1.9 TDI into 90q: resurrection and for sale

[audidub]

Finally! Now it should be on the road by the end of the month right

[jcarrick]

I'm really excited to see this thing run! I think this is the route I will go with my wife's 90 here soon


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[AngryTaco]

When does it get an hx45?

I suggest going to a colder step glow plugs and advancing the ignition distributor 12-degrees for max soot and powah

[scubagli]

Ignition distributor? Lol hope your kidding. Big singles don't work so well when your absolute max rpm is 7k...Dana you should consider a vnt conversion makes a world of difference on the ahu.

[dana]

i will likely put it together all stock and get it running, then decide what to do for tuning. Its an option for sure. Currently I'm going to just slap the k03 back on and run it as is. $$ is tight.

[AngryTaco]

Ignition distributor? Lol hope your kidding. Big singles don't work so well when your absolute max rpm is 7k...Dana you should consider a vnt conversion makes a world of difference on the ahu.

yeah lol

[PRA4WX]

Ignition distributor? Lol hope your kidding. Big singles don't work so well when your absolute max rpm is 7k...Dana you should consider a vnt conversion makes a world of difference on the ahu.

It sure has on mine.
Keep it coming, Dana. You are driving to BBQ-right?!

[dana]

yea, bbq 2016, see ya there!

[dana]

bad news for this project, but good news for my sanity. I'm picking up a mk4 tdi wagon to daily. I need something more modern than my mk2.
Going to sell my truck and my mk2 then continue on with the tdi quattro project. Of course the mk4 needs a bunch of crap and will budge in line in front of the poor neglected 90!

[PRY4SNO]

Wait... wut?

Talk about a 180˚ turn lol.

Are we talking proper quattro, or Haldex?

[dana]

Wait... wut?

Talk about a 180˚ turn lol.

Are we talking proper quattro, or Haldex?

no no, just a stock mk4 tdi wagon for a daily driver. Plans with 90 remain the same as before. I daily a mk2 right now and I need to upgrade to something more modern. Going to fix up the mk4 and daily that. It needs a flywheel, and obviously bigger injectors and tuning and a straight pipe.

....then switch back to working on the 90 again.

[my2000apb]

ive still got a good stock alh fw if you need it

[PRY4SNO]

Ahhhh, gotcha. You can haul plenty many Audi parts in the back of a mk4 wagon.

Plus the added benefit of being cheaper to run per mile than the Power Stroke.

Good call.

[dana]

ill be sad to see the powerstroke go, but I barely use it anymore. My days of buying a new car to part out every week are over and that is why i bought it in the first place. I have owned that truck longer than any other vehicle, and its probably the nicest thing I've ever owned. Now it just sits and rusts in its parking spot.

Tim, im going to convert to g60 SMF, and vr6 clutch so i can max out the stock turbo. The kits are pretty reasonable.

[scubagli]

I have a 4 puck unsprung stg3 clutch you can have for the price of shipping if you want it....it's alittle hash but totally drivable.


Sent from crazy town.

[dana]

Suppose its time to update this,

Because I'm a diesel newb, I had the head decked to ensure flatness. They only took off 5 thou, but in hindsight, it was probably not necessary. Since diesels have such tight piston-valve clearances, I realized that I new had shaved off .005" of the .015" clearance that the factory had the valve to piston clearance. I got creative and decided to carefully measure the valve length and shave the ends off on a bench grinder. I then spun the valves in a drill and polished them down on a straight edge with various grades of sandpaper. They are nice and smooth and are back to the factory clearances. Time will tell if this explodes, but I think not.




head all re-assembled.




spend a bunch of time cleaning, scraping, needle scaling, sandblasting (every bolt) and painting engine parts.








Then I made a little block off plate for the 1.8t turbo drain. The tdi drains back into the block, so i didnt need this port. I used an old drain from a 1.8t and cut off the flange and plugged the hole.






new timing components. There was an ungodly amount of veggie oil fossils everywhere here from a leaking injection pump main shaft seal.


coming together






did a little work in the engine bay before putting the engine back in (hopefully for good this time)
new tie rods for the car


new rack boot


vacuum brake conversion






then i decided i wanted a working factory oil temp gauge, so i removed my cap on the oil drain in the 1.8t pan and tapped it for the audi factory oil temp sensor.








engine going back in









spend a good 6 hours on the floor learning the wiring harness.


hell hole


getting it pared down


eliminated wiring


purchased a tdi 01e 4.11 6 speed quattro trans, this will make the whole project worth it. It became apparently to me after driving around my mk4 in 4th gear that I would need something with TDI gearing to make this swap worth the effort and money.



oh yea, and also....
[youtube]https://www.youtube.com/watch?v=P8lfaTSdElE[/youtube]

started right up on the first try. Very very pleased about that. The wiring is obviously everywhere, I just wanted to make sure my wiring theory was correct. Now its time to start organizing the bay and wrap the harness.

I also reinforced my engine mounts big time. Didn't get a pic of those yet, but they are much better than before.

[DE80q]

The youtube link didnt work over there It sounds great!

Is that still the flywheel you got from me?

[dana]

yep, that 80 flywheel works perfect. I am using a tdi 80 starter I got from germany with the spacer plate from a 2.0 fwd 80. All fit like it was made to be.

[PRA4WX]

Love it! Plans for mounts?

[dana]

transmission mounts? or engine?

Trans mounts will be home built out of steel and rest on the factory 90 rubber pads.

Engine mounts are home built out of an old winch mount plate and steel twin bed frame. Sitting on factory b3 chassis mounts with factory rubber.

[90quattrocoupe]

Niiiice!!

[PRA4WX]

Cuel! I look forward to see what you construct!

[dana]

They won't be pretty, and will likely be made from what remains of the winch plate I cannibalized for my engine mounts and whatever else I can get from my scrap pile.

[vt10vt]

They won't be pretty, and will likely be made from what remains of the winch plate I cannibalized for my engine mounts and whatever else I can get from my scrap pile.

Just do 911 engine mounts, you can buy a set of factory ones for nothing and I can set you up with some 85 shore bushings for them.

[dana]

how is their stiffness? I am kind of aiming for the opposite of normal since a diesel vibrates so much. I was thinking soft squishy stock rubbers would be the best option for me in this case. Never had my hand on 911 mounts, not sure what they are like.