TDI Golf: 115 PS to 150 PS Upgrade

Hi fellow diesel mechanics!
This is my first post in this forum because, unfortunately, I was unable to find answers to my questions using the search function...

I'm still driving a 2000 Volkswagen Golf IV GTI TDI PD with 115 horsepower.
I have now received an offer for a 150 hp Pumpe Düse TDI engine.

Engine with all attached components, wiring harness, intercooler, engine control unit (ECU), turbocharger, alternator, air conditioning compressor, power steering pump, etc.

It features a 6-speed gearbox and front suspension with a braking system.

What needs to be considered when modifying the engine?
I plan to have it inspected and approved by the TÜV later, and I'd like to find out about prices and other relevant details beforehand.

Is the transmission different between 115 and 150 HP TDI engines? Or do I not need a different one?

'My brake system has a rotor diameter of 278mm. What is the rotor diameter for the 150hp TDI, the 1.8T, and the R32? (Maybe it's worth buying the largest size right away?)'

4. Are there any differences in the exhaust system as well?

Hopefully, someone here can provide me with some information!

Best regards, Dan.jel.

P.S.: Chip tuning is not planned. For a 1.9-liter engine, it would probably be a bit too much.

You should carefully calculate whether something like that is really worth it. You can really buy new cars at a good price right now. I was recently at an Audi dealership, and without me having to negotiate much, they immediately offered me a 10% discount on a new A3 (the brand new model).
It's likely to be similar at VW. Why don't you ask how much it would cost to trade yours in for a 150hp TDI Highline?

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I've already typed everything here. You don't need to bother with the fuel tank conversion, since you already have a PD (presumably referring to a specific type of fuel system).

I would immediately install the FN3 brakes with 288mm discs, or the V6 brakes with 312mm discs (only available for rims larger than 16 inches!). You probably have the FS-III brakes with 280mm discs; I'm not familiar with 278mm brakes.
You'll need to install a larger brake system, as it was standard on the PD_150. You'll only get everything registered if it's modified to be VW-compliant using original parts. The FS-III is also overwhelmed by the power of 150 horsepower.

You'll need wheel bearing housings, a saddle, a saddle bracket, pads, and discs for that. You can usually find them at recycling centers for a reasonable price.

The gearbox is included anyway, so what's the question? The clutch is larger on the PD_150.

Exhaust system is the same.

It's really not worth it.

It's better to buy a chip for around 600 euros.
Save time and nerves.
Because a motor conversion is never as simple as you might imagine.
And all this because of 35 horsepower?

It really isn't worth it.

It's better to buy a chip for around 600 euros.
Save time and nerves.
Because a motor conversion is never as simple as you might imagine.
And all of this because of 35 horsepower?

Well, don't exaggerate, the renovation isn't that bad.

Wow.
You guys are really great!

Thank you very much for your answers! Special thanks to Julian!!!

I have FS-III brakes on the front of my car. I'm planning to buy the complete suspension struts with different brakes, and I think he even offered me the V6 brake kit...
Then I'll have to get winter tires in 16-inch size. I still have a few Montreal alloy wheels for that, which should fit, right?

Now I finally understand about the transmission, which is great!


If the conversion is successful, then I will have a 115PS PD TDI for sale!
E.ay Motors com, or something like that?
I would also like to sell it to one of the helpers here, as a thank you.
But I can't give you any information about the price yet; that will come later!

@Tagessuppe:
I already had a chip installed, and after 60,000 km, there was a hole in the piston. (No one knew if it was due to the tuning.)
VW fortunately provided me with a new engine block, including the turbo, exhaust system, oil cooler, etc. The engine control unit was reset to its original state, due to a possible inspection by VW to ensure that the new engine is now in good working order.
The 'new' one is about to reach 50,000 km, it runs great, but it just doesn't have enough power for me. (But that's why I still haven't driven it too hard.)

@kenny: Ein neues Auto kommt für mich nicht in Frage, den Wertverlust mache ich nicht nochmal mit! Außerdem bin ich dann wieder Testfahrer für VW/Audi! DaIt doesn't have to be.
I'm glad I've managed to fix most of the common issues that can occur in my Golf. (e.g., window lifters)

Best regards from the north,
Daniel.

A few more questions:

Can I take the shock absorbers from a V5? What kind of brakes does it have?

I probably don't need the 6-speed gearbox, as only the first gear would be different.
The clutch is connected to the engine.
Do I need the 150 HP gearbox, or is my 115 HP 6-speed gearbox sufficient?
Sure, I can provide multiple translations if they differ. Please provide the text you would like me to translate from German to English.
Maybe it has some advantages?

Okay, and by the way: What about the mass airflow sensor? Is that different too? At least is the air filter housing the same?
I'll probably go look for a VW with a 150HP TDI engine and compare it. Maybe I'll see one while I'm shopping...

Dan.jel wrote:

I already had a chip installed, and after 60,000 km, there was a hole in the piston. (No one knew if it was due to the tuning.) VW fortunately provided me with a new engine block, including the turbo, exhaust system, oil cooler, etc. The engine control unit was reset to its original state, due to a possible inspection by VW to ensure that the new engine is now in good working order. The "new" one is about to reach 50,000 km, it runs great, but it just doesn't have enough power for me. (But that's why I still haven't driven it too hard.)

*g* The famous "hole-piston" engine.
How powerful was the engine with the chip?
Was the chip installed in the 115 hp PD model?
Did they open the engine control unit after the engine failure?
They should have seen the soldering pads. Unless you applied VAG tuning.
But a soldered-in control unit doesn't necessarily indicate tuning.
"How much will you approximately ask for the old engine?"

Wishing you good luck and lots of fun with plenty of torque.

According to the dynamometer, the engine produced 145 horsepower, which is exactly 29 horsepower more than before. (This was recorded).

The chip was soldered into the control unit and then further modified based on test bench results.

'After the engine failure, thankfully, they didn't open the control unit. Thanks to the competent and experienced mechanic who didn't reveal anything! (I also had the control unit restored to its original state as quickly as possible; the reputable tuner did it for free).'

I can't give you an exact price yet, as it depends on how much I have to pay for the new one.

Hi!

Okay, so, if the chip is correct, the PD_115 engine also performs well. My acquaintance's has 140 horsepower and 408 Nm of torque and has already reached 130,000 km. I've seen PD_115 engines with a larger turbocharger producing a stable 190 horsepower and 538 Nm of torque, but that requires a racing clutch.

I would trade in the engine at the recycling center. They recently did a similar thing with a 1.6 to 1.8T conversion, where the recycling center took the old engine in exchange. During the previous brake upgrade from 256mm to 312mm, they also took the old wheel bearing housings. (www.r-a-r.de)

The MontrealII are definitely going to fail, it's just a matter of time because of the saddles, but they are working fine for now.

To be honest, I'm not sure if you need to make any changes to the suspension, or whether the load capacity is higher than what your PD (presumably a vehicle model) requires. Otherwise, simply changing the springs might be sufficient.
Regarding load capacity, please check the specifications. I believe the V5 has the same load capacity as the PD_150, but a VW dealership should be able to provide you with the exact figures. All the dampers are the same for the 2motion models, except for the GTIs, which have slightly shorter dampers.

Your 6-speed transmission should also fit, but you'll need to check the documentation to find out which larger clutch it uses. You should then install that clutch. However, I would recommend taking the entire engine, transmission, and clutch as a unit; that would be simpler.

The LMM (lambda measuring module) should already be included with the new engine, but it's the same for the PD (pump injector) models. However, it's better to get a new one along with the engine.

I only bought the new tires about 1000 kilometers ago.
A new one would cost extra again...

Similarly, the transmission would cost extra.
Can anyone tell me if the 6-speed gearbox from the 115 hp engine has a shorter gear ratio than the one from the 150 hp engine, or are they the same?

Regarding the brakes, I'll ask the 'friendly' mechanic.

Julian:
Can you provide me with more details about the larger turbo?
190 PS? That's amazing!
I could start by equipping my engine with it, and if that doesn't hold up, then I could go with the 150 hp TDI.
Then the engine control unit will also need to be optimized, right?

Okay, I have the Montreal tires from the year 2000, with a tire size of 205/55 R16. Are they smaller than the Montreal II tires?

Thank you again very much!

Okay, the LMM issue has been resolved.

I would roughly say that the PD_150 has a longer final drive ratio, while the transmission is the same. However, this should be verifiable by comparing the transmission code.

The rims fit. I know someone who uses the 99 Montreal with 312mm brakes in the winter, and it works. Anything 16 inches or larger will work from a brake compatibility standpoint.

'The 190 horsepower was a previous attempt by my tuner. I believe the PD_150 models have the VTN20 turbocharger, while the rest have the VTN17. I installed a larger turbocharger on the PD_115 models, modified the software, changed the clutch, and then took it to the dynamometer. I have the measurement report, and it shows approximately 538 Nm of torque at around 2100 RPM.'
I think the detuned version only has 470 Nm of torque; I should check that.
Definitely, that engine had become a real 400CDi nightmare.

The engine has now covered almost 60,000 kilometers.

Hello,

The 6-speed transmission in the PD-115, including the axle, was the longest ever installed in a PD model. Although it's only slightly longer than the one in the PD-150, it's still noticeable. Perhaps it will then achieve a full 218 km/h instead of 216 km/h.

'I also think the clutch from the PD115 could be used, as the difference between 310 Nm and 320 Nm isn't that significant.'

Wow, if that's 100% accurate, then I'll leave the transmission in!

Have I understood correctly that the engine doesn't have to rev as high to reach top speed?
If so, then that's only a benefit!

On the other hand, I've heard that the transmission with 115 horsepower has a shorter gear ratio in the first four gears compared to the versions with 130 and 150 horsepower. This would then mean an advantage in acceleration...

It's slowly entering the final phase now.
I still have a few more things to check, including with VW, and then I might buy the engine and pick it up.

Best regards, Dan.jel.

Now I've gotten a little closer to my goal!

I have the DRW gearbox installed with the ratios 68/21/26.
The 130hp TDI engine was fitted with an ERR system with the dimensions 62/16/20.
The 150hp TDI engine was equipped with an EFF system with the following parameters: 60/18/22.

According to statements from two employees, my gearbox may not be the optimal one, but I definitely reach the top speed at a slightly lower RPM when the engine allows it. (It's about 100 RPM less, but with a 130 HP TDI gearbox, it would probably be 600 RPM higher!!! >>All information is without guarantee!<<)

The other one:
I have the FS III brakes installed with 280mm discs, and according to our VW dealer, there is no larger brake available for the TDI...
Only the V5 model comes with the 288mm size, and the V6 model comes with the 312mm size.

If that's correct, I should have no problem getting approval from the TÜV (German technical inspection authority). So, Julian, here it is again:
Where did you read about the bigger brake?
Do I need to confront my VW dealer about providing incorrect information?

Best regards and have a great weekend!
Daniel.

Hello,

Use the DRW transmission. The PD150 will also reach the specified top speed with that transmission, and possibly even exceed it.
I personally drive a PD115 with DRW and a power box, and my top speed is roughly similar to my friend's PD130, but I'm faster going downhill.

By the way, the clutch is the same in the DRW as it is in the EFF .