Malone's MK3 TDI

[malone]

You probably remember my '97 Golf CL with the early 1.6/1.9TD Frankenmotor: Part 1 and Part 2. The engine died due to v-belt slippage on the water pump. The engine was eventually sold to Dave aka 935racer aka Passenger Performance, who dynoed 192whp with a bigger turbo. I bought a 2006 Jetta TDI DSG and it bores the heck out of me (my wife also took possession of it).

I still think of picking up another IDI, but I'm an ECU tuner, TDI donors are becoming cheaper, TDIs tend to get better fuel economy, and they support more low-RPM torque out of the box, so I decided to go that route for my new daily driver.

I picked up a '96 Golf CL and a '98 Jetta TDI donor car.

Progress:

• Perform intake cleaning
• Perform TDI timing belt job
• Install performance camshaft
• Install 400ft-lb torque clutch
• Install TDI engine + transmission in Golf
• Install 5 lug 11.3" VR6 brake parts with all new suspension bearings
• Install TDI pedal cluster in Golf
• Install telescoping steering column in Golf
• Install TDI wiring harness in Golf - almost complete. JS Performance takeover at this point
• Hook up coolant system and V belts
• Install cruise control in Golf
• Install heated seats in Golf
• Install coilovers
• Make a high MPG / performance switchable-on-the-fly tune.
• Completely re-do interior
• Full body work + repaint

Pulling the 1.8L 8v 90HP gas motor from the Golf:



Pulling the 1.9L 8v 90HP AHU TDI from the Jetta:



Cleaned out this intake gunk:


My friend helping pull the dashboard. We removed the dash+rebar from both vehicles. The Golf's rebar was literally dripping with rust while the Jetta's was rust-free (factory painted).


The joy of wiring (as I progressed into it I learned that it's not really difficult, just time-consuming):


Due to my upcoming 2 weeks absence, I'm leaving the rest of the conversion to JS Performance:

[theman53]

Good work. Can't wait to see what you do with the tune.

[catlin_cava]

Your my Hero! Ive always wanted to do a AHU into a MK3 2 door. Cant wait to see it done!

[malone]

Thanks guys. I'm thinking of trying a supercharger, but that's for way later (possibly at least a year).

Pros:

• Easy to install (replaces the A/C compressor) with short IC plumbing. A "250HP" supercharger that I have in mind is more compact than the A/C compressor
• Instant throttle response with virtually no boost lag
• Apparently no other TDI owner has tried supercharging yet

Cons:

• Less efficient than a turbo
• Fuel economy may be in a world of hurt

A clutched supercharger will reduce the MPG hit, however, and I won't mind daily driving NA if I want to conserve fuel. Twin-charging using stock turbo + big supercharger is another possibility and still easy to setup.

Anyway I'll post updated pictures in a couple weeks or so.

[RadoTD]

A "250HP" supercharger that I have in mind is more compact than the A/C compressor

Hmmm... what supercharger would that be? Lysholm possibly? I've always liked the idea of adding a supercharger in my engine bay somewhere 

[nathan_b]

I bet a k03 would just spin off somewhere and take off into space if you double-charged it lol.

1-Here is the end all ahu setup,
2-having your ecu modded to control vnt
3-install vnt

4-be a boss

5-???

6-profit?

 
sorry too much time on vortex.

I would try a supercharger, here is a trick, if you block the vac line to the map sensor, you can do a looot of stuff without going into limp mode.. not sure how you would control fueling based on boost, but it would sound SICCKK, and you could put a cool exhaust on it instead of the played straightpipe.

Just food for thought.

[malone]

Hmmm... what supercharger would that be? Lysholm possibly? I've always liked the idea of adding a supercharger in my engine bay somewhere 

I can't disclose the supercharger yet. It's an agreement that I have with a shop who's helping with the project. I hate withholding information, but it will be revealed if it's installed in my car. I can however tell you that it's not a Lysholm, which is a bit too large physically and too noisy.

I might tune a 2001 MK4 Golf TDI with an Eaton supercharger. Here's a picture of his exhaust that's already installed:



He definitely needed the muffler as his car is way too loud without it.

[malone]

install vnt

I already have a custom rear engine mount that will allow room for a standard VNT layout, just in case I go that route. VNT is good, but everyone including their mother and their dog have already done a VNT conversion. I tuned one TDI with THREE VNT turbos.

I will eventually decide between a GTB1749VB (cheap, simple to install, and still strong - highly recommended for a budget daily driver), a GTB1756VK (faster spool, more power overall, but it's either much more expensive or time-consuming to setup), or supercharger (unique, potentially instant throttle response, cool noise, but the charger that I'm considering is very expensive).

I don't want to push more than 24 PSI boost with the stock 300,000 km AHU engine, so whatever I do, I'm going to take it easy until I'm ready to drop in a fresh ALH TDI engine that can handle more boost and more torque.

I would try a supercharger, here is a trick, if you block the vac line to the map sensor, you can do a looot of stuff without going into limp mode.. not sure how you would control fueling based on boost, but it would sound SICCKK

I will keep the MAP sensor and I will experiment with MAF delete. Either the MAP or MAF values will determine how much fuel to inject, pretty simple. I will also either modify my boost control map to reflect the supercharger's boost ouput based on RPM (that's one way to keep the ECU happy), or disable the 'negative boost deviation' code/limp and simply set the boost control map to whatever max. boost I'll allow. Easy workaround. Another way is to spend time completely re-writing the ECU and remove all N75 control (it's pretty well entrenched in the stock software), but that won't make a better running engine.

[nathan_b]

Malone,

I'd pay $500 for a seminar where you thoroughly explained how to modify ecu's in the manner. (know how to immo delete?? lol)

You are beyond me for now.

[malone]

Last night someone smashed the Golf's driver side window and stole the turbo & downpipe. First time I've experienced a break-in. I posted this project in a local VW forum 2 days ago and I wonder if someone there decided that he needed my parts.

The turbo and downpipe had 300,000km on them so I'm not too bothered. It gives me an excuse to get newer ones. I also bought an identical MK3 Golf parts car for $250 (with Hella MK4-look headlights!) so I can replace the glass or door with minor inconvenience.

My Golf was parked outside and it's my fault for not properly securing all the parts. JSP was kind enough to offer a replacement turbo. I'm exploring various boost options right now.

[BigVWman]

That is pretty crappy 300k or not, i have to say if you ever catch them i hope you extract some justice! keep eye on local cl and ebay!

[rallydiesel]

People who steal stuff need to have their hands cut off.

Anywho, nice build except for the mk3 part. 

[RadoTD]

Maybe I should post a wanted ad on Dubberz and see if anyone in the abbotsford area has a turbo and downpipe to sell

[catlin_cava]

Maybe I should post a wanted ad on Dubberz and see if anyone in the abbotsford area has a turbo and downpipe to sell

Do It!!!! Then have some VWDiesel Justice

and That really sucks about the break in, I had my TDI broken into last week, they didn';t have time to take anything before I came flying out of the house

[keaton]

cool, so how much are you selling for?