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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 March 9th, 2010, 14:20   #1
Nitrox
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Good evening all!

It's with great pleasure that i'm starting a thread on TDICLUB.

I'm Nelson, aka Nitrox and i'm from the south of Portugal. I'm in vw's for a while now and i'm going to show you here one of my daily drivers.

I've been a reader of this forum for a while, there so much quality information for people like me who is doing a conversion. I hope to learn with you and of course i will share everything i'm doing to my car.

So, it's a Golf II from 1991 that had the 1600 TD.

When i bought it in 2007, it came like this:



The original 80hp wasn´t enough for me, so i started some mods:


Modified inlet manifold




Replaced the original k14 for a k24





Golf 1 Gti thermostat for the engine oil



~

Fitted a Mercedes Van Intercooler






and oil cooler from Mocal



Engine bay completed with relocated battery



Custom made battery holder














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Old March 9th, 2010, 14:32   #2
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The car also received a 02a CTN gearbox



With a new G60 Sachs cluth and flywheel




Gearbox selector in place:




Now the exhaust:

Handmade in 60mm stainless steel










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Old March 9th, 2010, 14:45   #3
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For the suspension i chose Weitec's coilovers




The pump received a 10mm head from a tdi, and i also did the governor mod. Turbo was at 1,4 bar.
I think it was enough for a optimistic 120hp









Having some fun in a twisty road





Then i swapped the steelies for a set of BBS RM's with 1" dishes



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Old March 9th, 2010, 14:57   #4
Nitrox
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Some videos:

http://www.youtube.com/watch?v=5GOFkLPKEls
http://www.youtube.com/watch?v=3vaE4vjYpy4

And a video a Friend made with me:

http://www.vimeo.com/3399679



Then in 2009 i decided to makethe trip to Worthersee Tour.

Here the car ready to go:








It's a 2700km trip to reach Austria. But the engine broke down Half way trip in a Highway in the south of France... Bad luck!

So finally it was time to get real power to this car. a TDI engine! The search of a donor car was on...
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Old March 9th, 2010, 15:07   #5
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And i finally found a wrecked Golf 3 with a AFN 110hp engine...

The car:










After a couple days, the shell was stripped

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Old March 9th, 2010, 18:41   #6
G60ING
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You are the VW person that I've seen make their own muffler. Keep the pics coming.


BTW I would not use the k-frame from your mk3 in the mk2. It stands a good chance of being bent.
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Old March 12th, 2010, 06:43   #7
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Quote:
Originally Posted by G60ING
You are the VW person that I've seen make their own muffler. Keep the pics coming.


BTW I would not use the k-frame from your mk3 in the mk2. It stands a good chance of being bent.
Thanks for the advice! I thought exactly the same. So i manage to find another one in decent shape!

I started to stip the engine bay:





And heres the difference between the Golf 2 k-frame vs Golf 3 k-frame:



I also kept the larger Golf 3 sway bar.
Also installed the front Passat cross member in order to have the better Golf 3 Tdi motor mounts.

Everything in place

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Old March 16th, 2010, 15:13   #8
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So, with the AFN engine out, time to change gaskets, seals, pulleys in order to avoid future problems!

With 250,000km on the clock, it's unusual to see a head clean like this:



AAZ gasket with new oil pump.








New timing belt, tensors, waterpump, etc.










I have deleted the A/C, so had to change the pulley system.






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Old March 16th, 2010, 20:00   #9
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Quote:
Originally Posted by Nitrox

Is that one of my old pop-off valve plugs?

I love the car. I have definitely given some thought to buying another MK2. I miss my old Jetta TD.
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Old March 16th, 2010, 20:53   #10
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Very nice car indeed. I like the wheels. How did you do the larger water-cooled oil cooler along with the sandwich plate for the air-air oil cooler?
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Old March 23rd, 2010, 09:33   #11
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Nice project!

Quote:
Originally Posted by vwmikel
I love the car. I have definitely given some thought to buying another MK2. I miss my old Jetta TD.
I miss mine too. I've been considering a MK1 or MK2 with a 1.6 TD sans turbo, and a little nitrous oxide (with a LDA equipped pump). I like the sheer simplicity of the IDI and the linear NA powerband.
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Old March 23rd, 2010, 13:18   #12
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Looks good, but you have your timing belt tensioner wound backwards.
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Old March 26th, 2010, 15:09   #13
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Quote:
Originally Posted by vwmikel
Is that one of my old pop-off valve plugs?
Quote:
Originally Posted by vwmikel
Hi! nop, this one was made here!

Quote:
Originally Posted by jjordan11
Very nice car indeed. I like the wheels. How did you do the larger water-cooled oil cooler along with the sandwich plate for the air-air oil cooler?


Just Bolted an accessory that came along with the sandwich...

Quote:
Originally Posted by ninedee_golf_tdi
Looks good, but you have your timing belt tensioner wound backwards.


Could you show me which one n the picture please?

Some news.
I installed a GT22 with a 1z exhaust manifold
































Now i have to sort a new back engine mount...
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Old March 27th, 2010, 13:44   #14
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Keep the info on this one coming.....looks very interesting and should be one fast Mk2 TDI when finished.....well done so far.
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Old March 27th, 2010, 17:54   #15
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Looks pretty nice so far! Keep us posted.
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