VW Golf II TDI

Nitrox

Well-known member
Joined
Sep 5, 2009
Location
Algarve
TDI
Golf II TDI
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














 

Nitrox

Well-known member
Joined
Sep 5, 2009
Location
Algarve
TDI
Golf II TDI





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










 

Nitrox

Well-known member
Joined
Sep 5, 2009
Location
Algarve
TDI
Golf II TDI


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



 

Nitrox

Well-known member
Joined
Sep 5, 2009
Location
Algarve
TDI
Golf II TDI

Nitrox

Well-known member
Joined
Sep 5, 2009
Location
Algarve
TDI
Golf II TDI
And i finally found a wrecked Golf 3 with a AFN 110hp engine...

The car:










After a couple days, the shell was stripped :D

 

G60ING

Top Post Dawg
Joined
Aug 5, 2001
Location
Alexandria, VA
TDI
No TDIs Currently, I have an R36 Corrado. I've had an ALH Corrado swap, AHU Corrado swap and 2003 TDI Jetta
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.
 

Nitrox

Well-known member
Joined
Sep 5, 2009
Location
Algarve
TDI
Golf II TDI
G60ING said:
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

 

Nitrox

Well-known member
Joined
Sep 5, 2009
Location
Algarve
TDI
Golf II TDI
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.






 

vwmikel

Vendor , w/Business number
Joined
May 5, 2005
Location
Las Vegas, NV
TDI
'94 Golf Sport TDI
Nitrox said:
Is that one of my old pop-off valve plugs? :D

I love the car. I have definitely given some thought to buying another MK2. I miss my old Jetta TD. :(
 

jjordan11

Veteran Member
Joined
Jan 5, 2008
Location
Lehi, UT
TDI
1988 Audi 80 quattro PD130, 1982 Westfalia TDI
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?
 

Mark@MaloneTuning

Vendor , w/Business number
Joined
Sep 24, 2003
Location
Blaine, Washington and Vancouver, British Columbia
TDI
'14 GSW TDI, '11 Golf TDI, '97 Golf Variant Syncro 1.9L TDI, '96 Golf 1.9L ASV TDI, '93 Eurovan Westfalia 1.9L TDI, '09 BMW 335d, '17 BMW 328d
Nice project!

vwmikel said:
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.
 

Nitrox

Well-known member
Joined
Sep 5, 2009
Location
Algarve
TDI
Golf II TDI
vwmikel said:
Is that one of my old pop-off valve plugs? :D
Hi! nop, this one was made here!

jjordan11 said:
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...

ninedee_golf_tdi said:
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...
 

leon10tagg

Veteran Member
Joined
Sep 26, 2003
Location
Northern Ireland
TDI
2001 Golf 90bhp ALH tdi, 2002 Golf PD100, 2004 Passat 1.9PD AWX, 2001 Golf 4-Motion, 1997 Audi A4 1.8t sport, 1998 Subaru Impreza 2.0t WRX
Keep the info on this one coming.....looks very interesting and should be one fast Mk2 TDI when finished.....well done so far.
 

Nitrox

Well-known member
Joined
Sep 5, 2009
Location
Algarve
TDI
Golf II TDI
So, i have been out for a while, i usually put in stand by all my projects during the summer...

So, new engine mount to give enough clearance for the turbo:













Also, i received 2 Displays for monotoring the EGT and IAT.

The parts are from Auberins.

Green for IAT:







And Red for EGT lol




They will be instaled in a votex double din console
 

Nitrox

Well-known member
Joined
Sep 5, 2009
Location
Algarve
TDI
Golf II TDI
So now the that the engine is in place, I started to work on other things.

Downpipe ready with a smooth transition 43mm to 60mm.






Also made a gasket from copper












It is starting to get some shape :D




Also did a rebuilt on the drive shafts

 

Nitrox

Well-known member
Joined
Sep 5, 2009
Location
Algarve
TDI
Golf II TDI
So, i sold the previous BBS RM in 15's in order to get 16's.

I want larger diameter as I think 16's fill much better the wheel arches of the Golf 2.

I bought a set of BBS RS 098 originally with Mercedes 5 stud.

Here here one the day they arrived:




Care was need, they lacked of shine...

So i disassemble them in order to polish the outer rims, proper center paint, new BBs logos and redrilled the center in vw bolt pattern 4x100.

Here the outer rims already with some sanding done...







Center redrilled

















And final result






I chose Falken ziex 205/40



preview on the car, the ride height not sorted yet :D



 

Nitrox

Well-known member
Joined
Sep 5, 2009
Location
Algarve
TDI
Golf II TDI
I started to work on the inlet pipes.

the pipe from the intercooler to que inlet manifold is 57mm.

I had to modify it to receive the new MAP sensor as well as the Auberins IAT sensor.

Pics:






















The welder did a great job!
 

Nitrox

Well-known member
Joined
Sep 5, 2009
Location
Algarve
TDI
Golf II TDI
I finally almost end all the pipe work :)














I'm swapping the old 256mm for a complete 280mm system from a Corrado G60.

They came a little rusty so care was need :D



While I'm at it, bought new seals and a painting will be done next




Until next time!
 

Nitrox

Well-known member
Joined
Sep 5, 2009
Location
Algarve
TDI
Golf II TDI
Good progress mate, like this alot!

Thanks mate! I also have an eye on your project :D

Calipers painted, new seals fitted, and goodridge braided hoses. I hope the brake power will be there...

The MC is a 22mm unit.







 

QuantumRallySport

Veteran Member
Joined
Dec 15, 2009
Location
VA
TDI
mk2
Looks great but.... Do yourself a favor and remove the GreenStuff brake pads and replace with something (anything) else!
 

Nitrox

Well-known member
Joined
Sep 5, 2009
Location
Algarve
TDI
Golf II TDI
I have a question for the experts.

I have been looking for a camshaft for my engine. And I ended on Dbilas cams.

They have 3 options:




Could someone please give me the carachteristics of the OEM unit? It is an AFN engine.

As I have shown, my setup will be a 2256v from alfa, bosio race 520 stage 1 nozzles and maybe a 11mm head. I'm aiming for 200-220hp.

Which of these 3 cams would be the best for my setup without loosing driveability and more important torque in low-middle rpm's but with having that little extra breathing in high rpm's. The engine won't do more than 5000 rpm.

Thanks in advance for your help...
 

myke_w

Vendor
Joined
Jan 30, 2003
Location
Cbus, Ohio
TDI
03 TDI Wagon
Great work on the swap, looks great!!

I'm currently doing a tdi mk2 jetta coupe (going to 1z / ahu) and need some ideas for IC plumbing.

I'm really interested to see the piping on the back side of the engine leaving turbo. I'm also interested in seeing how you plumbed the inter-cooler around the radiator and how you cleared the alternator pulley etc, and what you did to secure the piping up front.

Also curious what inter-cooler you used, and how it's mounted.

I was hoping you could post more pics in your thread that show how you got around the tight spots, show more details.

Also - Maybe I missed it, but where is your MAF? It looks like your intake pipe goes right into the airbox...
 

Nitrox

Well-known member
Joined
Sep 5, 2009
Location
Algarve
TDI
Golf II TDI
Great work on the swap, looks great!!

I'm currently doing a tdi mk2 jetta coupe (going to 1z / ahu) and need some ideas for IC plumbing.

I'm really interested to see the piping on the back side of the engine leaving turbo. I'm also interested in seeing how you plumbed the inter-cooler around the radiator and how you cleared the alternator pulley etc, and what you did to secure the piping up front.

Also curious what inter-cooler you used, and how it's mounted.

I was hoping you could post more pics in your thread that show how you got around the tight spots, show more details.

Also - Maybe I missed it, but where is your MAF? It looks like your intake pipe goes right into the airbox...
Thanks!

I will take pictures for you tomorrow so you can see more about the plumbing and clearence!

There is a big diference beetween your car and mine that changes everything, it's the front that holds the grill and the light!

My intercooler (Mercedes Sprinter van) will not clear the Jetta front because the lights are much bigger!

I will not run a MAF, the MAF map on the ECU will be desactivated by the chiptuner:D in this case MB POWER. (he did some race cars in the US and Canada, although he is portuguese!)
 
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