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Diesel conversion, VW TDI 1.9 ALH


couttsdesign

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  • 2 months later...

Ok, now that the rear end modifications are done it's time to move on to the front end modifications. This involves modifying the oil pan, front subframe, and center track rod.

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The oil pan interferes with the center section of the front subframe. Here I have already notched a section from the oilpan, but there is still not enough clearance...so chop chop to the center section of the subframe. I cut out about 1.5 inches.

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Here is the mock-up on the car with the oil pan windage tray installed. It's difficult to tell what's going on in the pic, but you can see the clearance between the oil pan and subframe.

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I used 1/4" steel to replace the metal cut out of the center section of the front subframe. I think this will be strong enough.

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Oil pan all welded up. Notice the section from this view. The "V" section is to allow room for the windage tray.

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Here are all the parts finished and ready to for installation. Note: no need for the driver side motor mount, so I chopped it off!

1973 3.0 CS sahara

2000 VW Golf TDI

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The other part of the front end modifications involves dropping the center track rod due to interference with the transmission bellhousing. I dropped the center rod 2 inches.

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Here's a detail shot of the center track rod. The ends are in the exact same location, just the center section was lowered.

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Here is the part installed in the car. Plenty of clearance to the bellhousing!

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And here is a view of all the parts installed. Notice clearance of the oil pan and center track rod.

1973 3.0 CS sahara

2000 VW Golf TDI

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  • 1 year later...
  • 4 weeks later...

WOW...it's been awhile since I've posted on this project.  Yes, I drive it on occasion.  In fact, I drove it to work today, 60 miles round trip. There are a few issues I'm still working out but I just don't have the time I used to have.  I had my first kid last year...new project :P.  Anyway, the main issue I'm trying to figure out is why the car goes into limp mode on occasion.  I think it's due to a bad VNT actuator, or sticky turbo vanes, or a bad N75 valve.  Power delivery is not smooth right now and the turbo boost will spike often, which is not a good for the turbo.  When the turbo is working correctly, you can really feel the torque and power delivery.  I use an app on my i-phone as a speedometer and my radio is a Jambox linked to my phone via bluetooth.  Overall, It's a pretty fucking cool car!

1973 3.0 CS sahara

2000 VW Golf TDI

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  • 3 years later...
  • 4 years later...

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