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Discussion Starter · #1 ·
Barely finished one project and already knee deep in another.
Just finished pulling the motor and transmission out of my B4 90 quattro.
I was going to enjoy the V6 a bit longer but the water pump failed on it... and since you have to take the front end apart to get to it, might as well just yank it out.

Plan is

- 2.5 TDI, yes, the one that was supposed to go into my old 4kq.
- 6-speed transmission
- RS2 shift linkage
- RS2 transmission mounts
- S2 intercooler and crossmember
- RS2 front bumper for functionality rather than look (stock bumper does not allow S2 intercooler).

That's about all... sounds simple, we'll see about that.. ;)

Pics of the car before the swap:







Update, 2019 TDI engine blown, now the car is sporting an ABY engine as close to original as possible to make is an S2 Limo.
 

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Discussion Starter · #4 ·
The engine was one year only 1990 Audi 100 tdi, starting 1991 the C4 cars arrived with AAT and ABP codes, ABP was identical to he 1T but had a vacuum pump and 115hp.
The AAT had both EGR and a MAF to meet more strict emission standards.

I looked into having the computer chipped, it is possible only by couple of people in Europe, one of them in Poland, goes by the ame Aligator on most of the tdi forums.
You can also go all out and install most of the stuff from later I5 2.5 tdi motors.

Main goal here is economy and simplycity.

Cheers
 

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Discussion Starter · #7 ·
varia said:
Keep us posted!

we really want to do a similar project, but the donor car will be an audi a6 (c4) wagon

why dont you try an s2 bumper? it will clear the s2 ic and much cheaper?
I already have the RS2 bumper (Rieger) and it cost me $100 new from RPI (had a small flaw).
The fogs and turns are Porsche 993 and bought cheaply used from a Porsche enthusiast forum ($200 for both sets).
Just need to make the mounting brackets now.

S2 bumper with all the grills fogs and turn signals imported from UK would cost me at least $700 if not more (got a quote today for 600 GBP).
If you can find me one cheaper I would consider, I do like the stock S2 look better.
Always had wet dreams regarding those rare S2 sedans ;)



Cheers
 

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Discussion Starter · #12 ·
Well... since as of 10am this morning I am officially unemployed, I thought i'll get some work done on this project.. :slap:

Cleaned the engine bay, what a pita that was... good thing it looks semi-clean, otherwise I would be pissed.. :D







And this has got to be the cleanest southern Ontario subframe I've seen, most of them crumble up and fall apart by now BTDT twice at a junk yard, this car must have seen very little winter use.



Tomorrow i'll get the engine cleaded up and throw the 7A pan on... also try to remove the stock V6 wiring (you can see I cut the engine side already).

Cheers
 

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Discussion Starter · #15 ·
I'll leave the details for my upcomming auto-biography :lol:

Yep, more time with the car not to mention the family!

Not too long though, I don't want to be forced to sell some of the cars just to pay the bills.. :frustrated:

Cheers
 

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Discussion Starter · #18 ·
Did some work finally, got the injection pump back on, took it off to clean the engine better.

Also this arrived this week (thanks Steve O).







After some grinding and swearing and some drilling we came to this.







They are held in with some sheetmetal screws for now, next will be welding them in.. I might ask Mr. Cook for his services, if I don't think my welds will hold up to the rigours and vibrations of the TDI.. :roll:
 

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Discussion Starter · #23 ·
More progress, moved onto the interior and harness swap.
After looking at the harness for several hours (minutes) it was clear that the proper way to install it is to remove the dash and HVAC, since I had to remove the pedal cluster anyway (more on this later) it was a no brainer.

What was a brainer was the PITA to remove the HVAC... that is one serious assembly... doh!

Here is the emptyness it left.



And here it is released into the wild.



I decided to change the heater core while it was out, however not sure replacing a stock German part with 150,000 km on it with a Made in China part is any better, time will tell.

Next came the pedal box...
Here it is..



Oops, I lost it..



Naah.. here it is.. poor little thing.. it's going to be made into a Honda or Toyota.. :( Unless someone wants one to mount on the wall.



And here is why the TDI pedals are different. The TPS sensor is mounted on the pedal box itself.. no throttle cable here.
This little gem is on it's way across the pond as I type this..




Looks like the clutch is at the post office, Mr. Cook will help out and supervise the welding of the motor mounts, and hopefully next week she'll be in there nice and comfortable.

One thing I don't have yet is the rad fan shroud, anyone have a plastic stock unit? I might splurge and get the RS2 unit, only if I can't find a stock one though.

Cheers
 

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Discussion Starter · #25 ·
Moral support always welcome.

Hoping to have the engine/tranny in early next week.

Clutch arrived today and I am picking up the flywheel tomorrow.. it's a special gem, has 5 window casting in the back for the computer to read timing.

Here is the original for 016 gearbox.



The ABP and AAT also use the 5- window reference casting but have built in pilot bearing portion to allow use of 01E.



Notice the dish? Diesels like heavy flywheels.. ;)

Cheers
 

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Discussion Starter · #28 ·
Thanks Peter, I'll PM you.

Only other thing I still need to figure out is how to by-pass the stock fuel pump.
TDI does not use a fuel pump, it's pure suction via the injection pump so I need to remove the pump out of the system (including stock fuel filter) and still have it work properly when the tank gets low on fuel.

Cheers
 

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Discussion Starter · #30 ·
Does anyone know if the electric vacuum pump from a B6 A4 would provide enough vacuum to power the booster.
I know it's there as a supplement, but not sure if it can do the job by itself.
That's another part I will have to sort out... the list is growing.

Cheers
 

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Discussion Starter · #33 ·
Thanks for the tip, looked into it and yes, actually having the pump in there is beneficial in many ways.
Just need to figure out the best way to drop the pressure.
Also wondering if the stock fuel filter will like diesel going through it... never hurts having two filters.. ;)

Here is more.

Mr. Cook came by on Saturday and helped me withe the motor mounts.







I think I screwed up the driver side a bit, but nothing that a shim/spacer won't fix.

Picked up the flywheel and engine hoist today, hope to have the transmission and rest of the wiring in tomorrow and possibly the enigne itself... we'll see how the weather holds up.. it's HOT HOT HOT out there... we haven't had any rain in over 3 weeks, the grass is deed..

Anyhoo.. few more questions, any suggestions on electric vacuum pumps on a budget. I looked at the B6 and Passat pumps but don't know if they are supplemental or actually provide full vacuum to the booster, anyone know? They are only $100 and would match the OEM better than some aftermarket Jegs unit.

Cheers
 

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Discussion Starter · #39 ·
a_CQ said:
It's same in Chicago here...high of 37*c in the shade! That's 97*f I think.

I saw that last picture and thought that driver's side mount looks a little high on the back end?

Martin, any way to find out how much vacuum those new OEM pumps are pulling? Otherwise, Summit sells vacuum pumps that many hot rodders use - I've looked at them when I was setting up ITBs, but it turned out that I had just enough vacuum on the brakes...it wasn't bad at all. So I think you don't need too much vacuum.
Actually it's the other way around, the front end of that mount is a bit low...

I've looked at the hot rod pumps as well, but they are $300/kit almost anywhere and I rather spend $100 on an OEM unit if it works.
Anyone has one of these B6 pumps lying around and willing to test how much vacuum it can pull?

Cheers
 

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Discussion Starter · #41 ·
That looks like the standard Audi cruise control vacuum pump.
The later TDIs had the mechanical vacuum pump like 4kq/Coupe, but because the this TDI was in typ 44 car which uses hydraulic assist they felt pump was not needed, doh!

Cheers
 

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Discussion Starter · #43 ·
I sweated my bag off today, but the engine and transmission are IN... yes, it's in.
Now, it hits the hood, a LOT... ;) But I think I can lower the assembly a bit and remove the plastic underbonnet trim and we might just squeeze in there.
Just too HOT here... I am soaked.

Pics to follow.
 

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Discussion Starter · #45 ·
Plenty, actually too much, so lower she can go and plenty.

Here are the shots.

Overall



Yep, she's sitting high, we can fix that NP.
Not as clean as Technoq's but this is only the DD/winter beater, so she'll get dirty in no time anyway.



All the way and some on the left side.



Right smack in the middle on the right side.



Not much space there.



Not bad, me likey.



More tomorrow.
 

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Discussion Starter · #48 ·
Nope, it's a K14. pretty tiny for a 2.5
My original thought were to go with a GT22V, but I rather do the go-fast bits for the '84 or the sport, this is going to be the pipe and slippers econo box.

Cheers
 
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