Audi 90 quattro with 2.5 TDI and 6-speed, plan B

[ralleyquattro]

BTW I still need one of those front upper rad support, anyone? Please.

[Warner]

looks great Martin, glad the build is moving a long well.

[barfbasket]

I am really happy with the gaps.

Where are they? :-)

[Dave]

yes the b3 b4 cornerlights are interchangeable

[ralleyquattro]

Got the vacuum pump routed and wired, kind of cool, but cycles on/off few times/minute by itself, might think about installing a holding tank to increase the volume and reduce the pressure drop from small leak etc.
Instrument cluster is wired and plumbed, still waiting for for RS2 fan shroud, but even without it I should be able to take it out for a small test drive tomorrow!

That's all for now.

[AudiSport4000]

Wow, first time I have seen this thread. VERY nice work Martin! I love the B4 styling and 5cyl's. Looks like mocking up and welding on the 5cyl engine brackets wasnt brain surgery, huh?

We have very similar tastes

[frostyflax17]

looking great martin.

very jealous and interested in the mileage you'll get with it.

very quick putting it together too!

[NiTeC]

hey Martin...the car looks mint man!

I must have missed it - what rad support are you in need of? I've got two kicking around - the V6 and the 2.0 ones - can't use them because of how I mounted the rad...or do you mean the lower support that mounts to the frame? I have the V6 one - big hunkin piece of pipe...

[Highlander]

Looking great Martin.

I'm looking forward to driving it.


Cheers,

Craig

[ralleyquattro]

hey Martin...the car looks mint man!

I must have missed it - what rad support are you in need of? I've got two kicking around - the V6 and the 2.0 ones - can't use them because of how I mounted the rad...or do you mean the lower support that mounts to the frame? I have the V6 one - big hunkin piece of pipe...

Thanks for the offer, I was looking for the upper front for I5 application, covered now, thanks

[Dr.Strangelove]

Hey Martin, is the gas pedal still available?

[ralleyquattro]

Yes, sorry, too many projects not enough time to keep it all straight.

Send me an email, that is the best way for me to keep track of it.
martin at quattro.ca

Thanks

[Dr.Strangelove]

I hear ya--will do.

[ralleyquattro]

Drove to the gas station to get some diesel... that's after spilling about a liter on my driveway.. doh!
THis stuff is worse than gasoline, it's slippery and won't come off.

Anyhoo, got one code, for the brake pedal, ahem, that's because I heel and toe, yes on my way to get some gas :slap:

That was solved promptly by removing the connector and bypassing the switch.

Other than that she smokes a little and the glow plug issue is still not resolved, I'll have to run it in by pass otherwise it takes 20s of cranking to get it going. With the relay in by-pass it starts on first crank.

Other than bolting back on the usual stuff like glovebox and driver side underdash tray, I am still waiting for the RS2 fan shroud, so no long drives yet, don't want it to overheat.

The engine is very torquey, no need to rev past 2000rpm. The rev counter works but I think it's in 6 cyl mode so I'll have to switch for a 5 cyl one.

I hope the smoking goes away or I'll have the enviro freaks on my ass.

To Be Contnued.

[Highlander]

Great news Martin..........well done.

Cheers,

Craig

[WRC]

Very cool!

[ChrisAudi80]

If it is one thing about diesels I don't like, it is the smoking. And the smell.

[PRA4WX]

Smoking?? Sounds like it needs more boooost! ;-)

[ralleyquattro]

If it is one thing about diesels I don't like, it is the smoking. And the smell.

Don't care much for smoke either, but smell, I simply love it.
Diesel smell, especially exhuast is something I could smell all day.
I almost wish they had cologe for men called Diesel No. 5, my secret wish for Christmas.
I love the smell of Diesel in the morning.

Enough with the fun stuff... back to work. Routed the glow plug override via cruise control "set" button (it's only grounding the relay).. and it broke the switch... Doh! Worked fine few times, then I decided to reinstall the under steering wheel cubby and poof she was gone. Clearly it didn't like to be put back together so soon.. I must take a leaf from Mike Hopton's "glove box" install instruction manual and wait at least 6 - months before even contemplating reassembly. :wink:

I'll get a more industrial typ 85 switch tomorrow and see how long it lasts.

Cheers

[80qtdi]

If it is one thing about diesels I don't like, it is the smoking. And the smell.

That's two things hahaha.

Martin, what do you have the injection pump timed at and did you time it electronically? The reason I'm asking is it shouldn't take more than couple revolutions to fire, regardless of the glowplugs not working. They will start w/o glowplugs down to 0-3C (with decent compression). The smoke should clear with more use, my audi's engine smoked up the whole shop, but after some decent loading of the engine all smoke went away. But if it's not timed 100% it will continue to smoke.

Keep up the good work. It's very motivating.

[WOMBAT]

smoking is ok - you're just "rollin' coal!"

8) Glad it made it out and back on its maiden voyage!

[ralleyquattro]

Martin, what do you have the injection pump timed at and did you time it electronically? The reason I'm asking is it shouldn't take more than couple revolutions to fire, regardless of the glowplugs not working. They will start w/o glowplugs down to 0-3C (with decent compression). The smoke should clear with more use, my audi's engine smoked up the whole shop, but after some decent loading of the engine all smoke went away. But if it's not timed 100% it will continue to smoke.

Keep up the good work. It's very motivating.

Unfortunately this is the first Tdi and one downside is that it can not be timed electronically, the following versions the AAT and AEL can be done with VAGCOM :frustrated:
So it was timed with TDC and pump lined up, that's all I can do with the tools I have.
There is a gauge which can be stuck on the end of the pump to verify the timing, but I don't have that cool stuff.
I think the gauge was used on all VE pumps, so I'll ask around if any of the old school mechanics still have one kicking around.

For now the smoke is not that bad and I'll see if it clears up.

Cheers

[Highlander]

Martin, what do you have the injection pump timed at and did you time it electronically? The reason I'm asking is it shouldn't take more than couple revolutions to fire, regardless of the glowplugs not working. They will start w/o glowplugs down to 0-3C (with decent compression). The smoke should clear with more use, my audi's engine smoked up the whole shop, but after some decent loading of the engine all smoke went away. But if it's not timed 100% it will continue to smoke.

Keep up the good work. It's very motivating.

Unfortunately this is the first Tdi and one downside is that it can not be timed electronically, the following versions the AAT and AEL can be done with VAGCOM :frustrated:
So it was timed with TDC and pump lined up, that's all I can do with the tools I have.
There is a gauge which can be stuck on the end of the pump to verify the timing, but I don't have that cool stuff.
I think the gauge was used on all VE pumps, so I'll ask around if any of the old school mechanics still have one kicking around.

For now the smoke is not that bad and I'll see if it clears up.

Cheers

Needs more boost........that will clear things up

[Lord_Verminaard]

Unfortunately this is the first Tdi and one downside is that it can not be timed electronically, the following versions the AAT and AEL can be done with VAGCOM :frustrated:
So it was timed with TDC and pump lined up, that's all I can do with the tools I have.
There is a gauge which can be stuck on the end of the pump to verify the timing, but I don't have that cool stuff.
I think the gauge was used on all VE pumps, so I'll ask around if any of the old school mechanics still have one kicking around.

For now the smoke is not that bad and I'll see if it clears up.

Cheers

Did you have the locking pin for the injection pump when you timed it? You can get a fairly cheap dial gauge and adapter from this guy: http://cgi.ebay.com/ebaymotors/VW-Diese ... 500wt_1182

I'm guessing you need more advance. Even the old IDI's will fire up without glows until it gets around 40 degress or so. Not sure how easy it is on an Audi with the injection pump in the back, but on IDI's a lot of times I will loosen the injection pump mounting bolts and fire it up, then while it's running, rotate the pump by hand in the bracket and listen until it sounds "right". If you are impatient like I am it might work a little better until you can get it timed 100%.

Brendan

[Dr.Strangelove]

Martin, dial indicators are pretty cheap. Finding an adaptor, or making one that fits into the injection pump could be a challenge. I aligned the sprocket on the injection pump on my 1.9TD my holding the gauge very carefully. Basically, you're looking for when the plunger inside bottoms out (or stops receding), then you add whatever deflection is specified in the manual by rotating the pump clockwise or counter (It's been a while). But, anyways princess auto sold me the gauge for $25 or so. I used a brass hinge inserted into the back of the cam to align it with the top of the head and the pin from another hinge to lock the pump. I'm not sure how the audis are setup though, but grab a gauge and see what you're working with. It could be within spec or it could be way out.