MK4 engine conversion from TDI to GT TDI

**devonutopia** · 20-12-2007,03:11 PM

From someone who spent THOUSANDS converting his pd100 to pd130, please do not try and convert your 90 to PD without seriously looking into what needs changing. I reckon you will need the following:

PD engine, PD gearbox, PD driveshafts, PD subframe complete (possibly)
PD wiring looms - as in ALL the wiring looms, engine, engine bay and inside the car.
PD dashbod, ignition barrel and ignition keys. PD main ECU
PD fuel tank and fuel pump. PD MAF, and many other engine bay "gubbins" - fuel filter housing, eg

You really want to find an entire written off GT TDI which is still complete internally and gut out your 90 Golf, swapping every single little component out the GT TDI into your shell. Unless your really into your cars (like I am sadlly....) this is a waste of money and effort. I did it because I wanted a project. If you simply want an upgrade, sell your car, take a loan out or something, then buy the GT TDI as a whole car.

PD115 - well, with a hybrid turbo, PD130 nozzles, intercooler, some other bits, you can get up to 190bhp. But you're talking about spending £3000, and thats before thinking about safety mods like uprated clutch, powerful brakes. PD115 as standard maps up to about 150 tops.
PD130 engines map up to 180bhp as standard
PD150 engines map up to 190bhp+ as standard

**Dj_Ghost** · 20-12-2007,03:37 PM

I don't even know what to do now. My golf is 1998 (S -reg) which is not a PD. The reason why I want to put 115 BHP because i will not have to do all this upgrades, it will be a quick swap. The labor work for me it's free, so the only thing I'm paying for its the parts.

**bora(ing) nick** · 20-12-2007,03:41 PM

Originally Posted by Dj_Ghost

I don't even know what to do now. My golf is 1998 (S -reg) which is not a PD. The reason why I want to put 115 BHP because i will not have to do all this upgrades, it will be a quick swap. The labor work for me it's free, so the only thing I'm paying for its the parts.

Not the case.... no matter what engine swap you do,(apart from the VE-110) most engine swaps will have a similar amount of cost and labour involved.

If you want more power... i'd sell your golf and put the 2-3k into buying a PD130.

I think you'll be impressed with that little jump for the time being, and then when you get used to what you have again, get it remmapped to 180bhp.

That way, it's far cheaper, and more reliable IMHO

Nick

**ini** · 20-12-2007,03:42 PM

I would sell your existing car, and purchase one with a 130/150 PD engine.

It is the best way forward.

**Crasher** · 20-12-2007,03:58 PM

Dj, the 115 IS a PD engine.

**devonutopia** · 20-12-2007,11:59 PM

But the 115pd is not quite an tuneable without spending 3k or so.

the 130 saves you buying and fitting a new turbo and injectors.

Do not take offence to this, DJ ghost, but you come across as someone who knows little about TDIs mechanically & electronicsally, so I would personally strongly dissuade you from trying this conversion. Even with your own "free" labour it will not be a quick swap. You're talking about the entire transplant of one car into another shell - not just an engine swap, plug in and go. I spent months researching the parts I needed, had an excellent resource in the form of an owners forum, and vagcom, and an excellent mechanic friend. Even then though, it took 3 months whilst problems were found, researched, and overcome. Can you really be without your car for 3 months? Maybe more? Also, the expense....! I did it for personal fun, challenge, whatever - it does not sound like you are, so just sell up, and try to buy a pd130, or pd115 if future tuning/power is not much of a preference.

**Crasher** · 21-12-2007,12:15 AM

"Never build a car you can buy".

**Col** · 21-12-2007,12:22 AM

If i were ever to do it, I'd plonk a PD lump into a MK2.

That would be worth the effort.

**Crasher** · 21-12-2007,12:30 AM

I drove one a while back, nearly rattled my teeth out!

**Dj_Ghost** · 21-12-2007,01:12 AM

You guys really put me off of getting that 115 BHP engine. The reason why I dont want to sell my car and buy another one is because I have spend 9-10K on that car. Alloys, full body kit, tinted windows, alarm with remote engine start, sound system and all other things which adds up. If there a chance me getting 180 BHP after all the remap, putting exhaust, induction kit on 115 BHP I will be more than happy for the next 3 years.