1.9 TDI swap into b3 90q: Holset? Yes.

death 4kqt · Nov 4, 2013

Figured i'd start a thread on this project. I got inspired from the other TDI swapped audis that have been around on the internet. Oilme has claimed his car was averaging over 45mpg, and that was the last thing I needed to justify the practicality of this swap.
I have been daily driving a mk2 1.6td and love the MPG, but I miss quattro so badly, especially in the winter.
The plan is to swap an AHU tdi into a 1990 90q 20v.

The basic plan is this
-stock 01a and driveline (*update, have 4.11 final drive TDI 01e from a euro b5 quattro TDI*)
-clutchnet stage 3 full face clutch (in case i get the bug for a bigger turbo and mega torque (*update, clutchnet blows donkey balls, and never sent me the clutch. Had to backcharge them through my bank to get my money back. Went with a spec stage 2+ 228mm clutch for a 2.0 fwd 80.*)
-stock ahu engine and turbo, bigger injectors and tune (running full tdi harness and ecu)
-front mount radiator and intercooler
-2.0 80 fwd flywheel
-rebuild both subframes and fix whatever other things i find on the chassis
-use all tdi accessories, adapt power steering lines to use 90 rack and tdi PS pump
-vacuum brake conversion

Going to be a bit of a slow-progress project, hoping to have it running in the car by next summer. The engine ran veggie oil, so i will be pulling the head and one piston and see if its fubared inside. Then I may need to rebuild depending on what I find.

here is the doner running, runs well, starts easy, that tiny little turbo sounds cool.

got the doner engine out last night, cleaned it up a bit.

pretty cool quattro script cloth

aorsinger · Nov 4, 2013

ive been considering the same swap

go get em!!!

DE80q · Nov 4, 2013

Very nice setup. Glad I could help a little. That 90 have the same platinum Q-script interior mine does. Very nice. I will be watching this one.

NiTeC · Nov 4, 2013

custom mounts for that AHU eh? are you building it up at all or using stock? I bored mine out to 2.0 using passat BEW pistons...cheap power with a Holset on there too...

will keep my eye on this as well...clean car for sure

WOMBAT · Nov 4, 2013

Awesome. Make me one too

AudiSport4000 · Nov 4, 2013

Dang, awesome project, Dana. I wish I knew more about diesels as this would be a cool project for the future.

Let the madness begin

death 4kqt · Nov 4, 2013

AudiSport4000 said:
Dang, awesome project, Dana. I wish I knew more about diesels as this would be a cool project for the future.

Let the madness begin

i think it will be super cool to have a high mpg quattro with decent torque. Diesels are pretty simple really, and the wiring part of the swap seems to be similar to a 10vt or 20vt type audi swap. There is a decent amount of info on the web about tdi swaps into other vehicles. Older diesels are even more simple, not a whole lot too them.
I think this thing will be kickass, the only pitfall may be the stock gearing. It may force me to swap a 6 speed in, or get tdi 4th and 5th gears for the 01a. Either way, thats not cheap, and want to avoid those at first.

death 4kqt · Nov 4, 2013

NiTeC said:
custom mounts for that AHU eh? are you building it up at all or using stock? I bored mine out to 2.0 using passat BEW pistons...cheap power with a Holset on there too...

will keep my eye on this as well...clean car for sure

for now, stock engine and turbo with bigger injectors and a tune. Planning on making custom mounts of some kind, that will become more apparent to me when i sit the engine in the bay and see what im working with. Car is pretty clean, has a couple nasty but very isolated rust spots that i have not seen on one of thse before. Luckily they are both in places that can be fixed and hidden pretty well. The paint and interior is amazing given the age and 290k miles.

scubagli · Nov 5, 2013

Dig it, put some diesel purge down the glow plug holes and let it sit over night before you pull it all apart. If any rings are hung up from the grease that will loosen them up....

death 4kqt · Nov 5, 2013

scubagli said:
Dig it, put some diesel purge down the glow plug holes and let it sit over night before you pull it all apart. If any rings are hung up from the grease that will loosen them up....

good cal, i did run some MMO (unsure if this actually does anything) in it for a good hour before i drained it and tore the motor out)
Crossing my fingers that this thing isn't going to be one of those grease horror shows inside like so many pics floating around around on the tdi pages.

scubagli · Nov 5, 2013

ahh it's really about how the person did it, if it ran good, its prolly fine. good luck!

death 4kqt · Nov 5, 2013

well, here is the kicker. I talked to a mechanic who worked on it and he had replaced the engine and IP a couple years ago because the lady boned it up badly on veggie. He said the rings were completely seized. But, i did find receipts after that where she paid someone to rework the veggie system. It was set up pretty well with a heated tank, fully heated lines, temp gauges, dual purge valves, and an alarm that sounds if you switch to veggie before the correct temp. Fingers crossed.

scubagli · Nov 5, 2013

It's really about shut down and the quality of oil...once again good luck I hope it's ok.

death 4kqt · Nov 11, 2013

i sold the intake manifold and all the EGR and cooler stuff. pulled it off and it was nearly plugged shut with soot. EGR + hippy chicks running veggie oil = fail

was pretty hilarious to de-soot it. I did this for about 15 straight minutes. So much molten crap came out of this thing, and it ended up pretty much clean.

berkltard hard at work, with her favorite pillow

WOMBAT · Nov 11, 2013

I like the laughter after making the first big fireball

death 4kqt · Nov 11, 2013

that one cleaned off the arm hair on my right arm. my face also was covered in soot. Im classy.

AudiSport4000 · Nov 11, 2013

"Check this shit out"

I lost it...thats hilarious!

Pete82 · Nov 11, 2013

very good conversions

I know of a 90 in the uk with a tdi quattro conversion. This was my fwd tdi that I converted to 6speed quattro with the later a4 quattro engine

worth blanking off the egr valve
i've heard of them with a straight thru exhaust that sounds quite good

in my 1.9tdi passat with a 90bhp engine I was getting 50+ quite easily

death 4kqt · Nov 11, 2013

gorgeous avant!

i planned on running with the EGR blocked off and with a 2.5" straight pipe from the turbo back.

Pete82 · Nov 11, 2013

thanks

and yeah that would be good. I know of places in the uk that do chips etc for these engines cheap. Even english ebay do them.

I remember my first tdi fwd avant with the 90bhp engine, a full tank from brimmed full to run out stranding me in the middle of the countryside and having to walk to the gas station got me 666miles exactly and That was flat out for the majority of the journey.

A couple of s2 forum members with fwd tdi's was getting 8-1000 miles taking it easy, it was a bit of a game to see who could hit the magic 1000miles to a tank mark.

1.9 TDI swap into b3 90q: Holset? Yes.

death 4kqt

aorsinger

DE80q

NiTeC

WOMBAT

AudiSport4000

death 4kqt

death 4kqt

scubagli

death 4kqt

scubagli

death 4kqt

scubagli

death 4kqt

WOMBAT

death 4kqt

AudiSport4000

Pete82

death 4kqt

Pete82

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