Rich's '91 80Q M-TDI

[death 4kqt]

what a great car, honestly i think i will do this for my next daily driver when my 1.6td jetta rusts out or explodes or both. I always wanted to do this but was afraid the mpg wouldnt be worth it. 45mpg is damn close to the 49 my jetta gets. mTDI quattro might just be the best daily driver ever.

[scubagli]

Nice to see Rich.

[oil_me]

death 4kqt wrote:[/quote]

what a great car, honestly i think i will do this for my next daily driver when my 1.6td jetta rusts out or explodes or both. I always wanted to do this but was afraid the mpg wouldnt be worth it. 45mpg is damn close to the 49 my jetta gets. mTDI quattro might just be the best daily driver ever.[/quote]

My favorite car was always my IDI diesel Jetta. It was a '91 auto/gas I converted to 5spd diesel. I used all parts from my ex-wife's '85 JettaD with over 400k on it. I put another 180k on those parts. (I still have the motors from all 3 IDI diesels. They still run ). I have a long term plan of putting one in my other A80q and make it a pickup or camper; something light and stripped down. The AHU isn't close to broken in yet @ 11k and has yet to yield its best mileage. Taller tires or a proper 5th gear would improve mileage even more with this car. My MKIV 99.5 TDI gives up 47 mpg around town every time unless I hit the highway, it goes up to 52. I just don't like driving it that much; It's bland, unchallenging even with its engine & susp. mods. Hondaesque.
Rich

[oil_me]

Nice to see Rich.

Yah, I saw you twice on the road in opposite ends of the county lol.
Rich

[death 4kqt]

well thanks rich, i got the bug so bad after seeing how awesome this car is and your mpg numbers that i bought a mk3 jetta doner car last night and put a deposit on a nice clean 90q.

[death 4kqt]

I used a flywheel from an '88-'92 B3 Audi 80 2.0 gas 4cyl. (012 trans.), SPEC stage 2-228mm pressure plate with an organic disc. The engagement is a little odd as all because of all the torque comes at once with a manual pump/throttle cable; not like an eTDI. It hasn't slipped at all in spite of that. If I must do it again; I'll machine the flywheel for a 240mm PP and maybe get a heavier diesel flywheel. The starter is from a '97 TDI A4q. The flywheel in your Iltis may be an earlier series ie: like you mentioned Audi 4000 or VW Dasher diesel. Here's a link to a thread which uses your setup I think.http://www.motorgeek.com/viewtopic.php? ... 9&start=50

sorry to spam your thread here, and excuse my ignorance. Will the stock 5 cylinder flywheel not bolt to the tdi crank? Is this why you must use the smaller 80 flywheel?

[oil_me]

death 4kqt wrote:[/quote]

I used a flywheel from an '88-'92 B3 Audi 80 2.0 gas 4cyl. (012 trans.), SPEC stage 2-228mm pressure plate with an organic disc. The engagement is a little odd as all because of all the torque comes at once with a manual pump/throttle cable; not like an eTDI. It hasn't slipped at all in spite of that. If I must do it again; I'll machine the flywheel for a 240mm PP and maybe get a heavier diesel flywheel. The starter is from a '97 TDI A4q. The flywheel in your Iltis may be an earlier series ie: like you mentioned Audi 4000 or VW Dasher diesel. Here's a link to a thread which uses your setup I think.http://www.motorgeek.com/viewtopic.php? ... 9&start=50

sorry to spam your thread here, and excuse my ignorance. Will the stock 5 cylinder flywheel not bolt to the tdi crank? Is this why you must use the smaller 80 flywheel?[/quote]
You're not spamming, I love questions. Yes, smaller flywheel (here's one BTW; http://www.ebay.com/itm/130595157805?ss ... 1423.l2649). Or you can use a 1.8t dual mass flywheel. It must be brand new, and high quality or it can fail in terrible ways. They are smoother & quieter overall. The single mass chatter some in neutral @ idle. Part of that earlier description of the clutch engagement has changed. I have a 12mm head/plunger on the pump that also lends to that effect. With timing changes and the inter-cooler the engine engagement is smoother now. I'm waiting for larger nozzles in the mail any day now which will also make the transition less abrupt. With the 12mm I'm a little under fueled with stock T4 nozzles.
Rich

[oil_me]

I just put in 16.00 gallons for 760 miles. Best tank ever @ 47.5 mpg. I don"t drive over 65 in my usual week. I also realize I need a flex pipe in the down pipe. That"s next.

[death 4kqt]

oh man, fantastic. Wish my 90 would hurry up and get here so i can get started on my swap!

[oil_me]

I installed a flex coupling in the downpipe in my quest to reduce vibration. The stock B4 diesel down-pipe with an AAZ or a 1Z engine had none. The A4 tdi from this period of overlap had a flex couple right after the turbo housing. This is what I did. I used a Vibrant flex couple with the interlocking liner.

[ralleyquattro]

Nicely done!
It is always a good idea, not even on the diesels.

here is mine on the 2.5tdi



And one on the 20vt ur-q.


Looking forward to more!

[oil_me]

I installed new, bigger, nozzles today. I've been waiting for correctly functioning injectors for 8 solid months. Third time's the charm. lol, The car starts easily, no smoke, less noisy. All is good so far. Now it's a matter of adjusting the pump timing for best mileage/power, lowest noise. I've been driving cautiously all these months because the previous injectors were wrong for a number of reasons. I cannot describe the relief of putting this episode behind me.
Rich

[PRY4SNO]

Congrats! I like this car, often wonder wonder when will be the next update... today's my lucky day

[oil_me]

A new milestone has been passed in a cloud of soot & tire smoke. I've babied this car since it's birth knowing the injectors were incorrect (too small and wrong pop pressures) and wanted to break it in slowly. That time has passed. I've been moving the pump timing up in .05mm increments to assess the power and driveability. @ 1.20mm the engine had no flexibility in the rev range, so I'm at 1.05mm for now. I've discovered the diaphram stop screw was at the the stock setting and wasn't fueling much at all under boost. I followed a procedure for tuning a Land Rover pump then tried a full pedal stomp through the gears. I sideways smoked 4 snow tires on dry pavement and scared myself good. I don't want to break anything so I'm not going to ever do that again. This thing starts in the first engine revolution when it was an honest -10º the other day. I blipped the throttle once and it held a steady idle. It has no block heater or starting advance mechanism and uses an IDI glow plug relay. I am pleased.
Rich

[death 4kqt]

that is excellent, i am so excited to have mine going. As far as breaking something goes, I think you are safe to romp as hard as you like on the drivetrain. My 90 with the holset on it got launched regularly spinning all 4 tires, wheel hopping, lifting a tire while on full boost and wild spinning. They are very strong. Thats a big part of the fun, being able to abuse them at will!

[ralleyquattro]

Brilliant.. got a vid??

[scubagli]

Good news Rich.

[oil_me]

Brilliant.. got a vid??

If it gets 10º or colder again this winter I will!
The 80q starts more quickly than my Jetta eTDI with an 11mm pump & same injectors; only fractionally less smooth idle initially.
I've moved the pump timing back up to 1.20mm as I've come to realize this set-up with a 12mm plunger will always make more noise than a 10mm eTDI will and I need to get over that fact. The clutch engagement is now much smoother with no jerkiness due to the correct injectors and a more appropriate timing range.
Rich

[stwquattro]

Very cool car AND engine swap.
Which injectors do you use?
My 5000 S Avant TDI-conversion has a 0460424124 fuel pump from an Iveco Daily 2.8TD truck...also impressive

[Justin517]

This is super cool.

I've always loved the lil dub oil burners, but never cared for FWD.

[oil_me]

Very cool car AND engine swap.
Which injectors do you use?
My 5000 S Avant TDI-conversion has a 0460424124 fuel pump from an Iveco Daily 2.8TD truck...also impressive

Your pump is my pump's twin brother (or 1st cousin). :-) The injector nozzles are made by Titan. The size is equivalent to Bosio PP520s They were calibrated by Franko6 in MO. I've been playing with the pump timing and settled at .83mm lift. Today I sent a wire transfer to the Netherlands for a 5spd 01A TDI gearbox. Fed tax refund = wisp of smoke. We've had so much snow this winter; I'm comfortably smug as I cruise the unplowed roads. It starts beautifully at -10º with no block heater, no start advance lever, and an IDI GP relay. This car has the best heat of any car I've had. It has a new heater core and new foam on the blend doors. I have useable heat at the windshield within 3 miles of leaving my house, even at 0º. I have yet to use the heated seats this season which work excellent BTW. I was going to drive the Jetta this summer but it's hard to put this car away. I just love how bone simple it is. With the gearbox installed; the dream will be fully realized. Thanks for the support y'all.

[death 4kqt]

oh man you are making me jealous. I just pulled mine outside into the snowy abyss to pressure wash out the bay, and it looks so natural out there surrounded by snowbanks.

[oil_me]

This is super cool.

I've always loved the lil dub oil burners, but never cared for FWD.

It's been my vision for over 20 years to have an AWD diesel.

[oil_me]

death 4kqt wrote:[/quote]

oh man you are making me jealous. I just pulled mine outside into the snowy abyss to pressure wash out the bay, and it looks so natural out there surrounded by snowbanks.[/quote]
I am so thrilled to see all these Audi/diesel swaps. We're going to have to have our own GTG down the road. My swap started when I saw this:http://forums.tdiclub.com/showthread.ph ... 380&page=6

[death 4kqt]

you should come to the carlisle show in may. I am hope to be able to make it this year with mine.