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1.9 M-TDI Conversion

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53K views 50 replies 18 participants last post by  Antun Gtd  
#1 · (Edited)
2.0L M-TDI Conversion

Hello

it's me again following on from the 2.4D Turbo Conversion my friend requires a new engine in his Non Turbo 1.9 T4 T:

so i've been looking at the option and the it looks like rather than going down the TDI Route we might go for a M-TDI Build :D

http://forums.tdiclub.com/showthread.php?t=352117&page=2

AHU Engine with a ABL VE Injection set up with LDA = M-TDI :eek:

then it can be tweaked mechanically and not having to mess with remaps etc.

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Has anyone on here done the conversion already , a friend of a friend has a T25 Syncro with a M-TDI Conversion and get a nice 45mpg fully loaded.
 
S
#3 ·
hey Brookster

Check this out

http://www.vwt4forum.co.uk/showthread.php?t=215346

Huge contribution from Penbryn all but convinced me to forget this.

Biggest problems are injection presssures (ABL pump won't do), can be sorted with a hybrid pump or custom injectors (difficult to spec) and timing (trial & error i.e. long time) After all this still may not run well.

| am reliably informed that fitting a tdi is actually very simple and straightforward.

Just out of curiosity | was offered a running, low mile 1.9 td today and was wondering if it was worth just upgrading this? Bigger pump piston, better injectors, bigger exhaust, increased boost and an L200 IC should be good for 100+ bhp and very easy to do. Still IDI though.

Any thoughts?
 
#7 · (Edited)
#9 · (Edited)
It's all down to what you want from the end result , reliable power and fuel economy :D yes TDI & OEM Management all the way and the 60 TDI Conversion are great T:

if you want to go high boost and power then the options are more open and at the moment there is no DIY Engine Mangement for Diesels like there is for Pertol engine like i have on my Golf were i can Data Log and tweak the map within 10 minutes ;)

That's why the US Forums are full of 4 Pots running 150bhp @ 1.5bar with M-TDI Coversions & VNT Turbo's in their Caddy's & Rabbit's
 
#10 · (Edited)
my mates 1.9D 1X Non Turbo went bang last week so he needed a new engine and quick install

so he went for a 1.9TDI AFN (110BHP) Passat Engine didn't come with ECU OR LOOM so he is going M-TDI with the Landrover Bosch 300tdi Injection pump

AFN Engine code c/w Garrett GT15 Turbo

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we've had it running on the old 1X Injection pump just to test the engine which ran it but the old pump was 200k miles old and leaking all over .

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Landrover 300tdi M-TDI Injection pump
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injection pump bracket had to be opened up to 68mm to take the new pump

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P
#12 ·
Still can't get it running. Need that DTI adapter so i can see what's going on in the pump. Not convinced the pulley locking pin has any relation to the timing any more. Might just have to feel for start of injection with a spanner on the sprocket.

I agree totally it's the way to go. The ecu doesn't really do a great deal more than the LDA does. Far more scope for DIY tuning with an MTDI.
 
G
#19 ·
Yay, someone else who is walking the M-TDI line. I did out of necessity.

I have a AFN, with a slightly tweaked ABL pump. Using the AFN injectors and inlet manifold with the ABL turbo. I finally have it running but haven't taken it out yet as it needs a few bits for the MOT.

First time running the pump leaked like Niagara falls, however, my very friendly diesel specialist did his magic and replaced the main shaft seals. Turns outwoutwhen they dry out, they tend to leak. I was a bit worried that the pump just wasn't going to hack it.

I just swapped the pump bracket over and cut the rear upper cambelt cover to fit.
 
A
#26 ·
Hello,

really sorry no, but it was very simple - like I say it was total luck rather than anything else.

I replaced the vacuum actuator on the VNT15 with a wastegate actuator from something like a GT15, then modded the actuator arm of the VNT turbo to almost full vacuum - this max boost initially. I took a t from the boost gauge line and ran it to the actuator. This meant than as the boost increased the vanes were opened slightly reducing boost. This regulated the boost quite well and didn't seem to have any horrific spikes. I'm afraid I can't remember what I did for the LDA, but I can't imagine the boost control for the pump would be any different- this wasn't my van - I was just helping a friend up north a while back.

I can't claim to have anything scientific knowledge about this - its efficacy depends on the actuator spring strength (maybe you also need a boost bleed to the actuator) - I think as a rough test it seemed to work out ok and crucially not overboost too much.
 
F
#32 ·
Why are people changing pumps and making things complicated. There is nothing wrong with the bosche ve type pump. It is more than capable of delivering enough fuel for 130 plus bhp on a 1.9td abl all you need to do is up the fueling, boost, fit an intercooler and upgrade the injectors.

Talk to the guys at project power to find out how easy it is.

M-TDI pump is a waste of time on an indirect injection engine on a TD the injectors fire into a swirl chamber. A TD is a Turbo Deisel. TDI is a Turbo Direct Injection. Blame misleading marketing hype. After all it would not be cool to have TDIDI on the back of your van to anounce your engine inferiority to the world.
 
#34 ·
YOU NEED TO READ THE THREAD FIXITAGAIN :eek:

This is nothing to do with IDI Engines I:

The thread is all about fitting a TDI Engine without using an ECU and all the ancilliary sensors etc .

Mechanical VE Pump running a TDI Engine T:


As for PP3 Injectors you need to look at my other build thread ;)
 
P
#33 ·
The old 1.9D pump struggles to generate the pressures required to open the TDI injectors and you have to advance the pump a lot to get it to even run. You can pump a TDI pump head on it but there's no point as it still has as smaller shaft.

The land rover pump is still a bosch Ve, but has the correct head and bigger shaft.

The whole point of it is that it's all mechanical, no ecu or wiring. It also has a load compensator (LDA) for adding fuelling under boost.

Far less hassle and expense and all the parts are readily available used. Can be done for £500. A decent remap costs £300.....
 
P
#36 ·
We had to advance it a whole tooth to even get it to run.

Didn't get it set up because the pump was leaking due to the higher pressure so had to chuck it and bought the landy 300 one.

Because of the higher break pressure of the TDI injectors the start of injection has to be much earlier to give enough time for the pressure to build. But as stated above it isn't recommended as the 1.9D pump has a mcuh smaller main shaft. It's not really up to the job.
 
#38 · (Edited)
Update -

Now have a 1.9TDI AFN Engine to use for the project

one of the pistons was damaged to the engine will be stripped down and re-bored to 1mm oversize so it will be a 2.0L M-TDI ;)

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The head will be skimmed and valves all machined etc
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M-TDI Injection pumps which will be modified
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Will be using APR Head studs and 3 notch head gasket to run 1.5bar boost

80.45mm - 1mm Oversize Mahle Pistons - http://www.hansdieselparts.com/TDIPistons1mm.htm

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