Philips Mk1 Jetta 1.9 TDI PD130 Project
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Philips Mk1 Jetta 1.9 TDI PD Project






It's surprisingly a good fit, so needs a few more things installed before I carpet up everything lol all in time 😉
List of past and present cars ive owned
1997 corsa 1.2 poop
2003 Ibiza 130 tdi hybrided to 240bhp
1991 Mk 2 jetta calypso green 1.6td
2001 MG ZT 190+ v6 in trophy blue…. Sold to my brother
2003 Golf GTI TDI 150 black leather heated recaros
the
1997 corsa 1.2 poop
2003 Ibiza 130 tdi hybrided to 240bhp
1991 Mk 2 jetta calypso green 1.6td
2001 MG ZT 190+ v6 in trophy blue…. Sold to my brother
2003 Golf GTI TDI 150 black leather heated recaros

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What wheels you going for?
Here's mine! 😊
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Decided to finish off the boot build and haven't I been busy lol
After 4 years of searching for a perfect mint new old stock rear bumper I finally found one and after 2 months of negotiation using google translator I finally had this sent over from Germany, anyway that's the boot almost finished










List of past and present cars ive owned
1997 corsa 1.2 poop
2003 Ibiza 130 tdi hybrided to 240bhp
1991 Mk 2 jetta calypso green 1.6td
2001 MG ZT 190+ v6 in trophy blue…. Sold to my brother
2003 Golf GTI TDI 150 black leather heated recaros
the
1997 corsa 1.2 poop
2003 Ibiza 130 tdi hybrided to 240bhp
1991 Mk 2 jetta calypso green 1.6td
2001 MG ZT 190+ v6 in trophy blue…. Sold to my brother
2003 Golf GTI TDI 150 black leather heated recaros

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Willcrook8 said
How have I only just found this! awesome work mate! Perfect engine, that's what is going in mine over winter!
What wheels you going for?
Here's mine! 😊
I'm going for the standard 15 inch pepper pots from an A3, they are fitted on some previous pictures
List of past and present cars ive owned
1997 corsa 1.2 poop
2003 Ibiza 130 tdi hybrided to 240bhp
1991 Mk 2 jetta calypso green 1.6td
2001 MG ZT 190+ v6 in trophy blue…. Sold to my brother
2003 Golf GTI TDI 150 black leather heated recaros
the
1997 corsa 1.2 poop
2003 Ibiza 130 tdi hybrided to 240bhp
1991 Mk 2 jetta calypso green 1.6td
2001 MG ZT 190+ v6 in trophy blue…. Sold to my brother
2003 Golf GTI TDI 150 black leather heated recaros

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Also managed to get the passengers door back, fitted and now with working latches, Windows and seals fitted
List of past and present cars ive owned
1997 corsa 1.2 poop
2003 Ibiza 130 tdi hybrided to 240bhp
1991 Mk 2 jetta calypso green 1.6td
2001 MG ZT 190+ v6 in trophy blue…. Sold to my brother
2003 Golf GTI TDI 150 black leather heated recaros
the
1997 corsa 1.2 poop
2003 Ibiza 130 tdi hybrided to 240bhp
1991 Mk 2 jetta calypso green 1.6td
2001 MG ZT 190+ v6 in trophy blue…. Sold to my brother
2003 Golf GTI TDI 150 black leather heated recaros

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I finished off wrapping a pair of orginal chassis leg cover trims to tidy it up mores and trial fitted! Nearly there 😉
List of past and present cars ive owned
1997 corsa 1.2 poop
2003 Ibiza 130 tdi hybrided to 240bhp
1991 Mk 2 jetta calypso green 1.6td
2001 MG ZT 190+ v6 in trophy blue…. Sold to my brother
2003 Golf GTI TDI 150 black leather heated recaros
the
1997 corsa 1.2 poop
2003 Ibiza 130 tdi hybrided to 240bhp
1991 Mk 2 jetta calypso green 1.6td
2001 MG ZT 190+ v6 in trophy blue…. Sold to my brother
2003 Golf GTI TDI 150 black leather heated recaros

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Just going to jack the post with mine! 😂

Keep it up dude!!
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Willcrook8 said
Need more updates!!!
Just going to jack the post with mine! 😂
![]()
Keep it up dude!!
I know I need to get more photos when things happen!!! Which they have been, I've decided to go back to the orginal dash and blower motor unit because quite simply the modern dash just doesn't suit the car at all, I've bought a donor car which as you can see is being broke for every single part so not only do I now have spares (including a beautiful spare front and rear window with both seals) but now have any trim or wiring loom including some rarer parts ;-)
I got some welding done to the firewall to bring it back to standard so going to seam seal it tomorrow and paint the firewall black!
I've got some things for sale if anyone wants to check the breaking section also.
List of past and present cars ive owned
1997 corsa 1.2 poop
2003 Ibiza 130 tdi hybrided to 240bhp
1991 Mk 2 jetta calypso green 1.6td
2001 MG ZT 190+ v6 in trophy blue…. Sold to my brother
2003 Golf GTI TDI 150 black leather heated recaros
the
1997 corsa 1.2 poop
2003 Ibiza 130 tdi hybrided to 240bhp
1991 Mk 2 jetta calypso green 1.6td
2001 MG ZT 190+ v6 in trophy blue…. Sold to my brother
2003 Golf GTI TDI 150 black leather heated recaros

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😜😉
List of past and present cars ive owned
1997 corsa 1.2 poop
2003 Ibiza 130 tdi hybrided to 240bhp
1991 Mk 2 jetta calypso green 1.6td
2001 MG ZT 190+ v6 in trophy blue…. Sold to my brother
2003 Golf GTI TDI 150 black leather heated recaros
the
1997 corsa 1.2 poop
2003 Ibiza 130 tdi hybrided to 240bhp
1991 Mk 2 jetta calypso green 1.6td
2001 MG ZT 190+ v6 in trophy blue…. Sold to my brother
2003 Golf GTI TDI 150 black leather heated recaros

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List of past and present cars ive owned
1997 corsa 1.2 poop
2003 Ibiza 130 tdi hybrided to 240bhp
1991 Mk 2 jetta calypso green 1.6td
2001 MG ZT 190+ v6 in trophy blue…. Sold to my brother
2003 Golf GTI TDI 150 black leather heated recaros
the
1997 corsa 1.2 poop
2003 Ibiza 130 tdi hybrided to 240bhp
1991 Mk 2 jetta calypso green 1.6td
2001 MG ZT 190+ v6 in trophy blue…. Sold to my brother
2003 Golf GTI TDI 150 black leather heated recaros

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Finally fitted ☺️🤗😆
List of past and present cars ive owned
1997 corsa 1.2 poop
2003 Ibiza 130 tdi hybrided to 240bhp
1991 Mk 2 jetta calypso green 1.6td
2001 MG ZT 190+ v6 in trophy blue…. Sold to my brother
2003 Golf GTI TDI 150 black leather heated recaros
the
1997 corsa 1.2 poop
2003 Ibiza 130 tdi hybrided to 240bhp
1991 Mk 2 jetta calypso green 1.6td
2001 MG ZT 190+ v6 in trophy blue…. Sold to my brother
2003 Golf GTI TDI 150 black leather heated recaros

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And getting the firewall cleaned down / prepped of resin that was going to originally grip the rubber lining

List of past and present cars ive owned
1997 corsa 1.2 poop
2003 Ibiza 130 tdi hybrided to 240bhp
1991 Mk 2 jetta calypso green 1.6td
2001 MG ZT 190+ v6 in trophy blue…. Sold to my brother
2003 Golf GTI TDI 150 black leather heated recaros
the
1997 corsa 1.2 poop
2003 Ibiza 130 tdi hybrided to 240bhp
1991 Mk 2 jetta calypso green 1.6td
2001 MG ZT 190+ v6 in trophy blue…. Sold to my brother
2003 Golf GTI TDI 150 black leather heated recaros

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I'll get more updates posted asap
Last edit: by PhilipMcTDI
List of past and present cars ive owned
1997 corsa 1.2 poop
2003 Ibiza 130 tdi hybrided to 240bhp
1991 Mk 2 jetta calypso green 1.6td
2001 MG ZT 190+ v6 in trophy blue…. Sold to my brother
2003 Golf GTI TDI 150 black leather heated recaros
the
1997 corsa 1.2 poop
2003 Ibiza 130 tdi hybrided to 240bhp
1991 Mk 2 jetta calypso green 1.6td
2001 MG ZT 190+ v6 in trophy blue…. Sold to my brother
2003 Golf GTI TDI 150 black leather heated recaros

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Finally I'm getting some really good vibes about the project after much debate of what the heck I was going to do with it… it's been 5 years since I started 😞
List of past and present cars ive owned
1997 corsa 1.2 poop
2003 Ibiza 130 tdi hybrided to 240bhp
1991 Mk 2 jetta calypso green 1.6td
2001 MG ZT 190+ v6 in trophy blue…. Sold to my brother
2003 Golf GTI TDI 150 black leather heated recaros
the
1997 corsa 1.2 poop
2003 Ibiza 130 tdi hybrided to 240bhp
1991 Mk 2 jetta calypso green 1.6td
2001 MG ZT 190+ v6 in trophy blue…. Sold to my brother
2003 Golf GTI TDI 150 black leather heated recaros

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I'll be honestly saying that it's been a relief getting this part finally

List of past and present cars ive owned
1997 corsa 1.2 poop
2003 Ibiza 130 tdi hybrided to 240bhp
1991 Mk 2 jetta calypso green 1.6td
2001 MG ZT 190+ v6 in trophy blue…. Sold to my brother
2003 Golf GTI TDI 150 black leather heated recaros
the
1997 corsa 1.2 poop
2003 Ibiza 130 tdi hybrided to 240bhp
1991 Mk 2 jetta calypso green 1.6td
2001 MG ZT 190+ v6 in trophy blue…. Sold to my brother
2003 Golf GTI TDI 150 black leather heated recaros

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Finally on… what do you's think of them welds
Also refitted the gearbox and inlet manifold was cleaned and now has been installed with a new gasket
List of past and present cars ive owned
1997 corsa 1.2 poop
2003 Ibiza 130 tdi hybrided to 240bhp
1991 Mk 2 jetta calypso green 1.6td
2001 MG ZT 190+ v6 in trophy blue…. Sold to my brother
2003 Golf GTI TDI 150 black leather heated recaros
the
1997 corsa 1.2 poop
2003 Ibiza 130 tdi hybrided to 240bhp
1991 Mk 2 jetta calypso green 1.6td
2001 MG ZT 190+ v6 in trophy blue…. Sold to my brother
2003 Golf GTI TDI 150 black leather heated recaros

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Finally got the gaskets needed so whipped this bad boy on
List of past and present cars ive owned
1997 corsa 1.2 poop
2003 Ibiza 130 tdi hybrided to 240bhp
1991 Mk 2 jetta calypso green 1.6td
2001 MG ZT 190+ v6 in trophy blue…. Sold to my brother
2003 Golf GTI TDI 150 black leather heated recaros
the
1997 corsa 1.2 poop
2003 Ibiza 130 tdi hybrided to 240bhp
1991 Mk 2 jetta calypso green 1.6td
2001 MG ZT 190+ v6 in trophy blue…. Sold to my brother
2003 Golf GTI TDI 150 black leather heated recaros

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The process took maybe 2 hours with a lot of careful cleaning with a friend helping, it was finally done, not to much signs that the old gasket was going to fail but since I was going to fit the upgraded headbolts, then this was the best time to do it all in one go





Tightening the head was simple enough, it's done in 4 stages.
First off is the pattern that the bolts are tightened
10 5 2 3 7
9 4 1 6 8
Is the method I used for the 10 long bolts that clamp the head down, this is done to evenly spread the gasket as its tightened
Tight is as follows
Stage 1) torque to 40NM
Stage 2) torque to 60NM in the same pattern
Stage 3) using a breaker bar, tighten the bolts 90 degrees
Stage 4) tighten a further 90 degrees
A useful tip if the engine isn't in the car is get a mate or two to hold the engine as best they can lol but yes there you go, that's the headgasket finished.
I'm going to fit the water flange, tandem pump and thermostat tomorrow. 😀
List of past and present cars ive owned
1997 corsa 1.2 poop
2003 Ibiza 130 tdi hybrided to 240bhp
1991 Mk 2 jetta calypso green 1.6td
2001 MG ZT 190+ v6 in trophy blue…. Sold to my brother
2003 Golf GTI TDI 150 black leather heated recaros
the
1997 corsa 1.2 poop
2003 Ibiza 130 tdi hybrided to 240bhp
1991 Mk 2 jetta calypso green 1.6td
2001 MG ZT 190+ v6 in trophy blue…. Sold to my brother
2003 Golf GTI TDI 150 black leather heated recaros

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Also the newmans camshaft finally arrived but I'll not be fitting it until the engine is started and running smooth as the first time it's started with the camshaft, it needs to be revved to 2000rpm for 15-20 minutes and I'd rather wait till I know factually that the engines sweet with no leaks etc before doing that

List of past and present cars ive owned
1997 corsa 1.2 poop
2003 Ibiza 130 tdi hybrided to 240bhp
1991 Mk 2 jetta calypso green 1.6td
2001 MG ZT 190+ v6 in trophy blue…. Sold to my brother
2003 Golf GTI TDI 150 black leather heated recaros
the
1997 corsa 1.2 poop
2003 Ibiza 130 tdi hybrided to 240bhp
1991 Mk 2 jetta calypso green 1.6td
2001 MG ZT 190+ v6 in trophy blue…. Sold to my brother
2003 Golf GTI TDI 150 black leather heated recaros

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