1999 Volkswagen Golf MK4 hatch 4motion

Updated: 09 Dec 2024

Bought this car in early 2015, which was almost an accident. While browsing random cars, spotted this Golf Mk4 1999 AGR 1.9 TDI in FWD category, but with 4motion on a trunk. Next day went to see the car, and indeed it was a 4motion, dead engine, dead turbo, pretty bad visual condition, but the price was just 950eur. And on the same day, we bought this car and towed it away.
Since then A LOT of modification was made, starting with work to get it back on streets, ALH engine swap, cheapest turbo that you can get, I believe it cost 15eur.
Ofc a need for a higher power never stopped, pump head, nozzles, intake pipes, intercooler. Started to grow slowly from 90HP to 130 - 170 - 200 etc.
The car was used as a daily vehicle with 100% focus on power gains and 0% on a visual look. Only this year (2018) a big emphasis was made on visual with paintwork, replacing all rusty/broken components. Recaro seats to feel comfy etc. Ofc, also a lot of performance modifications, and I don’t plan to stop on these numbers :)

It is simply not possible to write down everything that was done with this car, so feel free to ask any questions in comments.

1.9 TDI ALH Engine
1.9 PD130 Engine block with internals
Custom machined pistons to allow for higher lift cams and lowered compression.
G60 camshaft machined to fit vacuum pump socket
Ported head with custom valves and lifters
GTB2265 Hybrid from Audi & BMW GT22 Turbos with Billet rotor @2.9 BAR boost
Sachs SRE SMF clutch kit
76mm Downpipe and straight exhaust
60mm Intake pipes
0.370 Diesel nozzles
Carter FMP4600 Lift pump [100GPH@8PSI]
12mm Fuel lines
MSA15-EDC15 ECU conversion with OEM wiring from Golf.
Oil radiator converted to fuel radiator
Direnza coilovers
Seat Cupra Mk1 seats interlaced with Golf GTI OEM fabric

Comments

2,9 bar? Amazing! 500Nm out of a 1.9 is impressive. Do you want to tell a estimate how much everything costed? A German Youtuber tuned a MK4 Golf TDI aswell and got to 400hp with Methanol injection. He broke the front drive shafts at least twice already and pushes 2,7 bar. If the build is not /that/ expensive I could consider it in the future, 150hp 1.9 TDI are affordable used.

Yeap, 2.9 bar.
Car was not ready when run it on Dyno. It died after a pull :) Won’t tell any numbers untill there will be new pic from dyno.

PD150 (ARL) can get ~230hp with a proper tune and stock 2260 turbo. That’s the limit of nozzles. Upgrade costs around 500$.
Anyways it’s a lot easier with PD rather then with VP.

I don’t count expenses of my car :)