VW TDi conversion - how difficult?

Hey all,

Out of interest, what would I need to complete such a conversion?

Has it been done before? Would there be an ideal model Mk1 Golf to start with?

Any advice/opinions/direction much appreciated

o  :mrgreen:

will need a complete donor car as you need engine, clocks, loom, keys, etc.

will also need custom driveshafts made up

You want to be looking at MK3 tdi running gear for an easy conversion .

MK4 running gear will be harder and more expensive .

Yet to see this conversion any one got any links ?

i tell u what would be impressive, i drove a new 06 plate golf the other day just a standerd 2litre tdi thing, there really impressive on performance then i was expecting!

would be cool to see one of these in a mk1, ive not heard of anyone doing a tdi engne in a mk1 before, keep us informed.

If you're serious about it, then a little research on the Caddy forum could pay off because a couple of guys over there have successfully done this conversion. I guess the reason its hardly ever done, is that diesels tend to be lower-revving and thus produce more torque for the same power output (or looking at it another way, less power for the same torque as a petrol motor). This becomes more useful, the heavier the car - but of course the Golf is good because it is light.

I would have loved to do this swap instead of my 1.6 IDI turbo diesel, but I just didn't have the time or the money, its certainly on the cards at somepoint 8)

I'd imagine the ideal model to start with would be a diesel :wink: but probably not that much hassle with other models…

and as has been said it would be a good idea to get a whole donor car, or at least as much stuff as you possibly can just to make it easier.

there is an awesome thread over on vwvortex which is well worth a read here:
http://forums.vwvortex.com/zerothread?id=778864

and a couple of other good forums to check out are:
http://www.vwdiesel.net/phpBB/

and
http://www.tdiclub.com/

but basically, hell yeah do it! then you can tell me all about it when I get round to doing it :mrgreen:

I am dropping a 1.9TD into my mk1 golf as we speak,i opted for the L reg mk3 golf as its the last one with no ECU just a good old accelerator cable  :roll: i wanted to convert it in 8 hrs not 8 weeks so i went for the AAZ engine.I have put the mk2 GTD turbo on it,its a garrett T3 which is better than the tiny k03 that was on it.
My mk1 already has a mk3 TD box in it so its half there :wink:  
The AAZ is 75HP standard,it now has no cat  8)  no p/s,and a bigger turbo and it will be intercooled and its going into a car that weighs a lot less,im hoping for about 90Hp when the pump is set up and the boost is tweaked,the 1.9 TD has a metal head gasket so it takes more stick.I am using the 1.6 alternator/V belt set up as the serpentine belt set up tends to vibrate too much and can cause the crank pulley to leave the building  :?  so im keeping it simple,65A is plenty for a mk1 with basic electrics,the mk1 came standard with a 45A alternator.The clutch is a 210MM so its up to the job,the swap is quite easy,the mountings off a mk1 diesel need to be bolted to the mk3 lump,by the cambelt,im not shy to mechanicing as i do it every day but the tdi is a more complex job,and the donor cars were too expensive.
Bert

there is a guy called simon cooper who has done a few of these conversions into a mk1 had it pushing low 12s, he also had a mk2 golf in white with a tdi lump in it that was around 5 secs to 60 and 13 1/4

think he is currently putting a new  2l 16v tdi into a mk1 golf

Bert,

Have you modded the crank on the 1.9?

Worth doing unless you want varible valve timing  :wink:

Cheeseman,the car i brought had a new vw exchange engine fitted and a brand new fuel pump i paid 300 for the car which was cheap,when the engine was out i stripped it to clean/paint it and renew all oil seals,i was going to replace the old pulley for a new one and a new bolt and keep fingers crossed it didnt come loose or slip,when i took the pulley off i found the later TDI crank had been fitted with the later pulley so im tempted to keep the multi rib belt and 70A alternator on it,i am putting a new crank bolt in when the seals are done  :wink:
How is yours coming on? is it on the road yet? what intercooler do you recommend too?
Bert

do you have any pics of your progress so far

g40 if your talking to me  :dontknow:  i will take photos of the finished lump and photos when its going in etc.
Bert

ok cool.

cheers bert

How is yours coming on? is it on the road yet? what intercooler do you recommend too?

Coming on good.

2.5 inch stainless dowpipe fitted
Intercooler pipes finished
Needs a pipe for expansion tank to rad fitting and that's the engine bay sorted.

Still have to fab an exhaust system and fit all the interior - been wiring alarm, central locking, electric windows and ICE in.  8)

Drove it up the road a few times, seems pretty eager!

keep up the good work lads :mrgreen:  I was just telling bert mines been on the road now for just over a year and is going strong - I think you'll both be very happy 8)

my advice on intercooler would be if you're going to be modding it at all to get pretty much the biggest one you can sensibly fit in the front - get on ebay and have a look at what sort of things are available - keep your tape measure handy too :wink:


good luck guys

I bought a new 06 focus TDCI intercooler for less than ?30 from ebay.

Fits a treat - photos soon.

We must meet up to compare cars  :wink: show these GTI lovers what diesels can do  :twisted:
cheeseman pics would be nice  8)
cheers lads
Bert

Bert said

We must meet up to compare cars  :wink: show these GTI lovers what diesels can do  :twisted:
cheeseman pics would be nice  8)
cheers lads
Bert

Sounds like a great idea - maybe a sprint track at next year's annual meet - GTI vs GTD!

I will smoke you out in sweet smelling cooking oil fumes  :wink:
Bert

Bert said

I will smoke you out in sweet smelling cooking oil fumes  :wink:
Bert

I will smoke you out with tyre smoke and good old 99 octane!