1.9 TDI into 90q: resurrection and for sale

[vt10vt]

Stock are pretty squishy but the stiffer rubber versions still don't seem all that stiff

[chaloux]

When I used the stock s4/s6 rubber it was brutal and they ripped apart after about 3500km

[dana]

interesting...was your TDI on a stock turbo?

I think Rich was using stock mounts without issue, I'll need to review his thread.

[WOMBAT]

Dana doesn't drive his cars hard, stock mounts will be fine.

[dana]

clutch dumps every day!

[dana]

Dana doesn't drive his cars hard, stock mounts will be fine.

i like to take it easy, and my daily commute is pretty forgiving.
[youtube]https://www.youtube.com/watch?v=iLvd_Bh00_I[/youtube]

[DE80q]

at least now I understand wanting the quattro so badly!

[dana]

:rofl: at least now I understand wanting the quattro so badly!

its pretty much a necessity 6 months out of the year!

[PRY4SNO]

Hope you have a belly pan!

Er... wait.

Hope you don't, and feel like making some out of aluminum and selling them to folks like me.

[dana]

Hope you have a belly pan!

Er... wait.

Hope you don't, and feel like making some out of aluminum and selling them to folks like me.

my mk4 in the video did not....and I ended up doing this later this spring.



The 90 has the factory belly pan, but really with AWD i'll be able to go much slower up that hill during mud season and should be able to get by 99% of the time. With Front Wheel Fail, I have to keep the speed up to make the climb and thats what does the damage.

[PRY4SNO]

Shitty! At least both the sump and belly pan are easily enough found at a wrecker for a mk4.

If you ever make an aluminum b3/b4 pan, I'll buy one!

[dana]

Shitty! At least both the sump and belly pan are easily enough found at a wrecker for a mk4.

If you ever make an aluminum b3/b4 pan, I'll buy one!

It actually might not be too hard, especially since I have the stock plastic stuff to model after.

The mk4 pans are $49 brand new! I guess they sell a few of those.

[PRY4SNO]

It actually might not be too hard, especially since I have the stock plastic stuff to model after.

Exactly my thoughts... you should do it! You know, for the community

[scubagli]

Rich is using stock 4k diesel mounts. So you driving it?

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[dana]

not driving yet, but engine bay is getting close to being ready for final wiring harness build. I've been getting pretty anal about the crossmember i built for the intercooler and radiator. Also, the piping is taking me a long time since I am trying to make it look decent. I spend a bunch of time and money on some real tool boxes and i build a nice new welding table.

Getting back into the car this week to finalize charge piping and then button up engine bay so i can build my harness to lay in it correctly.

[scubagli]

Sweet, I need to buckle down on the 4k, just bought a multifunction welder, ac/dc tig stick and plasma in one unit. That should help...

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[dana]

nice! that sounds excellent. Plasma and TIG would step my fabrication game up significantly! Thats a ways off in the future, since I just got real toolboxes and workbench for the first time.

[dana]

a little more progress. Been working on this regularly, but progress is slow. I think I'm getting more anal every time I build a new car, and its taking me way longer to perform simple tasks like charge piping, and engine bay layout. I'm finding it hard to make a TDI look like it belongs in this car.

got some used tool boxes and build a new steel welding/fab table.




I needed to get the factory air temp sensor into the piping, post intercooler. The factory bung is plastic, so i replicated it out of steel. Got some DOM tubing that was just about 1" I.D. and replicated the factory plastic bung out of steel using a grinder to match pipe profile and a cutoff wheel to cut the clip groves. Works well, not too pretty, but its hidden in the car anyway.





Charge piping in progress


airbox adapter made from an old winch plate:
















Then I drilled a hole that is the right size for the sensor portion to fit into the airstream, but small enough to retain the sensor on the outside of the pipe.


the final product

Charge piping complete minus a couple 1/8 npt bungs i need to add to the charge piping for boost gauge, ecu and n75 connections.

[DE80q]

Looking great! I think this will be my next swap.

[dana]

Looking great! I think this will be my next swap.

i hope its worth it. I'm glad that Rich has a running car and is loving it, definitely helps with the motivation. Its really not that straight forward of a swap. I did a 20vt swap in 2 days, going from a running daily 7a to a running daily 3b, 48 hours! This damn swap is taking me forever.

[scubagli]

Lol yeah it isn't direct.

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[PRY4SNO]

Wow, love the airbox adaptation, looks killer!

[chaloux]

Looks fuggin awesome Dana. Charge piping looks great. Mine was SO ghetto in comparison.

To answer your question way back when, yes my alh was stock turbo.

[dana]

thanks guys! the charge piping has taken me a long time! Way longer than it should, but i think it came out well.

now its starting to look like a real engine bay again!

Intercooler and radiator crossmember is complete. You can't really tell, but there is some framework that the radiator sits on and the intercooler mounts to. It ties the whole front end together (kind of like the b5 cars) so you can take the entire assembly off the car in one piece. Should make servicing pretty easy.



there is so little room in there for a fan, i had no choice but to direct mount a slim fan. I lined the back of it with foam and made some backing plates to spread the load out to the edges of the radiator. It is very solid now, and I think will be no problem unless I crash into something.






you can see my reinforced motor mount here




added some boost fittings for boost gauge, ecu and n75


MFTS adapter made. A bit ugly, but looks good installed.


all the coolant piping and charge piping is finally fitted!


I was able to use 95% oem stuff.
-top hose is OEM 2.0 audi 80 with the oil cooler connection cut out and replaced with my coolant sensor bung.
-bottom hose is the stock audi 90 20v top hose cut to fit
-the rest of the stuff is a mix of the OEM tdi stuff and b5 a4 hoses.

[audifreakjim]

I just finished doing an aluminum version of that using the factory bungs from an old coolant flange. Yours looks great, welding old oil soaked cast aluminum, yeah..