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TDI Conversions Discussions on converting non TDIs into TDIS. More general items can be answered better in other sections. This is ideal for issues that don't have an overlap and are very special to swaping engines.

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Old May 18th, 2019, 19:51   #106
J.Klassen
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Alright, so while I had the intercooler out to fix the leak I decided to change the angle on it as well. Just to give me some more room to get my hands in between the intake and the turbo.


All welded up!

So now we fast forward through the first driving season. the truck first moved under it's own power Christmas 2017 and I drove it till the spring 2018. There were a bunch of hiccups along the way (which was to be expected) and now we pick up the story with a list of things to modify over the summer of 2018.

First up is the exhaust tips. Apparently I lost one over the winter. They were only the clamp on type and the little diesel must have shook it right off.

I wasn't really liking the dual tips anyway. Time to try a more Duramax style of tip.



It's almost round, but who's going to get down there and check anyway, right.

Much better!

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Old May 21st, 2019, 17:54   #107
Geobmx4life
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As always, love the fabrication and progress!!!
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2005 Golf TDI, VNT 17, Malone stage 4, Spec stage 2 clutch, .658 5th gear, FMIC, Ventectomy, NewSouth gauges, BuzzKen 2.5 turbo back exhaust, Evolution Skidplate, Helix OEM Reps retrofitted with Morimoto Bixenon mini's, FK coils, 18in Serrons. Frostheater
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Old June 20th, 2019, 20:13   #108
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Over the first driving season I had a few issues with the turbo manifold. I know, some of you probably saw it coming, but hey it was my first manifold and now it is time for round two.

First I got the dimensions of the pieces I was going to use and made paper templates so I could mock it up and know how much to order. I cut the old manifold apart to reuse the flange.

After a little waiting the pieces show up from Ace race parts. I am using 321 Stainless weld els and straights. 321 can handle some serious heat. I think they use it in jet engines. Anyway more than enough for the ALH.

Let the cutting and fitting begin!






Ready to be welded together
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Old June 22nd, 2019, 19:04   #109
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Thank you for documenting this!
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Old June 25th, 2019, 18:43   #110
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Thank you for documenting this!
No problem! I ghosted on tdiclub for a while and gathered most of the information I needed to do the swap. It is a great resource for everyone. Now I feel like it is my turn to put some info back into it.
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Old June 25th, 2019, 19:03   #111
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Welded up and into the engine bay it goes! I like this shot because it shows how the exhaust flows out of the head and through the turbo really well. In this pic you can also see the egt probe bung location, right before the turbo. I have seen some people install the probes in the downpipe after the turbo out of convenience, but that can give false readings by a couple of hundred degrees F.

Hmmm, looks like the downpipe will need a little rework as well.

I added a turbo/manifold support brace for this second go around. It may not be necessary but it helps me sleep at night lol. It is made of a bolt and some tube. By putting a nut in the middle I can put a bit of upward tension on the turbo after it is installed to help hold up the weight.

A couple pics of how the inner fender got chopped. This new opening allows me to tighten the bolts for the manifold and intercooler so much easier.


Turbo together and ready for the intercooler, but it looks like that will have to be modified too, what's new haha.
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Old September 29th, 2019, 18:12   #112
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So the intercooler got modified to stand straight up allowing for good access to the turbo from above. It still clears the hood too, but only just.





Now a new charge pipe was needed. And by new I mean that I only had to change the orientation of the silicon elbows and add a couple on inches of length to the pipe between them.




Moving the turbo meant that the intake needed to be lengthened also.





And the downpipe needed a new kink.



Here's a couple of shots of the engine bay with the changes complete.



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Old September 30th, 2019, 19:44   #113
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How in the world do you get anything done and still keep that white clean? I'd spend 40% of any one work session cleaning
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Old October 1st, 2019, 10:20   #114
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For your air to water intercooler pump, how did you do the wiring? Does it run off of a sensor, switch, or all the time?

Right now I have mine off of the battery with a switch in the cab. Future I will add a fuse and relay that will trigger off of an ignition source. Have thought about a sensor, but haven't found a good solution.
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Old October 14th, 2019, 18:22   #115
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How in the world do you get anything done and still keep that white clean? I'd spend 40% of any one work session cleaning
Its actually not that bad. The engine doesn't have any leaks since I re gasketed the whole thing before it went into the truck. I just recently re sprayed the valve cover because it got chipped during the install and was annoying me. Honestly the pics kind of hide how dirty it is as well.
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Old October 14th, 2019, 18:29   #116
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Quote:
Originally Posted by sriner View Post
For your air to water intercooler pump, how did you do the wiring? Does it run off of a sensor, switch, or all the time?

Right now I have mine off of the battery with a switch in the cab. Future I will add a fuse and relay that will trigger off of an ignition source. Have thought about a sensor, but haven't found a good solution.
I thought a sensor might be good also, but I didn't know how I wanted to activate it, whether it be temp or maybe boost pressure based. That all seemed complicated so I just have it wired to come on with all the other accessories. It runs constantly when the vehicle is on. With it on all the time I thought there might be a problem in the winter with it getting too cold and something possibly icing up, but that has not happened so I think I am just going to leave it alone.
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Old October 14th, 2019, 18:49   #117
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Can anyone guess what this is going to be?





The truck has always had a problem with axle wrap in the winter. It was mainly noticeable when I had to go through deep slush or down somebody's driveway that was not plowed very well. I could get into a situation where it would start bucking, but I needed to apply more power and was unable to for fear off destroying the u-joints. This was also only a problem in 2wd but since the truck has an LSD I like to drive around as much as possible without having to go into 4x4. I saw this solution on some off roading fourms and decided to try it myself.





There is no binding whatsoever and the truck still has full articulation. The top tube is a slip joint with a smaller tube and it runs down the center line of the vehicle. There are 3 pins, one on the cross piece connected to the frame and two on the differential. It works really well. The only noticable noise happens sometimes during the 1-2 gear shift. But I think I almost completely cured that recently by adding some metal to the smaller tube in the slip joint so that it has a snugger fit.



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Old October 16th, 2019, 07:53   #118
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Nice antiwrap bar. If you can put a grease nipple in the slip joint it would probably do wonders for longevity of it. Most people use a shackle but im liking this better.
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Old October 20th, 2019, 18:31   #119
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Nice antiwrap bar. If you can put a grease nipple in the slip joint it would probably do wonders for longevity of it. Most people use a shackle but im liking this better.
Thanks! I agree that a grease nipple would be a good idea. Maybe a few of them spaced along the length of the top tube. I did grease the pipe as I slid it into the other one and that seems to work. Next time I pull it apart I think I will add some grease fittings though.

I looked around at a few different off road websites and people had shackles and rod ends and bushings and all kinds of things going on. Then I saw this type of design and decided it was good for me because of its simplicity.
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Old October 20th, 2019, 18:44   #120
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After doing all those mods I decided that I needed to do a little shake down trip before winter showed up and I would have to start driving it everyday.

I went up some local forest service roads (lots of shaking) to the snowmobile club chalet. On a good year the snow is right up to the deck, and that is compacted where everyone stops and the groomer goes.



A little higher up past the chalet is a ministry of transport beacon for airplanes. It looks like something alien haha.



When I got back I pulled the valve cover, just to see how things were doing. This is after a couple winters of use. I change the oil for each new driving season with Rotella T6 5w40. I probably only end up putting on 5000 km or less per season.

Looks clean as a whistle. The Colt stage 2 cam even stills has the speckles on lobes. I don't know what they are but they haven't rubbed off.



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