1996/7' VW GOLF mk III, Project / conversion, Need HELP.

[DieselMonkey]

Guys, im new to this forum. I viewed regularly but didnt have any need to post until now.... anyway, my winter project (i know, long time off), will be turbocharging and intercooling a 1.9D Mk3 Golf. Its a 1997 model with quite a bit of electronic equipment on the fuel injection pump. At the minute i am collecting the needed parts.

The 1.9D and 1.9TD are very similar units, same compression ratio etc... and after asking a local turbocharging specialist, 'TB' Turbo's, lancaster, Eng. They said its perfectly fine to turbocharge any VW Diesel after 1995, as the bottom end was strong enough to take it. They hadnt carried out the job on a Golf, but had done so, on many of the 'Caddy' vans, which is the same engine (1Y).

Currently i have an inlet manifold, exhaust manifold and KKK K03 turbo from an engine of the same year, and in the mail is the correct Bosch fuel injection pump that ran with this setup from the factory. An intercooler will also be fitted.

My question is, can anyone see any problem in changing the injection pump, in relation to the electronic side of things. The immobiliser unit can be simply changed from my pump to this one but there are at least 4 other wires. Are these direct replacments ?

Also, are the fuel injectors for the AAZ engine (1.9TD IDI), 2 stage ? the Haynes manual says they are but i think its wrong. I thought that was only a feature of the TDi engine.

And lastly, can anyone see any serious problems with my project ? After asking many experts, they all think the absence of under piston cooling wont be a problem as i am using a front mounted intercooler (large as possible) and only run fully syn. oil. Again, TB turbo havent had any problems in VW conversions, there price is £2500 ! I have collected all my parts (except intercooler) for under £250, although the turbo will be stripped and re-built at the cost of £280 just to be sure.

Any help is much appreciated. Thanks, DM.

[fspGTD]

Guys, im new to this forum. I viewed regularly but didnt have any need to post until now.... anyway, my winter project (i know, long time off), will be turbocharging and intercooling a 1.9D Mk3 Golf. Its a 1997 model with quite a bit of electronic equipment on the fuel injection pump. At the minute i am collecting the needed parts. The 1.9D and 1.9TD are very similar units, same compression ratio etc... and after asking a local turbocharging specialist, 'TB' Turbo's, lancaster, Eng. They said its perfectly fine to turbocharge any VW Diesel after 1995, as the bottom end was strong enough to take it. They hadnt carried out the job on a Golf, but had done so, on many of the 'Caddy' vans, which is the same engine (1Y).

Currently i have an inlet manifold, exhaust manifold and KKK K03 turbo from an engine of the same year, and in the mail is the correct Bosch fuel injection pump that ran with this setup from the factory. An intercooler will also be fitted.

My question is, can anyone see any problem in changing the injection pump, in relation to the electronic side of things. The immobiliser unit can be simply changed from my pump to this one but there are at least 4 other wires. Are these direct replacments ?

Also, are the fuel injectors for the AAZ engine (1.9TD IDI), 2 stage ? the Haynes manual says they are but i think its wrong. I thought that was only a feature of the TDi engine.

And lastly, can anyone see any serious problems with my project ? After asking many experts, they all think the absence of under piston cooling wont be a problem as i am using a front mounted intercooler (large as possible) and only run fully syn. oil. Again, TB turbo havent had any problems in VW conversions, there price is £2500 ! I have collected all my parts (except intercooler) for under £250, although the turbo will be stripped and re-built at the cost of £280 just to be sure.

Any help is much appreciated. Thanks, DM.

Welcome to the board!  I doubt you'll have a problem without the piston-cooling oil jets.  Just don't push the thermal limit to the max and you'll probably be fine.  Especially with a big exhaust and an intercooler.

I can answer your question about the 1.9lTD injectors.  There are 2 versions, depending on if the donor engine was equipped with a catalytic converter or not.  The Passats vs the Golf/Jetta 1.9lTDs were apparently different in this regard.  One version of the 1.9lTD injectors are indeed 2-stage.  They are deeper and fatter than a standard injector.  I've got some fuzzy pictures of them that might help give you an idea of what they look like:

[HughF]

Nice to see someone else in the Uk, good luck with the project...

Hugh
Dorset

[fspGTD]

Another thought: you might want to run a turbo from a 1.6lTD rather than from a 1.9lTD.  Reason is comparing EGT numbers of "well fueled" 1.6lTDs vs 1.9lTD, the 1.6lTDs run cooler and I believe it's because it's got a less-restrictive turbine section.  By doing this, you will sacrifice peaking your torque at a higher RPM, but you will also see lower exhaust gas temperatures and also you will gan a little better high-RPM power.  This could be an important consideration for you if you are turbo-ing a block without the oil-squirters.  Good luck!

[DieselMonkey ;)]

Guys,

OK, well i'm not sure about the injectors.

The guy im getting the pump from is selling me a set that were fire damaged, e.g, the engine went on fire and hes selling them to me so i can possibly have them service exhanged. But a few more questions - does it matter about which type of injector is mated to which pump ? - do the 2 stage injectors have a different pump setup ?

Anyway, hes giving them to me cheap... is there anyway i can change the internals of my original injectors or any suggestions of what i can do with my injectors ? Will there be a big difference in performance if i leave my originals in place ?

I'm fitting an EGT gauge just to be sure.

Any more comments much appreciated. Thanks. DM

[fspGTD]

I can say that the delivery valves (also referred to as "unions" - the things that screw into the 4 injection pump outlets.) have different part numbers depending on which 1.9lTD injector is used.  I'm not sure what the differences are.  When it comes down to it, it will probably be quite easy to get it to run and even probably will work OK.  It may just not be optimized with mismatched components...

I am currently running the 1.9lTD 2-stage injectors on my '84 1.6lTD pump with early (1.5/1.6D/TD) style unions, for example!   :?  (I would LOVE to get my hands on a set of 1.9lTD 2-stage unions, to try out...)

[DieselMonkey ;)]

Thanks so far for the help.

Few more things, will injectors that crack off at higher pressure be critical to making a lot more power, i.e, using my original ones.

Do you have any idea what the electric parts are going to be like to change ?

Also, the lines that run to the boost sensitive pump device, i have seen some use 2 pipes, and some use only 1 pipe. Of course there is always one connected to the inlet manifold, but i was wondering if the same sized outlet on the back of the wastegate actuator has any role here ? If not, whats this for ?

And lastly, what about pump timing ? I have a list of the VW specified values, but since this is a conversion, can i go by these ? Even though the comression ratios are the same between the D and TD, the TD's con rods are shorter by maybe 2 - 4 mm or so, i DO have the correct size somewhere, but not at hand. What will this mean for my project ?

Thanks again for all the help. DM

[OM617]

I can answer your question about the 1.9lTD injectors.  There are 2 versions, depending on if the donor engine was equipped with a catalytic converter or not.  The Passats vs the Golf/Jetta 1.9lTDs were apparently different in this regard.  One version of the 1.9lTD injectors are indeed 2-stage.  They are deeper and fatter than a standard injector.  I've got some fuzzy pictures of them that might help give you an idea of what they look like:

What is different besides the obvious larger body size? Is that to accommodate the 2-stage springs?

[subsonic]

Also interested in difference.

[dogday]

Anyone know how this project turned out?

DD