Golf GTI TDI PD130M6 - Melted... Destroyed... 
Hello,
I am posting this on TDIClub because without this forum, I would probably never have built a project like that and, I appreciate people sharing their project so, why not doing this for mine also. I am not a mechanic at all but I do understand a lot about mechanic.
My Past Projects (TDI and non-TDI)
1. : '90 Honda CRX Si with '95 GSR engine
2. : '92 Jetta with '98 TDI engine
3. : '92 Passat Syncro with '98 TDI engine
I still have my Syncro TDI and use it on a daily basis and as a winter car. I love the performance of it and the overall enjoyment it gives driving this in winter. I could keep this only car and put money on my house but, temptation wins again and I need to build another project.
The Engine : PD100 or PD130
I always dreamed of driving a Golf TDI with a PD130 or PD150 engine that are available in Europe but, importation is complicate and expensive so I looked at several options.
I looked at buying a PD130 ASZ or PD150 ARL engine but due to availability and importation fees, those two engines were quite expensive and I resign to buy a PD100 BEW engine.
I had that engine sitting in my garage for a few weeks and I saw a post on TDIClub for a PD130 ASZ engine. This needed to be mine. It is already on the American continent (Does Sarah Palin knows where this is?) and I can always sell back my PD100 BEW engine without loosing money.
Road Trip (Montréal, QC - Baltimore, MD - Montréal, QC)
This trip was very funny. After a night without sleeping more than 4 hours (I saw the post and got excited), I woke up Friday morning at 7:00am and went to work. I came back home at 7:00pm and left home toward Baltimore at 11pm. Cross the border at Saturday 12:30am. The I-87 in NY state near the Canada is a very sleepy road but we made it to Baltimore and got there at about 11:00am and 1000km later.
The engine was there like promised, sitting in an unfinished MK2 project. I notice that the 6-Speed 02M transmission was attached to the engine and I was not aware at all and did not thought of asking before leaving home last night. So, I end up bringing it all with me (Engine, Transmission, Starter, Shifter and some other parts). To me, this was one of the good days that you will remember a long time. Everything fitted in my MK3 Golf GTI VR6 trunk. The suspension did sit lowered but the roads in U.S.A. are much better than our roads in Quebec so I did not worry that much.
It's now 3:00pm on Saturday, 32 hours without sleeping but during the day it's not that bad to keep ourselves awake. We left Baltimore and headed back to Quebec. Another 1000km of driving awaits us.
Everything was going well until the night starts to kick in. Once the sun goes down, we became very tired and we were stopping more often and went to a Marina in Kingston, NY because my friend want to see a sailboat for sale. We relaxed for an hour and felt better. Back on the road after, again on that I-87 near Albany, it became hard to drive with all those reflector on the side of the road, they are too much eye-catching. Coffee was not good enough other than to keep us stopping for washroom. Drank my first Red Bull and did not feel any effects to keep us awake. I found out two things that help you sway awake in those extreme tired moments. Adrenaline or holding a coffee while driving. I now clearly understand how Jason Statham felt in the movie Crank.
Our last stop before the borders were at a Dunkin Donuts and the guy there was on his last day before going to the US Army and told us he was making very nice deals. After 40 hours without sleeping, this was an extremely funny situation and we could not stop laughing in front of him and we end up with 2 coffee and 12 donuts for $1.79. That kept us awake up to the border.
24 hours after being in the U.S.A., we crossed the border again on our way back. It is Sunday 12:30am. I "declared" what I bought and after 15 minutes, we were done with them and now no more stress for how many fees they will charge us. I came back home at 2:00am and went to bed shortly after.
We stayed awake for 44 hours without sleeping. This was very dangerous and I don't need anyone to let me know that. But, that was my only chance of getting that engine. It was a very nice road trip and very well worth it!
The Body
Now that I have the perfect engine for my project, I need a shell to put this in. I wanted a MK4 Volkswagen and one of my requirements was that it needed to be a German-made car. This leaves me very few options. Early MK4 Golf or a Jetta Wagon.
I bought a '00 Golf TDI with a blown engine at 465 000km. The previous owner changed the turbo actuator and did not empty the intercooler and under boost, the engine swallowed oil and rods and piston were all blew up because of a $100 fix and lack of attention to do a professional job. That was not my problem but became my solution.
The body is in very great condition. The engine bay is in mint condition, under the car is just perfect and the overall body condition is great. The two fenders will be changed under VW 12 year’s corrosion warranty and some touch-ups will be needed but overall, the body is in excellent shape even with half a milion kilometers on the clock.
The car is equipped with Air, Cruise control and the sunroof. Those last two are still working perfectly well. The brakes and suspension are totally shot. Most of the parts are the original ones on the car. I'll have all winter to source some upgrade parts for it.
The Conversion
Didz, one of my friends and an exceptional mechanic, removed the old ALH engine along with all useless parts and installed the ASZ engine and transmission. It was a very straightforward swap since everything came out of an European Golf.
Once everything in place, I moved the car to another of my friends who is also another great mechanic and has a lot of custom projects to his record including, a MK3 Jetta Coupe with a PD150 ARL engine at a 6-Speed transmission, soon to be 4-Motion.
I moved the car to him to install the remaining parts that requires custom fabrication skill. I got a VNT20 turbo from Kerma TDI that was suppose to be a direct bolt-on but we found out that the turbo oil drain was facing upward, not very good for a gravity drain. The turbo was opened and new holes were drilled and tapped to have 6 possible angles instead of 3.
Once the exhaust manifold and reclocked turbo in place, the actuator is now interfering with the tubular exhaust manifold. The rod for the actuator needed to be extended and now goes right between 2 of the exhaust manifold runners. It looks pretty nice.
The turbo oil return line was way to short to connect the turbo to the engine. We finally end up using a '96 AAZ oil return line that match pretty well.
The ALH downpipe was modified to match the VNT20 turbo flange and a new flexible was used. It should last for a very long time. I also add a cat convertor and the rest of the exhaust is the 465 000km one that is still in great condition.
I already purchased a Passat PD130 Intake Manifold (same as PD150 but inlet on transmisison side) to ease the installation of a Front Mount Intercooler. A Race Pipe was used and EGR removed. A custom intercooler kit with 2.5" diameter was added and fit very well. The intake duct is on 3" piping.
After a Thousand kilometers
I now have the car since 10 days and, The engine rides like a new one. Transmission shift very well and you can easily feel the stock 130 Horsepowers. I will winterize the car in the next few days and I am not sure if it will be chipped before or after winter.
I will source some new brakes, suspension, a new interior because this one is very dirty and with bigger brakes, i'll need bigger wheels. Should be in very good condition after all those necessary upgrades.
Credits
I need to give credits to 3 person for this project without them, It would have been quite complicated to do a project like that.
Didz
Named Tintin - http://www.vwquebec.ca/forum/showthread.php?t=210977
Paul @ KermaTDI
Thank you for looking and I hope you enjoy it
Hello,
I am posting this on TDIClub because without this forum, I would probably never have built a project like that and, I appreciate people sharing their project so, why not doing this for mine also. I am not a mechanic at all but I do understand a lot about mechanic.
My Past Projects (TDI and non-TDI)
1. : '90 Honda CRX Si with '95 GSR engine
2. : '92 Jetta with '98 TDI engine
3. : '92 Passat Syncro with '98 TDI engine
I still have my Syncro TDI and use it on a daily basis and as a winter car. I love the performance of it and the overall enjoyment it gives driving this in winter. I could keep this only car and put money on my house but, temptation wins again and I need to build another project.
The Engine : PD100 or PD130
I always dreamed of driving a Golf TDI with a PD130 or PD150 engine that are available in Europe but, importation is complicate and expensive so I looked at several options.
I looked at buying a PD130 ASZ or PD150 ARL engine but due to availability and importation fees, those two engines were quite expensive and I resign to buy a PD100 BEW engine.
I had that engine sitting in my garage for a few weeks and I saw a post on TDIClub for a PD130 ASZ engine. This needed to be mine. It is already on the American continent (Does Sarah Palin knows where this is?
) and I can always sell back my PD100 BEW engine without loosing money.Road Trip (Montréal, QC - Baltimore, MD - Montréal, QC)
This trip was very funny. After a night without sleeping more than 4 hours (I saw the post and got excited), I woke up Friday morning at 7:00am and went to work. I came back home at 7:00pm and left home toward Baltimore at 11pm. Cross the border at Saturday 12:30am. The I-87 in NY state near the Canada is a very sleepy road but we made it to Baltimore and got there at about 11:00am and 1000km later.
The engine was there like promised, sitting in an unfinished MK2 project. I notice that the 6-Speed 02M transmission was attached to the engine and I was not aware at all and did not thought of asking before leaving home last night. So, I end up bringing it all with me (Engine, Transmission, Starter, Shifter and some other parts). To me, this was one of the good days that you will remember a long time. Everything fitted in my MK3 Golf GTI VR6 trunk. The suspension did sit lowered but the roads in U.S.A. are much better than our roads in Quebec so I did not worry that much.
It's now 3:00pm on Saturday, 32 hours without sleeping but during the day it's not that bad to keep ourselves awake. We left Baltimore and headed back to Quebec. Another 1000km of driving awaits us.
Everything was going well until the night starts to kick in. Once the sun goes down, we became very tired and we were stopping more often and went to a Marina in Kingston, NY because my friend want to see a sailboat for sale. We relaxed for an hour and felt better. Back on the road after, again on that I-87 near Albany, it became hard to drive with all those reflector on the side of the road, they are too much eye-catching. Coffee was not good enough other than to keep us stopping for washroom. Drank my first Red Bull and did not feel any effects to keep us awake. I found out two things that help you sway awake in those extreme tired moments. Adrenaline or holding a coffee while driving. I now clearly understand how Jason Statham felt in the movie Crank
.Our last stop before the borders were at a Dunkin Donuts and the guy there was on his last day before going to the US Army and told us he was making very nice deals. After 40 hours without sleeping, this was an extremely funny situation and we could not stop laughing in front of him and we end up with 2 coffee and 12 donuts for $1.79. That kept us awake up to the border.
24 hours after being in the U.S.A., we crossed the border again on our way back. It is Sunday 12:30am. I "declared" what I bought and after 15 minutes, we were done with them and now no more stress for how many fees they will charge us. I came back home at 2:00am and went to bed shortly after.
We stayed awake for 44 hours without sleeping. This was very dangerous and I don't need anyone to let me know that. But, that was my only chance of getting that engine. It was a very nice road trip and very well worth it!
The Body
Now that I have the perfect engine for my project, I need a shell to put this in. I wanted a MK4 Volkswagen and one of my requirements was that it needed to be a German-made car. This leaves me very few options. Early MK4 Golf or a Jetta Wagon.
I bought a '00 Golf TDI with a blown engine at 465 000km. The previous owner changed the turbo actuator and did not empty the intercooler and under boost, the engine swallowed oil and rods and piston were all blew up because of a $100 fix and lack of attention to do a professional job. That was not my problem but became my solution.
The body is in very great condition. The engine bay is in mint condition, under the car is just perfect and the overall body condition is great. The two fenders will be changed under VW 12 year’s corrosion warranty and some touch-ups will be needed but overall, the body is in excellent shape even with half a milion kilometers on the clock.
The car is equipped with Air, Cruise control and the sunroof. Those last two are still working perfectly well. The brakes and suspension are totally shot. Most of the parts are the original ones on the car. I'll have all winter to source some upgrade parts for it.
The Conversion
Didz, one of my friends and an exceptional mechanic, removed the old ALH engine along with all useless parts and installed the ASZ engine and transmission. It was a very straightforward swap since everything came out of an European Golf.
Once everything in place, I moved the car to another of my friends who is also another great mechanic and has a lot of custom projects to his record including, a MK3 Jetta Coupe with a PD150 ARL engine at a 6-Speed transmission, soon to be 4-Motion.
I moved the car to him to install the remaining parts that requires custom fabrication skill. I got a VNT20 turbo from Kerma TDI that was suppose to be a direct bolt-on but we found out that the turbo oil drain was facing upward, not very good for a gravity drain. The turbo was opened and new holes were drilled and tapped to have 6 possible angles instead of 3.
Once the exhaust manifold and reclocked turbo in place, the actuator is now interfering with the tubular exhaust manifold. The rod for the actuator needed to be extended and now goes right between 2 of the exhaust manifold runners. It looks pretty nice.
The turbo oil return line was way to short to connect the turbo to the engine. We finally end up using a '96 AAZ oil return line that match pretty well.
The ALH downpipe was modified to match the VNT20 turbo flange and a new flexible was used. It should last for a very long time. I also add a cat convertor and the rest of the exhaust is the 465 000km one that is still in great condition.
I already purchased a Passat PD130 Intake Manifold (same as PD150 but inlet on transmisison side) to ease the installation of a Front Mount Intercooler. A Race Pipe was used and EGR removed. A custom intercooler kit with 2.5" diameter was added and fit very well. The intake duct is on 3" piping.
After a Thousand kilometers
I now have the car since 10 days and, The engine rides like a new one. Transmission shift very well and you can easily feel the stock 130 Horsepowers. I will winterize the car in the next few days and I am not sure if it will be chipped before or after winter.
I will source some new brakes, suspension, a new interior because this one is very dirty and with bigger brakes, i'll need bigger wheels. Should be in very good condition after all those necessary upgrades.
Credits
I need to give credits to 3 person for this project without them, It would have been quite complicated to do a project like that.
Didz
Named Tintin - http://www.vwquebec.ca/forum/showthread.php?t=210977
Paul @ KermaTDI
Thank you for looking and I hope you enjoy it
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