Chirsis Audi Coupe Quattro 1.9 TDI Swap (AFN)

[Chirsis]

Hello, i'm newby here but anyway -here's my story.
Long time ago I wanted to build a project like this.
And finaly i made it.
So I bought Audi Coupe Quattro B4 (1991), with 2.8 V6 Engine.
After 3 days, i took out the engine.
I bought this car for 1k Euro.
Note that I'm working and swaping the engines outside, I have no garage for that, so yeah... Some might say it's sick, but I dont care, I just stick to the plan.
Okay!
Then i bought 1.9 TDI AFN engine, bought 11mm fuel pump, 2.5 AEL nozzles and this is how the story begins.
This is a picture of my audi when i bought it. (Old owners picture)

And here it is in my place.

Here's the V6. This engine would be great as a table.

No more V6.

Since I bought 11mm Fuel Pump, this mount had to be made bigger, because the head of the pump didn't fit inside.

Had to buy different engine mounts:

By the way - i left my old 2.8 Gearbox, because ain't got money for 6gearQgearbox yet.
Intake manifold from 130hp PD 1.9 tdi.
Measuring engine mounts before welding them.

And here's my dad in the picture working on the mounts:

Here are the mounts allready painted in the right color.

I knew that the V6 clutch won't handle the Power so I bought Audi S2 clutch.

 

[Chirsis]

. Sorry for this double post.

 

[Chirsis]

In the flywheel we had to drill new holes so everything can be fit:

And there goes the heart:

Had to put in and take out the engine 3x, because at starters, there were some problems with the gearboxes fitting with clutch.
Here you can see modified front so I could fit the new IC.

This is how it looked at the beggining:

Bought 4 BAR MAP sensor, and here U can see the flange wich was made by my father:

Custom Stainless steel pipes for IC, also made by my dad

This one looks a bit better:

After that the Wiring started. Some of the wiring jobs, i'd say most ouf them I did myself. It took me lot of time, lots of headaches, but I did it.
Had a help from an electrician guy aswell.
And here are some first runs.

http://www.youtube.com/watch?v=sTA_oEweVJo&list=UUsKdF496k9kc4x1Cz6E-pSA&index=1&feature=plcp

At the beggining, Diesel Fuel pump couldnt pump up enough fuel thru the Engine Fuel Pump wich is in the Gastank, so I had to remove it. After that - everything went well

 

[Chirsis]

Bought VNT20 turbo from Audi V6 2.5 TDI.
Since I bought this turbo, the best (cheapest) thing to do was this:
Got Exhaust manifold from 1.6 VW Golf (JR engine code)
And yet flanges have been made:

Great success:

Had to make some custom job to Oil pipe:

Bought Air Filter it's not placed like in the picture now, but oh well, here's the picture at the beggining:

 

[Chirsis]

Remake of the IC position. Now its MUCH better:

Started to Fit the panel back in. Wire nightmare looked like this at the beggining:

After that, my father helped me to make Straight exhaust pipes:
60mm pipes

Here are some video of testing the sound: a bit better than before:
http://www.youtube.com/watch?v=HGUAl3zaVac&list=UUsKdF496k9kc4x1Cz6E-pSA&index=1&feature=plcp

And here's a video of testing a little with no exhaust.

https://www.youtube.com/watch?v=4B59zv1qsSU&feature=youtube_gdata_player

EGR Was removed, MAF was removed.

 

[GTiTDi]

This is awesome! I want to do the same thing but with an Audi 4000CS Quattro, The problem is the 016 doesn't have the dual bolt pattern like your CQ. I am thinking of making an adapter plate so I can keep the manual locking differentials! I was going to use a 2.0 TD but I would need a new cylinder head..http://www.motorgeek.com/viewtopic.php?t=47709&p=600341

 

[scubagli]

How's the Tdi like those gasser gear ratios, what's your mileage like?


Sent from crazy town.

 

[Chirsis]

How's the Tdi like those gasser gear ratios, what's your mileage like?


Sent from crazy town.

Gear ratios are not that bad, since the gearbox is from 2.8 V6, wich has quite long gears.

 

[scubagli]

Are you driving it regularly yet?
I'm asking because I always wanted to do something similar...


Sent from crazy town.

 

[Chirsis]

Are you driving it regularly yet?
I'm asking because I always wanted to do something similar...


Sent from crazy town.

Yeah, but it's not chipped yet, but anyway it has some power.

http://www.youtube.com/watch?feature=player_embedded&v=qENHOKbOSpk

 

[GTiTDi]

looks like a lot of fun!

 

[scubagli]

That's what's up!


Sent from crazy town.

 

[TDIMeister]

Awesome project, I just love B4 CQs!

Always wanted to do this to one.

Nice to see more and more members from Latvia. Been there 3 times and loved it each time!

 

[Razor B]

That is a nice build. I'm considering a build like this for my coupe. You mention the 6 speed gearbox that you wanted to get for this conversion. Do you know which ones will swap in with minimum rework? I'd like to avoid rewelding the motor mounts, but I will if I have to.