1988 audi 80 quattro to pd130

[jjordan11]

I contacted Geoff today regarding a stage 1 pd camshaft grind, I'll probably send it in next week to get the work done. Before I put the engine in the car I inspected the cam for wear and there was some, I was a bit dissapointed with it, but it was to be expected with a higher mileage PD. I don't think/I hope the wear isn't too bad that the cam will be a paper weight. I'll measure the camshaft lobes when I get back into town next week sometime.

More updates soon.

Jon

[hid3]

Nice project!

Sorry to hear about your cam. How many miles does the PD engine has got?

If I were you, I'd repplace camshaft and stuff now in order to avoid problems/repairs/downtime in the future. Once the cam wear has started it will develop at accelerated speed..

[Scott_DeWitt]

Originally Posted by jerry_m

Nice project!

Sorry to hear about your cam. How many miles does the PD engine has got?

IIRC the engine was in the 60-70,000 mile range. Also might want to get with TDIsyncro regarding PD cams, I think he had something brewing.

BTW Jon you should see your alternator next week.

[jjordan11]

Made some progress after work tonight. Wiring is getting closer to completion, I need to check some power supply wiring at home. I need to get an origional oil pressure switch for the Audi still. I also got the camshaft sent out to Geoff at Colt Cams yesterday, I'd like to get it running and driving before it snows too much here. More updates soon.

Jon

[jjordan11]

I decided that now was the time to do the camshaft oiling mod that franko6 outlined in one of his threads. It wasn't too bad and makes sense to do due to the wearing of the bottom camshaft bearings. My new lifters came too. So now the wait for Colt Cams to grind my camshaft and return it.

Has anybody used non-stretch bolts (10.9 or 12.9) for the camshaft caps and also the injector rocker shaft? I remember seeing a thread for maybe getting arp to design a stud to hold down the injector rocker shafts, but I don't think that anybody has went that route yet. I have been searching for the right length/diameter/thread bolts with even an allen head that is grade 12.9, but it's proving to be difficult. I'll probably end up just replacing the cheese head screws, I wouldn't know what the torque spec would be with a non-tty bolt anyways.

I also got about 70% of the wiring done. I've decided to mount the ecm in the location of the motronics fi unit, it should be well protected and I have plenty of wiring thanks to the rhd British Audi that the engine and harness came out of.

I installed the oil pressure switch and found one of the signal wires for the instrument cluster, it is grounded at rest and looses it's ground with oil pressure. I also connected the coolant temp gauge to the sender that was tapped into the flange.

I have been thinking lately (now that I am getting closer to finished) about the driver's side motor mount on the chassis side that I welded. As other's have pointed out I don't think that it is strong enough. I need to re-think the design of it, I sure wouldn't like the mount to fail. I'd rather it overbuilt than good enough .

More updates soon.

Jon

[TDIsyncro]

PM Franko6 or Rod Bearings for the bearing cap and rail bolts, I think they have both replaced with standard 12.9 grade metric bolts.

If you get the info, please post back here for others.

[jjordan11]

I just got off the phone with Geoff there at Colt Cams. He said the cam was caught just in time (which I definitely believe), there was a visible wear mark on the tips of every exhaust lobe. My camshaft is done and he should be shipping it back to me this week, I'll post some pictures when it arrives .

I spoke with Scott D. about cryo. treatment and also wpc treatment, I think it sounds like a good idea. I brought it up with Geoff, he wasn't opposed to it, but didn't necessarily think it was necessary. What do you guys think?

I also talked with franko6 regarding the 12.9 grade fastners for the camshaft caps and rocker arm shafts. They should be on their way to here. I'll post the cost and torque method/values when I receive them.

[jjordan11]

Working on some of the periferial wiring for the car. I decided to use the Audi 80 cruise control switch and tie it into the ecm to supply the signals and have the ecm control the cruise. Only one problem, the pins for the cruise are 44, 45, 46, and 14 according to the AWX wiring diagram and also the edc 15 ALH diagrams I am looking at. With my wiring harness those pins are blank (no wires) . I suppose that maybe cruise control was an option in England? Anyone know if I could just put wired terminals into the empty terminal slots and activate cruise in the ecm?

I have the vehicle ready to start (minus the camshaft), but all the necessary wires are hooked up and good. I was concerned for a little bit concerning the speed signal to the ecm. Normally it goes from the sensor to the cluster than to the ecm. I didn't know if the ecm had a built in digital converter or not, but I don't think that will be an issue now as the 80's cluster gets the analog signal then sends out a signal to the old cruise control module and to the differential lock control module. I would assume that the signal going to the cruise module would be a converted signal, I'll hook up the dso just to make sure before I wire it into the ecm though and report my findings.

edit: Here are some pictures of the connector, pins 44, 45, & 46 are the leftmost three toward the camera.



Here's a messy shot of the wiring in the driver's footwell.



It looks worse than it is, most of the wiring on the floor are wires that are from the original 80's engine harness.

[vwmikel]

You probably won't have an issue wiring up the cruise and then just enabling it in vag-com. There are coding instructions around somewhere. I had to do the same thing. On my car I have the VSS wired to both the cluster and the ECU. Both seem to work fine. I have my doubts that the output signal from your cluster will work properly with the ECU, but it's worth a try. Maybe Dakota digital has something that will condition the signal for you.

[jjordan11]

Ok, thanks Mike. I'll try a direct connection to the ecm from the speed sensor. That would be easiest. After I get it going I'll need to have you chip it and we'll do the map based program you have. I'll pm you later when I'm ready for it. Are you planning on going to TDIfest in Portland?

[vwmikel]

Originally Posted by jjordan11

Ok, thanks Mike. I'll try a direct connection to the ecm from the speed sensor. That would be easiest. After I get it going I'll need to have you chip it and we'll do the map based program you have. I'll pm you later when I'm ready for it. Are you planning on going to TDIfest in Portland?

I really have no idea yet...when is the Portland thing? This summer?

[jjordan11]

Here is a link to it. http://forums.tdiclub.com/showthread.php?p=2770732
I'm not sure if I will be able to go, but I am more tempted now than ever to go .

[hid3]

jjordan11, be sure to post HIGH QUALITY pics of the old cam/followers/bearings when you replace them. The pics might help to guess the general wear on PD130 engines...

[tomiisp]

for enabling CC just use Login 11463 in Vag-com
ECU speed signal not need goes from cluster instr. , I have directly connected speed sensor from gearbox to ECU (paralell with cluster) without any problem (speed sensor is ,,pasive,, and it have two states - switched to ground and nothing , like simple button).
Signal GND/12V also work fine with ECU , ECU gets GND state as active

btw, when you replacing camshaft, I highly advise replace also o-ring sealings on injectors, they are common source of problems (engine shaking on acceleration/idling, fuel leak to oil, low pressure of fuel on injector input because it leak over o-ring to return line-this can be checked on Group 13 at VAG-com, if one cylinder goes over +2.0mg at warm that can be bad o-ring...)

and at last,one trick how to set-up 100% sync between camshaft and crankshaft, just look at Group 4 in VAG, last 4th value, there is sync value, ideal is 0.0 to +0.5, if you have negative values (+/-0.5 is fine) you can have growed fuel consumption and some lost of power, positive values have negative effect on power and engine noise

small tip, basic ,,tunning,, you can get with using SW from AVF engine, you get higher torque and more smooth engine running opposite to AWX soft (I advise to use 019KF from AVF on AWX engines >=2003), only difference between AWX and AVF is in clutch, AWX have 228mm(5 level gearbox) and AVF have 240mm (6 level gearbox and higher torque)

[jjordan11]

hid3 I sent you an e-mail with high resolution pictures, if anybody else wants some picts of the cam and lifters send me a pm with your e-mail address and I'll send the pictures.

Thanks Tomi, I was able to get the wiring done last night. I can't start it yet, due to the missing Cam , but it was cool to hear the lift pump turn on when I turned the ignition on for the pre-prime. I hooked up vag-com for the first time and activated cruise control. I looked at the measured values for the cruise and it's not working like I thought it would yet, I'll have to do some more figuring.

I still need to do the exhaust and the intercooler piping, I have all the silicone pipes and t-bolt clamps, just not the metal pipes. I also need to make a bracket for the fuel pump, I am re-locating it to along the bulkhead of the vehicle.

More updates soon.

Jon


Edit: I figured out the cruise control, I had some wires reversed. I was trying to figure out the different locations based on the diagram, but I ended up doing a bench test of the 80's cruise switch and matching them to the ecm's inputs. It appears to be functioning correctly now. We'll see when it's driving.

Now there are only 4 codes that need to be cleared up via programming. egr solenoid, intake manifold flap, missing message from airbag, and instrument cluster. It should have missing message from abs, it will probably show up later though.