1995 90 quattro V6 to 1.8t Conversion

[Audilard]

You should let me have that Pelican Blue S2 bumper.

[Mcstiff]

Interesting spot for the battery, is that a v1 location or final?

Car is coming together nicely!

That is where Audi put it!

The RS2 (and S2 Estate/Limo I'd guess) have it in the hatch:



Of course, you could always put it on the other side to offset some driver weight:

[Dave]

Yup, like Ed said, that is the OEM location.

You should let me have that Pelican Blue S2 bumper.

You wouldn't even give me your crappy plastic battery cover!

[Audilard]

Yup, like Ed said, that is the OEM location.

You should let me have that Pelican Blue S2 bumper.

You wouldn't even give me your crappy plastic battery cover!

I'd be happy to entertain a straight up trade.

[Dave]

Picked up some Big Brakes, they won't be staying yellow...


Got the downpipe mocked up, and a friend is doing the final welding on it



Same friend sold me a european Audi S2 airbox, It is made for this chassis, and is therefor a perfect fit. I adapted the smaller 1.8t MAF to fit the inlet and everything ties in very nicely:

[Dave]

[my2000apb]

looks awesomely OEM!!!

[EDIGREG]

[araipilot]

Looking very nice Dave, I love the big brakes, where did you get the bumper painted? I am looking for a good body shop

[Dave]

Big thanks to Nate (araipilot)! got the downpipe done and installed:


Got some of the final wiring done, hooked up an OBD2 port and kept the OBD1 ports just for kicks, hopefully this is the last time I had to pull the Fusebox:


Made an extention for the A/C Speed sensor (trying to keep A/C in this beast):


Plastidipped some badges, black on white looks good:



Hooked up a boost gauge, cut out the vent to make it work, need to run a switched dimmable power line to it so it will illuminate, it already has a red bulb inside: (also have a nice solid 20hg of vacuum while running)


Trying to figure out if i can run an early style knee parcel shelf to have a nice spot for the ECU.

[araipilot]

Dave coming along nicely, I will be looking forward to having a ride in your newest creation. Cheers Mate!!

[Dave]

[youtube]http://www.youtube.com/watch?v=zWmDxNu4ejM[/youtube]





I was able to take it for a drive this weekend, everything seems to be in order. pulls nicely. Needs to have the exhaust attached. I also have a small brake issue which existed prior to the swap. the booster doesnt seem to hold pressure, i have to pump it a few times before the brakes want to work... not a good thing, I'm guessing it is the booster at this point since i put in a new check valve at the time of the swap.

[Dave]

I drove the car a few times to work and such over the last month. I have been trying to figure out some small problems, which were keeping me from wanting to drive the car daily.

First: My windows weren't working, Utah is already in the 90s some days, and i haven't charged the AC system yet, so i got caught a couple days driving home in a 90 degree greenhouse with the windows stuck up.

Second: the temp gauge reads as if it were an 'A4' temp gauge, so operating temp is reading on my gauge as over heating, but is really just sitting at the operating temp but in a 'straight up and down style'. This was troubling just because i want accurate information, and it worries me to see the gauge not reading right.

Third: My wiring for the OBD plugs wasn't working properly. I wanted to be able to scan and log and see whats going on with the car. It was annoying because if i unhooked the ECU, the vagcom could connect to the climate control or abs systems just fine. as soon as the ecu was plugged in, i'd lose all communication. Frustrating.




I ticked away at these problems this week, probably 30-45 minutes a night, and can say that i think that all 3 of them are solved! Windows had a connection at the fuse box that had come off when i pulled out the fuse box and i didn't see it when i hooked everything back up. I picked up a new temp switch from an ABA engine that is supposed to give me proper read out to my gauge(big thanks to Lee and BikerJim for the advice). My schematic for the k-line was inaccurate so i had the wrong wire hooked up to my k-line and was shorting everything out. Did a wire trace and found the correct wire and everything is happy.

I also installed a new JHM Short shifter that i got for my birthday, and an Alpine head unit that matches the illumination in the car. I rewired the headunit so that it is all hooked up correctly, and now when i turn the stereo to 'radio' my antenna powers up and extends! Feeling like things are getting dialed in. I ordered a 'correct' radiator from Europe and it showed up, so hopefully if i can find an hour or two this weekend i'll get the new radiator in and get the AC system flushed and charged!

[lorge1989]

Glad to hear its running well. And it looks great too! Its gotta be pretty peppy with the K04

[Dave]

Well sadly the joy only lasted a brief 500 miles or so. The pilot bearing decided it didn't want to live anymore. So i stopped driving it for a month, knowing we were moving soon and i was too busy packing and prepping to tear it down. Well now we have moved and unpacked so i found some time to start tearing it back down. I was going to just pull the transmission, but i already needed to actually install the intercooler and wrap up some other things so after laying under the car prepping to pull the trans i realized i'm just going to pull the engine.

Weekends work:


and of course the offending, bled out, part:


I'm sort of happy that it was an obvious problem, and the diagnosis was correct. Nothing worse than thinking your problem is something, you pull the engine and realize everything is fine... I was happy to see a failed bearing!

[WOMBAT]

"Nothing worse than thinking your problem is something, you pull the engine and realize everything is fine... I was happy to see a failed bearing!

amen to that!

Really respect the execution of this swap Dave - I hope I can do the same to the cabriolet some day

[Dave]

Did a big push over the past couple weeks to get it ready for a local euro car show, i'm happy to say that i was able to get it done in time... Although i didnt get a chance to test drive it and get it up to operating temp before leaving for the show... luckily it went smoothly! (other than some sticky calipers that like to smoke ....)

Quick repass on the wiring:


added an intercooler while it was out. My fabrication tools include an angle grinder and a drill, so be kind.


back together:








Some day i'll get a european rear bumper to clean up the back end...

[PRY4SNO]

You make all your hard work look so smooth. Car is legendary already.

Nice work.

[Dave]

You make all your hard work look so smooth. Car is legendary already.

Nice work.

Thanks dustin, as a generally rule I'm an OEM+ sort of guy and like my installs to look like something that could be mistaken for stock. I like a clean nice look, but i like the power upgrades too.

[Dave]

Pic Dump:











Heater core blew up:










Converted to Euro Tails:

[ChrisAudi80]

Could be... I have no idea how similar the N/A 1.8 is to the 1.8T...

I'm pretty sure that is why I was getting crazy boost when I had a PCV related boost leak... the ECU doesn't know how much boost is being made, it just extrapolates from MAF numbers.

Where was this boost leak in the PCV system? I have erratic boost with my AEB right now. Overboosting.
Its stock besides switching to E85, 630cc injectors and piggyback to control the fuel.

I have a separate topic on this, but not a lot of input at the moment.

[lorge1989]

Car really does look amazing.

Where did you get that sticky black stuff that seals up the tail lights?

[alxdgr8]

Car really does look amazing.

Where did you get that sticky black stuff that seals up the tail lights?

You can find it at your local auto parts store. Ask them for butyl tape.

[k2exoman]

This project is awesome!
Looks stock and sounds great.
Are you planning to push the 1.8t beyond the k04?

[Dave]

This project is awesome!
Looks stock and sounds great.
Are you planning to push the 1.8t beyond the k04?

Yeah, not exactly sure what direction I want to go, i have a set of rods, but haven't chosen a turbo yet. I really want to get around 300awhp in it with a low spool.