Project Caddy TDi.........the search for boost

[foxyjay]

A quick hello to introduce my Caddy and my intended plans.

If you look on most popular VW forums you'll see foxyjay or foxy and all my previous projects.

This is my second van project in the past few years............I previously had a T4 which was a TD, and I converted it to a 1.9 TDi using a Mk3 Golf and a 1Z engine. My blog is on the T4 Forum.





Its an sdi with light water damage which has bolaxed the engine and dampened the sound deadening inside.
The van arrived last week and my plans are already growing.

The seats and flooring are out and interior dried.








I've scrapped the idea of just replacing engine and have decided on tdi transplant from known good donor car.

I bought a late Seat Altea on Monday with body damage which will be the donor for whole mechanicals under the bonnet.

[foxyjay]

Well some progress finally........

Have removed the front off the caddy and today have the stricken pony out......







Front stripped out of the Altea.....rad pack off and carefully disconnecting minimal piping and wiring...noting what goes where.





It's a good job I'm happy and capable / experienced with wiring and electrics....looks like I will have to separate the engine/ecu wiring from the nearside engine bay loom, and the scuttle loom in order to make it work with the caddy.
The Altea has two wiper motors, whereas the caddy has just the traditional one-off.

I've started pairing out the caddy loom to again separate out all evidence of SDi installation, and make ready for the TDi install.
The caddy doesn't have a glowplug relay under the fusebox either, whereas the Altea does.
Much of the basic wiring is identical however which is of course the plan -to make it as easy as possible!

The Altea ECU is away being virginised ready for putting in the caddy......can add immobiliser pairing with clocks and key when I decide what clocks to run.

[broadmoor]

Fair play...that's a big enough task.
Best of luck

[stumpymark]

Good effort dude, loads of work there!

[foxyjay]

Shot of the caddy wiring loom coming apart......



Centre tunnel now clear after SDi exhaust front pipe cleanly removed

[Tonz]

last pic.... workshop floor needs cleaning...

[foxyjay]

last pic.... workshop floor needs cleaning...

You meant to say "mowing"....

[w69]

i luv threads like this I get all excited!!

[foxyjay]

i luv threads like this I get all excited!!

I can sense your excitement........perhaps your medication is wearing off?

[foxyjay]

Well, after toiling over wiring schematics for both Caddy and Altea for two evenings and drawing out a simplified diagram to allow direct comparisons, I had it cracked.

Took a whole half day to carefully strip out both wiring looms without damaging wiring, and carefully unplugging wiring from fusebox etc, and to get the TDi loom ready to meld into the caddy.....



Plus



Equals

[foxyjay]

A bit more progress, despite only spending a wee few hours this week.......

*New bonnet, wing, front & rear bumper, headlights picked up (panels need painting as are yellow!)
*Fitted Altea accelerator pedal....the floor peg upstands are right length
*Removed existing control stalks and installed cruise control, MFA control, and correct module...all ready for future
*Removed existing steering wheel and fitted flat-bottom model with US-Spec "GLi" emblem!





*Got rear Caddy Life (new) seats delivered....£50 well spent! Just await mushroom bolts to arrive.



*Considering de-catting the TDi installation - a simple cut open and remove guts I think
*Cleaning my Audi S4 alloys and about to fit two new tyres to make ready for the van

[foxyjay]

Want to tone down the chrome so have done the obligatory Carbon-Effect front emblem.....

I have two qualities of Carbon film - one cheap and the other 3M brand.
This is the cheap stuff just to see how it goes.....it's thinner and wraps sharp bends easy but it does tend to wrinkle.
A hairdryer helps to stretch and shape the film without creases.



Also experimenting with the headlights - going to do the "Joey" mod on these....(ie black out the chrome bezel with paint).

This is the duff light with bust clips and had no back cover on it so was dusty and a bit of a fly graveyard!
The glass isn't too aged or chipped so will likely keep it for a spare.
Used a hot air gun and a slender medium blade screwdriver with long shank to get into the groove and dig the sealant out.
As has been said on the DIY guide - once you know where to guide the screwdriver, heat and effort, the second one should be much easier.

[broadmoor]

Nice ....

[foxyjay]

Seem to have run into a problem with the aspiration boost pipes......the altea induction pipe to the turbo runs directly into the hydraulic pump.

Heres the problem......

[Bow]

Urghhhhh that's a pain. Anyway of relocating pipe, is this one which goes to intercooler