www.tdiclub.com

Economy - Longevity - Performance
The #1 Source of TDI Information on the Web!
Forums Articles Links Meets
Orders TDI Club Cards TDIFest 2016 Gone, but not forgotten VAG-Com List Unit Conversions TDIClub Chat Thank You




Go Back   TDIClub Forums > VW TDI Discussion Areas > TDI Conversions

TDI Conversions Discussions on converting non TDIs into TDIS. More general items can be answered better in other sections. This is ideal for issues that don't have an overlap and are very special to swaping engines.

Reply
 
Thread Tools
Old June 25th, 2008, 16:21   #61
TDIsyncro
Veteran Member
 
TDIsyncro's Avatar
 
Join Date: Nov 2005
Location: Saskatoon, SK
TDI(s): Audi/TDI x 2
Fuel Economy: 50-60mpg HWY, depending on speed and wind
Default

Quote:
Originally Posted by shortysclimbin
Very Very nice! With all these cool tdi swaps going on now Its hard to focus on my project! I would like to make a few suggestions/ ideas if you dont already know this... But I would suggest replacing that pump from the AWIC kit with something a little bit more stout. I would also suggest about a 3 gallon spare water tank for daily driving. Other than that It looks great! I really like how the car will look oem from the clean install parts.
Thanks. LOL I have trouble focusing on mine too. I had not looked at the resevoir tank size yet so I appreciate your input on that. I have a friend that works in the medigass industry and should be able to get a nice stainless steel canistor for this use. As for the pump, are you thinking that the GPM rate of that pump is a bit low? I was just debating this with a friend yesterday ( I am a bit concerned about the seals on it too). I have bosch coolant pump here, but that one is may be a bit to big. I will have to dig it out and take anouther look at it. IIRC it had 1" fittings on it. I was thinking I might install the one from the kit first and hook up two thermocoulpes to monitor the delta T I am getting through the AWIC.
I you have any other comments and suggestions, feel free to leave them.
__________________
2001 Audi A4 - New Project - 2.0TDI CR 450HP All Turbo
http://forums.tdiclub.com/showthread.php?t=270527
2007 Canyon w/2011 TDI CJAA CR
http://forums.tdiclub.com/showthread.php?t=415533
TDIsyncro is offline   Reply With Quote
Old July 12th, 2008, 21:57   #62
TDIsyncro
Veteran Member
 
TDIsyncro's Avatar
 
Join Date: Nov 2005
Location: Saskatoon, SK
TDI(s): Audi/TDI x 2
Fuel Economy: 50-60mpg HWY, depending on speed and wind
Default

Injured my lower back this week..so what should of been good prgress this week has turned into a snales pace.

I picked up the turbo adapter plate on Wednesday. Ended up getting done in a conventional machine shop, rather than the CNC route. I was able to stand for a few hours today, so I took that opportunity to do some die grinding of the exhaust manifold and adpater plate.



Here is the Exhaust Manifold and adapter plate prior to die grinding. The yellow is the area to be removed and blended.





Here the blending is almost done. Before finishing the transition, I need to remove adapter and fit to turbo again to ensure a smooth transition. I should not have to touch the turbo housing.






This is a top view of the manifold and adpater. The stainless EGR blank off plate can also be seen here, but needs clean-up yet.






Here are a few other parts, all 316 stainless, but need clean-up yet. On the left is the EGR blank off plate that will go on the intake manifold. To the right is the adapter plate that replaces the shudder valve assembly with a 2" nipple. Top of pic is the future intake nipple, yet to get a barb machined onto the end and welded up to the plate.



If I am feeling good enough, I hope to get the intercooler and turbo mounted by late tomorrow or Monday.I can then also get the map sensor pocket located and fit.
__________________
2001 Audi A4 - New Project - 2.0TDI CR 450HP All Turbo
http://forums.tdiclub.com/showthread.php?t=270527
2007 Canyon w/2011 TDI CJAA CR
http://forums.tdiclub.com/showthread.php?t=415533

Last edited by TDIsyncro; July 12th, 2008 at 22:03.
TDIsyncro is offline   Reply With Quote
Old August 1st, 2008, 12:35   #63
TDIsyncro
Veteran Member
 
TDIsyncro's Avatar
 
Join Date: Nov 2005
Location: Saskatoon, SK
TDI(s): Audi/TDI x 2
Fuel Economy: 50-60mpg HWY, depending on speed and wind
Default

Time to hyjack my own thread. Spent the last 7 days (less work) swapping an AHU into my syncro wagon. This is a transplant job from my written off syncro sedan AHU. Most was just a swap over. Cleaned up the wiring better. Went back to a G60 rad, instead of the 16V set-up in the sedan. Also replaced the angle drive unit driving the rear drive shaft, and covered off some other maintenace issues.



This is the G60 ready to be pulled.






Here is the down pipe I made when previously installed. Nice thing about it is I can install engine with it bolted on.






AHU sitting in new home and tested with VAG-COM and short warm up.



So just have to get safety inspection next week and the wagon should be on road. That means I can get serious in my Audi project - ie - engine removal next coming weekend.
__________________
2001 Audi A4 - New Project - 2.0TDI CR 450HP All Turbo
http://forums.tdiclub.com/showthread.php?t=270527
2007 Canyon w/2011 TDI CJAA CR
http://forums.tdiclub.com/showthread.php?t=415533

Last edited by TDIsyncro; August 1st, 2008 at 12:53.
TDIsyncro is offline   Reply With Quote
Old August 1st, 2008, 12:48   #64
TDIsyncro
Veteran Member
 
TDIsyncro's Avatar
 
Join Date: Nov 2005
Location: Saskatoon, SK
TDI(s): Audi/TDI x 2
Fuel Economy: 50-60mpg HWY, depending on speed and wind
Default

Took an hour last night to make a minor mod to the turbo. The factory bearing cartriage/exhaust housing on the GT2056V was pined in a position that was not favorable for the BHW oil lines nor for actuator location and discharge location.



You can see the angle relationship between the exhaust flange and compressor discharge in this pic.






I wanted to be able to re-clock this without having to play around with the actuator adjustment/rod length.

You can see the factory pin hole location in this pic.






I made up a template with 13 marks. These are the possable indexing locations available. I transfered two of them onto the turbo exhaust housing and drilled with 3/32" dia holes.





New holes shown here. These index 27.7 deg on the first and 55.4 deg on the second. I ended up using the first hole (27.7 deg), as it was almost a perfect location.





In this pic, you can see the new relationship of compressor housing and exhaust housing. The oil feed fittings and oil return fittings are now directly at the top and bottom locations, respectivley. The OEM oil feed line will just need a bit of manipulation to fit. The return line will need a striaght 1" long section added to the very end where the flange is.
__________________
2001 Audi A4 - New Project - 2.0TDI CR 450HP All Turbo
http://forums.tdiclub.com/showthread.php?t=270527
2007 Canyon w/2011 TDI CJAA CR
http://forums.tdiclub.com/showthread.php?t=415533

Last edited by TDIsyncro; September 1st, 2008 at 06:57.
TDIsyncro is offline   Reply With Quote
Old August 27th, 2008, 17:26   #65
TDIsyncro
Veteran Member
 
TDIsyncro's Avatar
 
Join Date: Nov 2005
Location: Saskatoon, SK
TDI(s): Audi/TDI x 2
Fuel Economy: 50-60mpg HWY, depending on speed and wind
Default

EDIT - I called ECS Tunning. Crank/Flywheel Bolt torque rating is 60Nm + 1/4 turn.
__________________
2001 Audi A4 - New Project - 2.0TDI CR 450HP All Turbo
http://forums.tdiclub.com/showthread.php?t=270527
2007 Canyon w/2011 TDI CJAA CR
http://forums.tdiclub.com/showthread.php?t=415533

Last edited by TDIsyncro; August 29th, 2008 at 13:00.
TDIsyncro is offline   Reply With Quote
Old August 31st, 2008, 19:01   #66
TDIsyncro
Veteran Member
 
TDIsyncro's Avatar
 
Join Date: Nov 2005
Location: Saskatoon, SK
TDI(s): Audi/TDI x 2
Fuel Economy: 50-60mpg HWY, depending on speed and wind
Default

Did final installation of turbo today. The slow drawn out planning and waiting for bits and pieces made an easy install.


Here you can see the stainless EGR blank off plates, oil feed line (just reworked the OEM line), weld flange and v-clamp on exhaust outlet. The outlet on this turbo is 2 1/4". I will make a cone to expand to 3" immediately after the turbo.





With re-clocking the turbo I had a choice between just a vertical extension to the oil line or the use of a spacer. I choose to get a stainless spacer cut (water jet cut) to extend the reach of the OEM oil return line.




As you can see in this pic, it made a nice clean install.
__________________
2001 Audi A4 - New Project - 2.0TDI CR 450HP All Turbo
http://forums.tdiclub.com/showthread.php?t=270527
2007 Canyon w/2011 TDI CJAA CR
http://forums.tdiclub.com/showthread.php?t=415533

Last edited by TDIsyncro; September 1st, 2008 at 06:54.
TDIsyncro is offline   Reply With Quote
Old September 1st, 2008, 06:47   #67
TDIsyncro
Veteran Member
 
TDIsyncro's Avatar
 
Join Date: Nov 2005
Location: Saskatoon, SK
TDI(s): Audi/TDI x 2
Fuel Economy: 50-60mpg HWY, depending on speed and wind
Default

Also Installed the ECS flywheel.


RS4 Pressure Plate and Clutch




Replaced seals on tranny Input Shaft





Pulled CV flanges to replace with the DWM flanges, and replace seals.





Did a test fit with tranny, starter, clutch assembly and engine. While I was doing this I realized I had not picked up a pilot bearing yet. Nor did I have the shroud that goes between the flywheel and engine..so I will have to pull off the flywheel and then reinstall.


You can see in the pics the dual bolt pattern (2 or 3 variations) that the bell housing has for a variety of engine options. Everything lined up good.
__________________
2001 Audi A4 - New Project - 2.0TDI CR 450HP All Turbo
http://forums.tdiclub.com/showthread.php?t=270527
2007 Canyon w/2011 TDI CJAA CR
http://forums.tdiclub.com/showthread.php?t=415533

Last edited by TDIsyncro; September 1st, 2008 at 06:51.
TDIsyncro is offline   Reply With Quote
Old September 10th, 2008, 20:53   #68
TDIsyncro
Veteran Member
 
TDIsyncro's Avatar
 
Join Date: Nov 2005
Location: Saskatoon, SK
TDI(s): Audi/TDI x 2
Fuel Economy: 50-60mpg HWY, depending on speed and wind
Default

Got going on the engine removal today. Took the exhaust system of first. Everything was in such good shape. All the exhaust bolts and hanger bolts came off with minimal effort. I was very impressed with the design and quality of every bracket, bolt, etc.
After the exhaust was off, I removed the CV's, pulled the wire harness from the ECU and removed a bunch of other smaller items.
I then dropped the sub frame about 3" so I could pull the engine and tranny together in one shot.














Anyways, my goal was to have the engine pulled by the end of the day, and I got her done by 7:00PM, so I am happy with that. Now I have to jump back on some house renovations for a couple days, then back to the BHW engine/tranny assembly and install in the weekend. I can see a small list of items I will have to pick up to make things fit. (such as A/C lines and steering pump lines, different heater hose lines?) These minor things may trip me up a bit on progress as it would be a pain in the ass to change out some of these things after the BHW is installed.

Oh, I also went out to a local wrecker yesterday and pulled some ALH wire harness stuff I needed. I will post a few pics on that tomorrow.
__________________
2001 Audi A4 - New Project - 2.0TDI CR 450HP All Turbo
http://forums.tdiclub.com/showthread.php?t=270527
2007 Canyon w/2011 TDI CJAA CR
http://forums.tdiclub.com/showthread.php?t=415533

Last edited by TDIsyncro; September 10th, 2008 at 20:58.
TDIsyncro is offline   Reply With Quote
Old September 12th, 2008, 18:44   #69
momo_focus
Newbie
 
Join Date: Sep 2008
Location: Toronto, Ont
TDI(s): Jatta TDI
Default

update please
momo_focus is offline   Reply With Quote
Old September 12th, 2008, 21:22   #70
TDIsyncro
Veteran Member
 
TDIsyncro's Avatar
 
Join Date: Nov 2005
Location: Saskatoon, SK
TDI(s): Audi/TDI x 2
Fuel Economy: 50-60mpg HWY, depending on speed and wind
Default

Finished the tranny CV flange change out today. Installed the bell housing/engine shroud I was missing, and assembled the tranny and BHW together.

I also got the engine in the A4 with the motor mounts bolted down and one CV axle on. Fitting the engine in was a bit of a problem with the larger turbo. I had to pull it out about 4 times and finally ended up adjusting the frame rail a bit and shimming the passanger motor mount. This gave me exhaust housing clearance from the frame rail. The starter cable will need a new route.
The ARL wire harness is going to be a bit messy for routing as it is completly in the wrong orientation for the ECU plenum on the A4. I will have to do something custom with the heater hoses. I will take one more day this weekend to work through some of these issues.

Sorry no pics tonight, I can not get the wifes camera to communicate with my computer right now.
__________________
2001 Audi A4 - New Project - 2.0TDI CR 450HP All Turbo
http://forums.tdiclub.com/showthread.php?t=270527
2007 Canyon w/2011 TDI CJAA CR
http://forums.tdiclub.com/showthread.php?t=415533
TDIsyncro is offline   Reply With Quote
Old September 13th, 2008, 08:00   #71
TDIsyncro
Veteran Member
 
TDIsyncro's Avatar
 
Join Date: Nov 2005
Location: Saskatoon, SK
TDI(s): Audi/TDI x 2
Fuel Economy: 50-60mpg HWY, depending on speed and wind
Default

OK, got the pics off. It was dark last night, so I am going to retake some of them. Here are a few teasers. I will fill in the rest later, as I don't have time right now.




EDIT - I used the V6 engine mounts. They worked good. It took some wriggiling to fit it in the first time. Scratched the paint in a few places..erg. Any ways, happy it in there. I had to do some frame rail adjustments and relocation of starter wiring to provide clearance for the larger turbo. I also shimmed the passanger side about 1/4". CV's, rear drive shaft, shifter linkage etc is all hooked up at this point.


__________________
2001 Audi A4 - New Project - 2.0TDI CR 450HP All Turbo
http://forums.tdiclub.com/showthread.php?t=270527
2007 Canyon w/2011 TDI CJAA CR
http://forums.tdiclub.com/showthread.php?t=415533

Last edited by TDIsyncro; September 21st, 2008 at 21:29.
TDIsyncro is offline   Reply With Quote
Old September 16th, 2008, 08:05   #72
Scott_DeWitt
 
Scott_DeWitt's Avatar
 
Join Date: Apr 2004
Location: Texas USA
Default

That sure does look purtey!
__________________
www.advancedautomotion.com
Scott_DeWitt is offline   Reply With Quote
Old September 16th, 2008, 12:36   #73
shortysclimbin
Veteran Member
 
shortysclimbin's Avatar
 
Join Date: Oct 2004
Location: Virginia currently
Default

I would almost think you would want a different intake on that? I dont have one to swap with you but maybe someone here might be able to help you out. It just looks like piping will be a pita otherwise. Did you fit new injectors in it yet btw? She is looking good and you are moving well on it.
shortysclimbin is offline   Reply With Quote
Old September 18th, 2008, 09:29   #74
TDIsyncro
Veteran Member
 
TDIsyncro's Avatar
 
Join Date: Nov 2005
Location: Saskatoon, SK
TDI(s): Audi/TDI x 2
Fuel Economy: 50-60mpg HWY, depending on speed and wind
Default

Quote:
Originally Posted by Scott_DeWitt
That sure does look purtey!
Thanks Scott. I should make some good progress this weekend..the next batch of misc parts are pretty much all lined up now.

I have not had an easy time trying to find a used 1.8T power steering hose. I overlooked that one. Today I had my 2.8V6 one modified at a hydraulic shop. Lot less money and one day turn around.

Any tips on installing the pressure side hose?? It was miserable to remove. 10deg/turn in a blind hole with a box wrench.
__________________
2001 Audi A4 - New Project - 2.0TDI CR 450HP All Turbo
http://forums.tdiclub.com/showthread.php?t=270527
2007 Canyon w/2011 TDI CJAA CR
http://forums.tdiclub.com/showthread.php?t=415533

Last edited by TDIsyncro; September 18th, 2008 at 09:38.
TDIsyncro is offline   Reply With Quote
Old September 18th, 2008, 09:37   #75
TDIsyncro
Veteran Member
 
TDIsyncro's Avatar
 
Join Date: Nov 2005
Location: Saskatoon, SK
TDI(s): Audi/TDI x 2
Fuel Economy: 50-60mpg HWY, depending on speed and wind
Default

Quote:
Originally Posted by shortysclimbin
I would almost think you would want a different intake on that? I dont have one to swap with you but maybe someone here might be able to help you out. It just looks like piping will be a pita otherwise. Did you fit new injectors in it yet btw? She is looking good and you are moving well on it.
thanks. I think the intake will be good. It may look better when you see where the AWIC will be mounted, it is just a 180deg reducer turn from the AWIC outlet into the intake nipple. However, I am thinking of replacing it in the future to create a cleaner look.
The injectors? Well, for now they will stay stock. From what I understand, they are the same part number as the PD150 units so should work good for my purpose.
__________________
2001 Audi A4 - New Project - 2.0TDI CR 450HP All Turbo
http://forums.tdiclub.com/showthread.php?t=270527
2007 Canyon w/2011 TDI CJAA CR
http://forums.tdiclub.com/showthread.php?t=415533
TDIsyncro is offline   Reply With Quote
Reply


Currently Active Users Viewing This Thread: 1 (0 members and 1 guests)
 
Thread Tools

Posting Rules
You may not post new threads
You may not post replies
You may not post attachments
You may not edit your posts

BB code is On
Smilies are On
[IMG] code is On
HTML code is Off

Forum Jump


All times are GMT -7. The time now is 14:58.


Powered by vBulletin® Version 3.8.5
Copyright ©2000 - 2017, Jelsoft Enterprises Ltd.
Copyright - TDIClub Online LTD - 2017
Contact Us | Privacy Statement | Forum Rules | Disclaimer
TDIClub Online Ltd (TDIClub.com) is not affiliated with the VWoA or VWAG and is supported by contributions from viewers like you.
1996 - 2017, All Rights Reserved
Page generated in 0.17463 seconds with 9 queries
[Output: 143.47 Kb. compressed to 120.06 Kb. by saving 23.41 Kb. (16.32%)]