    Join Date
    Dec 2007
    Location
    Bristol
    Posts
    644
    Quote Originally Posted by rusty_nuts View Post
    You need to tickle the hubs with a grinder to allow clearance for the bigger cv's. There's a thread on it in the how to section of the forum.

    http://www.vwcaddy.com/showthread.php?42579
    Thanks! That solves the binding then, anyone experiences the strut and boot clash?

  10. #30
    Join Date
    Dec 2007
    Location
    Bristol
    Posts
    644

    She lives....

    Some progress on the caddy - finally reached the point that it could be taken on a short test drive!

    • Larger 9 inch servo and master cylinder is installed, and brakes bled.
    • Cooling system finished - I don't have any pics but ended up needing to make the lower pipe up with two silicone 90 degree bends and a coupler
    • Glow plug relay finished off
    • Drive by wire pedal set up finished. A mk4 golf TDi pedal has been used, with a bracket made up to hold it in place. To start it, I bought the left hand drive bracket, and modified from there - it's not necessary if you have good fab skills... but thought it would be a good starting point.


    I didn't take enough pictures on the way, but here are a few...

    Temporarily mounted the mk3 golf cable gear change, if can be mounted properly later on when I know where to place it around the centre console:
    2019.05.26 - Update 01.jpg

    Speedo cable installed in to the O2A box:
    2019.05.26 - Update 02.jpg

    Temporarily removed the intercooler for now:
    2019.05.26 - Update 03.jpg

    New brake light switch positioned:
    2019.05.26 - Update 04.jpg

    2019.05.26 - Update 05.jpg

  11. #31
    Join Date
    Dec 2007
    Location
    Bristol
    Posts
    644
    The Mk3 golf immobiliser was bypassed using an immobiliser emulator (eBay job). The car starts and runs ok, but the ODI port is not working to read any faults on the car?

    One place said that this is because the immobiliser control box is missing - is this correct? And does anyone know if just the box needs to be there, or all of the ring / key etc too?

    Any help would be appreciated

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