VW 1.9L PD TDI Marinizing

Discussion in 'DIY Marinizing' started by pandman, Apr 21, 2014.

  1. pandman
    Joined: Apr 2014
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    Location: Port Angeles

    pandman New Member

    I am working through building a VW 1.9L PD TDI engine for install into a custom built 19' dive tender. I was going to post to another thread that is similar but it is too old to reply to so I figured it is time to start one that is current to see what interest or knowledge there might be now.

    I have started out with a 150hp ARL engine from a Seat Toledo. I am looking for anyone else that has made an attempt at this with the newer TDI. It is going well so far but I am wanting to get a cooled exhaust manifold. I have contacted a UK VW Marine shop to see if I can get them to send me the one used on their 1.9L engine. Unfortunately, the 1.9L is not available here in the USA just yet. This is too bad. I remember seeing one at a booth at the 2007 Ft Lauderdale boat show. I was hoping they would have made it here already. So far, only the 6 and 8 cylinder versions are here and even then, only a select few Mercury Marine locations even know about them...
     
  2. moTthediesel
    Joined: Apr 2006
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    moTthediesel Junior Member

    I'm not sure about the pumpe duse engine, but the earlier 1.9 TDI engines can use the same manifolds as the old 1.6 VW diesels. If that is also true with the PD engine, you could use an exhaust manifold from an old Pathfinder marine engine. Those can be found fairly easily for short money.
     
  3. rustybarge
    Joined: Oct 2013
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    rustybarge Cheetah 25' Powercat.

    Why not fabricate one your self?

    Enclose the whole manifold in a steel cooling box by putting one side of the box between the manifold and the exhaust ports, and then making a small cooling box; into this box insert a tube larger than the exhaust jointer between the manifold and the pipe...hey presto!

    ...or you could wrap coils of thin copper pipe around the manifold to cool it! high pressure microbore pipe would be perfect.
     
  4. moTthediesel
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    moTthediesel Junior Member

    I was going to do that, I even had a damaged VW head to use as a building jig, but I found a complete Pathfinder engine for $200. The VW engines are tricky to build manifolds for because they are counter flow heads and have the intake and exhaust on the same side.

    The manifold I got with the engine I bought was made by Bowman in England, and includes an internal tube style heat exchanger. They are still made and are available new, but they are pricey, like over $1000.
     
  5. shakescreek
    Joined: Nov 2009
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    Location: northern B.C. Canada

    shakescreek Junior Member

    I have had a 1.9pd from a seat ibiza cupra in my welded aluminum jetboat for 7 years and 1300 hours now with no issues. It is engine code bpx, 160hp stock rating and I believe is mechanically identical to your arl with the exception of the water pump. I have upgraded to a larger turbo and am running a custom tune at about 230hp. I have been very happy with the engine so far and expect to get many more years of use out of it. I am running a dry exhaust so just built my own tubing header out of stainless. Since the turbo is using the heat energy in the exhaust to drive it I feel it is counterproductive to suck any heat out of the exhaust pre-turbo with a water-cooled manifold unless it is absolutely necessary. In my case it is not as I have plenty of air flow in my engine compartment to keep things cool. Sounds like a cool project you have going and I think you made a good choice on the engine. Keep us posted on how it works out.
     
  6. Steve W
    Joined: Jul 2004
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    Steve W Senior Member

    I will be keeping an eye on this thread, the VW TDI engines are great engines, I have been driving them for nearly a decade, first a 96 Passat and currently a 05 Passat, my son installed one from a 96 into a Corrado, very reliable in my experience. I have toyed with the idea of converting a pair for a displacement power cat. If anyone has a lead on a cheap pathfinder for harvesting I would appreciate a pm.

    Steve.
     
  7. roedel
    Joined: May 2013
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    roedel Junior Member

    I am currently tooling an complete marinizing set with wet exhaust manifold for the 1.9L ALH Tdi engine. It will run based on a mechanical injection pump.

    Not sure the exhaust fits to the PD pumpe Duese version though but i will check...

    Here a link to the forum i posted the current progress, the wet exhaust cast is very challenging, but i am at the point of no return, lots of $$$$ invested :)

    http://forums.tdiclub.com/showthread.php?t=413125
     
  8. Steve W
    Joined: Jul 2004
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    Steve W Senior Member

    Just thought id check and see how your tdi project progressing?

    Steve.
     
  9. roedel
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    roedel Junior Member

  10. dinoa
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    dinoa Senior Member

    Nicely done.

    Dino
     
  11. Steve W
    Joined: Jul 2004
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    Steve W Senior Member

    Ive checked out your progress on the other site, very nice work so far, congratulations. i will be very interested when you get a kit together. Could you clarify which engines it will fit as im not fully up to speed on the designations. I drive an 05 PD tdi wagon and also have the engine out of my old B4 Passat which is a 1Z AHU i believe which is the engine i am interested in marinizing, what im not familiar with is the SDI designation and also the term M-TDI ?

    Steve.
     
  12. roedel
    Joined: May 2013
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    roedel Junior Member

    Hi Steve,

    SDI is the Non turbo version = Suction of the Direct Injected VW Diesel engine.

    TDI is the Turbo version of the Direct Injected engine.

    m-Tdi is the direct injected Turbo engine with mechanical injection VE pump.
    The engine i am using, ALH type (after the year 1999.5) came only with a electronic injection VE pump.

    Also the predecessor of the ALH engine generation often referred to as the 1z. The 1z had a different head and engine block came with electronic controlled injection.
    The 1z is easy to identify by the oil filter that points downwards, the ALH has an Aluminum oifilter housing that points upwards with an interchangeable filter insert.

    Note most all TDIs from VW or Audi after 1995 were electronic injected.

    The advantage of the mechanical injection is the easy of operation, just one cable for the start stop solenoid. Different injection pumps from other TDI Diesels from that time period can be used for that purpose such as Land Rover, Fiat, Iveco.

    My set will fit the ALH and the earlier 1Z engines, should be available second half of the year. Stay tuned for updates.
     
  13. roedel
    Joined: May 2013
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    Location: CA

    roedel Junior Member

    Hi Steve,

    SDI is the Non turbo version = Suction version of the Direct Injected VW Diesel engine.

    TDI is the Turbo version of the Direct Injected engine.

    m-Tdi is the direct injected Turbo engine with mechanical injection VE pump.
    The engine i am using, ALH type (after the year 1999.5) came only with a electronic injection VE pump.

    Also the predecessor of the ALH engine generation often referred to as the 1z. The 1z had a different head and engine block came with electronic controlled injection.
    The 1z is easy to identify by the oil filter that points downwards, the ALH has an Aluminum oifilter housing that points upwards with an interchangeable filter insert.

    Note most all TDIs from VW or Audi after 1995 were electronic injected.

    The advantage of the mechanical injection is the easy conversion, just one cable for the start stop solenoid.
    Different injection pumps from other TDI Diesels from that time period can be used for that purpose such as Land Rover, Fiat, Iveco.

    My set will fit the ALH and the earlier 1Z engines, should be available second half of the year. Stay tuned for updates.
     
  14. Steve W
    Joined: Jul 2004
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    Location: Duluth, Minnesota

    Steve W Senior Member

    Thanks Roedel, I think the 1Z and ALH are probably the best choices. I will be following this thread for updates.

    Steve.
     

  15. roedel
    Joined: May 2013
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    Location: CA

    roedel Junior Member

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