Mk2 4 door 1.9 tdi engine conversion

Discussion in 'Mk2' started by Adamss24, Jul 14, 2021.

  1. Adamss24 Forum Member

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    As per title I have a 1990 vw golf mk2 with a 1.9 tdi conversion, car started as a 2.0 gti then one of the previous owners did a full swap on in 2005 with gearbox, engine and wiring loom all from a low mileage vw golf mk3 tdi. I bought it about 6 months ago as a non runner, the PO stated it damaged an injector and as it was only running on 3 cyl. Anyway, car looked tidy enough in the pictures, a deal was struck and I went with my trailer to pick it up- on a heavy snow storm- it made driving interesting ! Took the head off to find a droppped valve on cyl 1 and head damaged beyond repair. A mate had a AHH long block so I used rods and pistons from that engine and rebuilt with twin valve springs, new stem seals and lapped in valves ! Started on the button !
    Drove it for a few weeks but power was lacking- injectors were some Opel dti spec from the part number of the nozzle, switched to some AFN injectors and still no power ! In the end I fitted a set of bosio race 520 nozzles into a fresh set of injectors just to discount the nozzles ! Ulterior I found a piece of valve stem lodged into the turbo which held the wastegate open thus no serious boost ! a new turbo was modified to fit which supplied enough torque to slip the vr6 clutch on the car ! Now I am just tidying the interior a little and need to sort out both cills as they need attention ! Car has lowered sport suspension TA Technix which is comfortable but a bit soft at the back. I sourced a set of rial mesh 3 piece split rims but they have a high offset and the tyre is rubbing on spring cups at the back !
     

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  2. Adamss24 Forum Member

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    And a few more…
     

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  3. Adamss24 Forum Member

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    Next on the cards is getting the turbo converted to vnt, still debating if to go edc15 or stay with Msa15 Ecu. I need to get a 3 bar map sensor but the sensor is inside the Ecu. Cheaper solution is to run additional wires and use an external sensor. Beauty with edc 15 is added Flexibility when writing maps, and quicker computing power- maps are crude in the older Ecu !
     
  4. Matt Golf Forum Member

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    Nice work
     
  5. Tristan

    Tristan Paid Member Paid Member

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    What sort of power are you expecting?
     
  6. Adamss24 Forum Member

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    Will shoot for 220-250 Bhp, i don’t think
    mk2 golf can put much more without drama, I am struggling with my other one to keep it on the road and that’s with a wider track, better brakes, slicks and better power train altogether…I have plenty spare turbos to try, from mundane gtb2056vl to ball bearing gtb2260vklr and a few hybrids all the way to a 79mm compressor and 2” turbine !
     
  7. Tristan

    Tristan Paid Member Paid Member

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    That's gonna be a quick machine.
     
  8. Adamss24 Forum Member

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    It is already ! Only boosting 1.6 bar with bosio race 520 and 11mm injection pump and can slip the vr6 clutch !
     
  9. davidut5 Forum Member

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    I converted a 1z msa to edc, only had the edc plugs with some wires. It was not very hard, the edc likes each wire to ecu and msa has more grounds and live's together, these need sorting. Still is a 1z with a 11mm mk4 pump from an auto box and mk4 edc ecu and big turbo from a CASA 3.0tdi converted to vacuum actuator.
     
  10. Adamss24 Forum Member

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    Sounds like a very interesting proiect your car ?!!
     
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  11. Adamss24 Forum Member

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    Got the new coilover kit yesterday, will try and fit them on the car when I have a few hours of quiet !
     

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  12. Adamss24 Forum Member

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    Suspension and wheels fitted…goes well and handles good !
     

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  13. Adamss24 Forum Member

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    Wheels are a bit marmite, you either love it or hate it !
     

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  14. Adamss24 Forum Member

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    Found another set of these wheels in 16” in Zagreb, the owner is asking for 1700 euro…would love to own them but they are priced a bit too steep !
     

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  15. Adamss24 Forum Member

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    Not much happening lately, I took the body kit off to reveal rust on both cills and a rear wheel arch, why Vw thought that having plastic arches is a good idea ? Anyway the car is sitting sorry for itself, it’s parked at the back of my garage waiting for it’s turn to get in !!
    So far the wooden steering wheel has gone (fitted a Votex jobbie out of a ur Quattro) and I will replace soon the mk3 dash pod with a digifiz I sourced last year, working on the loom as I mentioned in my other posts !
    Unfortunately I broke my mobile phone a few times and lost many, many pictures, will update the thread as I go along !
    Preparing the big turbo for my race mk2, that needs some welding doing as well-nothing major !
     
  16. Adamss24 Forum Member

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    The bodywork is not on the golf as never took pictures but you get the idea ! 4E86E51E-D052-403B-ADBE-972E36094726.png 849A6897-9FF8-4AFF-ABE1-FAAE5E795248.jpeg D2A13C1B-6091-48F9-B5A8-8D5B1B66603C.jpeg 3DB00F4D-80B2-4833-9931-3A2FF08B2372.jpeg BD2FA5A1-84B3-411B-9688-D012D404F58E.jpeg 849B77F1-B7AE-4913-A9B0-878BFBE9D345.jpeg 962380CA-F124-451E-A131-F07B0CA96696.jpeg 7A707F1B-4310-4A0A-8C87-8BE2DAD7C64C.jpeg 0152B91A-8536-4B86-A59A-A5902E5787E4.jpeg
     
  17. Adamss24 Forum Member

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    Also pictures of the new turbo for my other car… 386BEC38-303F-40DA-8151-6D41ED4A3A26.jpeg 3AB7FCC1-A3B2-41C1-8F41-BAB3C530BDC4.jpeg A20B8472-E2EA-4B74-B2F5-CD0C5D2228D1.jpeg B06CCC2C-1EEF-4001-A7F1-780AFB0999F5.jpeg 568FDF2C-02B1-401D-827A-C82D207A1DB9.jpeg
     

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  18. davidut5 Forum Member

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    Nice to do mods, but what happens when you get pulled over in traffic and get your car MOT/RAR, and different engine, wheels, suspension, exhaust system etc.
    The red jetta with tdi conversion got pulled over in Bucharest and no more papers (talon ridicat). My brother got it home on a tow truck, now its sitting in the backyard for a few months. Lots of stuff to get it back to original for mot/RAR!
     
  19. Adamss24 Forum Member

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    I have the same issues, the rar is so fricking mean, they look at everything: wheels, tints, etc. it’s harder and harder to get the ITP/MOT certificate as there’s pictures required and every modification made needs to be tuv approved…
     

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