MkIV PD115 Engine Replacement

[BlackSeedyEye]

Hiya, I have a mkIV Golf PD115 and have hit problems and was wondering if anyone has performed engine replacements from the lower hp models to the 130 or 150 and what they can advise.

A few days ago my engine began playing up making a misfiring sound whilst driving. The next time I started it up it smoked quite a bit until I had driven it for a few minutes, so I called out a very helpful VW Assistance technician who took the top cover of the head off with me and pin-pointed the clattering sounds to be coming from cylinder four nearest the gearbox. After a few phonecalls we were informed that this was not uncommon on that engine when approaching the 130k miles mark, which mine is.

The final diagnosis is that the piston nearest to the gearbox has failed due to over-heating which has led to it deforming a little and thus the compression was not reaching enough to let it combust the fuel going in. It's time for a new engine, a mere 6000 miles after getting the timing belt done but it's going to be very hard to find a low mileage PD115 engine (code: AJM) because almost all diesels are purchased to be driven.

I am proposing to fit a PD130 or 150 engine but need to know if this will even be possible and what is required to do this. I appreciate a remap may be quite essential due to the mix and match of parts but does anyone know if all the loom will fit and if the current ECU will even know what's happening if the different engine is fitted. Also, I bought a PD150 turbo a few months ago and due to this happening I now intend to fit this at the same time and remap the car to suit.

I would really appreciate your thoughts and experiences regarding this so I can make a start at sourcing a replacement engine.

 

[sssstew]

Its entirely possible. Your best bet is to pick up a accident damaged/written off mkiv golf and transfer the bits over. makes it easier.

 

[muddyboots]

You might also need to check the intercooler arrangements - do the Golf 150s have bigger intercoolers than the 130s ?

Does the 115 have a 5- or 6-speed box ? If it's a 5, you'll probably want to go for the 6 speeder as it'll be capable of handling the torque outputs. Even in you already have a 6 speed, you might find the ratios a bit short for the higher output engines - and considering the mileage it might be a good opportunity to fit a lower mileage or a recon box.

And depending on how far you intend to go performance wise, it might be wise to slip in a better clutch that won't slip...

Welcome to the curse of SCN...wave goodbye to any thoughts of not modding !
You've got a good opportunity for some serious modding if that's what you (and your wallet) fancy

 

[craig-pd130]

Disclaimer -- no practical experience to be found in this post.

To echo Sssstew's & Muddy's comments, a PD130 should be the easiest swap as it is the same intercooler layout as the PD115. I believe the 115 & 130 engines are pretty much identical apart from ECU map, so you should be able to use the same fuel lines, loom connections etc etc. You'll probably need to swap ECUs too.

Another vote for a PD130 with the 6-speed box, they have more torque as standard than the 5-speeders.

The PD150 motor has a number of changes, and will be more expensive anyway simply 'cos there's less of them around.

 

[sssstew]

the 115 has a 6 speed box, and uses the same intercooler as the 130.

 

[micky 32]

Disclaimer -- no practical experience to be found in this post.

I believe the 115 & 130 engines are pretty much identical apart from ECU map.

No, totally diffferent engine, the 130 is the same as the 150. the 150 will just as easy fit as it shares the same inlet manifolds etc as the 130, only difference is the 150 has an added egr cooler which is easy taken off if you dont want it.

The PD 130 intercooler is slightly fatter than the PD115, also with a different part number.

 

[craig-pd130]

Micky -- interesting, I know the 150 has some different internal components to the 130, so is the 115 different internally again? Or is it different layout for the inlet etc?

 

[stoneyfordNI]

100 and 115 are similar , softer internals smaller turbos etc than the 130/150s

inlet etc is same as 100, AFAIK

 

[micky 32]

Micky -- interesting, I know the 150 has some different internal components to the 130, so is the 115 different internally again? Or is it different layout for the inlet etc?

The 115 was the earlier design etc, The 150 internals are the exact same as the 130, its the same longblock and it even shares the same injectors. All the part numbers for the 130 are the same as the 150. Ive listed them somewhere in the FAQ.

There are some different part numbers internally between the 100 and 115 but some are the same, conrods for example. The inlet manifolds look the same on the 100/115 and turbo. ive a feeling the 100 is just a newer 115, very similiar.

 

[prc]

The 100 and 115 are pretty similar. Not sure about the UK but you can get 115's in both 5-spd and 6-spd here.

The swap for a 130 is pretty easy, but you'll need the ECU and you should swap the IC.

 

[sssstew]

afaik the 115 was only ever availble with 6 speed here.

 

[prc]

IIRC they had lower torque figures. Think the 6spd came with 310Nm and the 5spd with 285Nm.

 

[micky 32]

no the 6 speed are 285. i think they were only 310 in the sharan( could be wrong though)

 

[prc]

couldn't find anything on the golf, but the A4 was available in both. Also found that there's a 5-Spd version of the A4 PD130...