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GTiTDi September 29th, 2012 11:45

And now, for something completely different; Audi 5cyl Turbo Diesel build up!!
I recently picked up an '87 Audi 4000CS Quattro, which had been sitting for quite some time with CIS fuel injection woes. I had worked on it when it was up and running years ago, and had fond memories of test driving it in the snow. When I came across it languishing behind a local general repairs garage, I figured I would try to save it.
sad Audi :(
Off to a new home
here is a video of running it on ether since the main fuel line to the accumulator is rusted out...
So, with having to revamp the fuel delivery system against me, and desiring to upgrade the stock engine to something a bit more exciting, I started going through my available options.
First thought was, AHU swap. I would have to get a Euro 4cyl bolt pattern 016 trans to use the AHU without an adapter, or I would have to change to a more modern Torsen diff setup since the later gear boxes are dual bellhousing bolt pattern, but I want to keep the manual diffs.
Having to keep a five cylinder to use the stock driveline, I thought about a 10V turbo MC1 or MC2, which can be had cheap. Nearly everyone with a 4KCS quattro does that swap though.
For A LOT more money, I could get myself going building a 20V turbo...But that can get scary fast....I don't want to spend too much building this car...

SO this is where my path went astray of the norm...

30 years ago, my father and one of his good older friends, Lee Fenton,who was a huge influence on me and like a true guru, were huge into diesel power. They loved M/B, VW, Peugeot diesels, and collected many M/B 220 and 240Ds and one 1983 Audi 5000 TURBO DIESEL!!! They got it cheap because its Auto tragic slush box was pooched after 129,000 miles,,,BIG SURPRISE RIGHT???:D
Needless to say, they never got around to fixing or finding another transmission for the Audi, but they knew the engine would be worth saving to repower something else some day....So they would periodically run it...But the last time I remember it running was over TWENTY YEARS ago..I was like 5-7 years old or so IIRC...
My friend Lee passed away due to complications from cancer, he was nearly 80 years old. If you knew him and his various exploits racing motorcycles , you would be amazed he lived that long! (He raced motorcross in the late fifties before there was anything remotely similar to a dirt bike)
After Lee died, his shop and vast collection went to his son, who is also a friend of mine. He is cleaning up the shop and getting rid of some of the more rotted out cars, and the Audi was one of the first on the list....
I stopped him and told him Lee would want us to at least save the motor.
I did. I got it out in a couple of afternoons.
I highlighted the cool "turbo"script with my greasy fingers!!
What better temporary cover than an old Beetle hood?

Here is a video of it running after being dormant for so long!

So the plan is....
Pull head, port, polish, maybe bigger exhaust valves (33mm rather than 31mm)
MOAR FUELZ !!Turn up IP, governor mod, If I win the lottery it is going to Giles!!!
Inter cooler
MOAR BOOST!! The stock K24 should be more than adequate and is in excellent condition.

VeeDubTDI September 29th, 2012 11:47

Can't wait for videos!! Cool project. :D

GTiTDi September 29th, 2012 12:03
The intake manifold is virtually identical to the 10V turbo gassers minus the throttle body and most of the mounting bosses aren't drilled and tapped! I am thinking of modifying a Gasser intake to replace the PD intake on my GTDI....

burpod September 29th, 2012 12:56

nice :D that thing is gonna be SWEET! if you want, i'll rebuild that engine for ya!! ;)

GTiTDi September 29th, 2012 13:02


Originally Posted by burpod (Post 3948869)
if you want, i'll rebuild that engine for ya!! ;)

No, but you are welcome to come over and take notes!!! :D

GTiTDi September 29th, 2012 13:06

Since intercooler setups are a tight fit on these inline fives, I am contemplating modifying a gasser turbo intake to hold a air to water intercooler a la boost lag and or plumbing is enticing :eek::cool:

burpod September 29th, 2012 13:15

chris, remember i think i have this water/air or something intercooler in the shed! i think it may have even come from an audi??

better watch the garage door at night, else i'll sneak in and rebuild that block :D bwaaahahahhahaa

GTiTDi September 29th, 2012 20:14

Here is the kind of intercooler Pod gave me!

Growler September 30th, 2012 05:27

Wow what a sweet motor to have floating around.

Def will be following this one.

GTiTDi September 30th, 2012 09:24

NO RUST on the turbo flange studs/nuts!! I am amazed!
K24 is mint...
The vane style vacuum pump is positively lubricated where it bolts to the cylinder head, a nice long lasting design IMO
the trusty old Bosch VE pump sprocket lock tool fits the 2.0TD's IP of course...There are also notches marking the locked position of the pump, very cool!

Frankencar September 30th, 2012 13:36

100% win! Me like! :D

Matt-98AHU October 1st, 2012 09:49

Niiiice! Cool story and awesome idea. Love the sound of 5 cylinders!

bhtooefr October 1st, 2012 10:31

Why am I not subscribed to this thread yet?

Seriously, this thread is win.

GTiTDi October 2nd, 2012 07:31

Ordered a bunch of "whole sale closeout" parts from Rock Auto. Most of the stuff is Beck/Arnley, which I have been told is usually re-boxed name brand parts. For the amount of stuff I got and how much I paid, it should be worth it! Some of the parts are hard to find! I got two head gaskets, a two hole and a three hole, and I am contemplating running the three hole to slightly reduce CR so I can crank up the boost...I did this on my 1Z build and it seems to have worked out fine, the few times I have driven with a boost leak were surprisingly not TOO slow ha ha!

bhtooefr October 2nd, 2012 07:36

Personally, I wouldn't screw around too much with compression - you don't want to go below 20:1 or so, as these IDIs need all they can get for good startup characteristics.

Also, being a 1983, it may not have the very latest glow plugs. So, update the glow plug system to as new as you can get it (the system in the Canadian 2.4NA Eurovans would be ideal), for the fastest, most powerful glowing.

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