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1995 90 quattro V6 to 1.8t Conversion

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  • 1995 90 quattro V6 to 1.8t Conversion

    So I got an old friends 90, He was actually the friend who originally turned me on to older Audis, I mostly watched and slightly helped him put a V8 into a b3 80 which became Javad's V80 (that term was coined by my friend first). After that I got my own 90 and started tinkering, he moved on as well, and came back to buy this B4 90. By that time i was much more familiar with these car than even he was. I machined a set of URS4 hubs for him at Hank's old lab in Utah, gave him my rotors that were re-drilled to 5x112 and sourced him some KW coilovers when i sourced mine. Little did I know that in the future that car would be coming my way.

    So we struck up a deal, and I had the car shipped out to Utah:

    his picture


    Pics as delievered:






    The car had a bad thermostat and undocumented timing belt history. So i knew my first order of business.

    Did the belt and some clean up:



    Installed a euro front bumper:


    Bought a cheap ($100) set of wheels and tires since the tires were completely dry rotted and bald on the Borbets:



    And i've been driving it and sorting out other small issues. I always had intentions on doing an engine swap, and I was sort of waiting to see what came along. I would have loved to do an I5 20vt swap, but there is a bit of fabrication involved and donor cars don't pop up all that often. The other idea was an I4 20vt aka 1.8t. Which do pop up pretty often. I already had sourced some 1.8t engine brakets since they poped up cheap in europe:



    and so I set out to watch the local classifieds for a cheap 1.8t donor. I wasn't expecting to buy anything soon, but this popped up this past weekend and it followed me home...





    Very very clean under the hood, very clean inside as well, but with a bad trans. It set me back 500 bucks, but i already have a buyer for the interior and should have one for the wheel/tire combo that will already pay off that price tag.

    I have also purchased a european b4 cabrio harness from a 1.8 (non -t) which should help with the wiring of this car, i assume i'll have to add in the N75 wiring, and the MAP sensor wiring, but the ecu plugs are the same as the 1.8t, and the chassis and fuse box connections are the same as the b4, so I'm hoping it will be a mostly plug and play ordeal, I like keeping things clean and simple.

    So short term plans:
    Part the A4.
    prep the engine
    find Flywheel and clutch setup
    sort wiring
    and swap it all over.


    Long term:
    Rebuild short block (rods, clean, new piston rings, bearings, ect)
    Possible valve and valve spring swap
    larger turbo, most likely GTX-3071R
    T3 Style exhaust manifold
    Injectors and tune.
    6 speed swap



    We'll see how it all plays out. This is a very "loose" plan and is always subject to change.

    As the car sits today:

  • #2
    ummm, why "find" a flywheel/clutch setup? is the B5 an auto? if so, you need to either machine the crank snout down or find a manual crank. i have one you can have for free.99 plus shipping, BUT the machine shop said it was a couple thou out of round? i was building race car motor so i just found other cranks.

    and if the B5 is manual, it has the clutch setup you need already.

    Comment


    • #3
      Originally posted by speeding-g60 View Post
      ummm, why "find" a flywheel/clutch setup? is the B5 an auto? if so, you need to either machine the crank snout down or find a manual crank. i have one you can have for free.99 plus shipping, BUT the machine shop said it was a couple thou out of round? i was building race car motor so i just found other cranks. and if the B5 is manual, it has the clutch setup you need already.
      Looks like its an autobox?? (I copied and pasted this photo and blew it up and the shifter looks autobox to me). Its midnight here so I will have to wait until the AM to find out the real answer. (I had no idea that the automatic transmission engines had a different crank than a manual transmission engine, seems strange):

      Last edited by UrS4boy; 28 January 2014, 16:16.
      RS2'd 93 UrS4 5 spd sedan
      94 UrS4 V8 6 spd manual avant

      Comment


      • #4
        yeah, and the brake pedal in this one too. and yeah Dave told me its an auto.

        the difference in the crank is the snout for the FW/flexplate. the auto has no provision for a pilot bearing, needed to support the input shaft.

        Comment


        • #5
          Cool project Dave. You back state side again?

          I've got a couple of manual crankshafts around. Gimme a shout if you need one.

          Comment


          • #6
            few seconds with a grinder and a bearing later and an auto block was fitted into my 90q think it might have been from a speeding-g60 thread i copied from even..

            Comment


            • #7
              Originally posted by speeding-g60 View Post
              i have one you can have for free.99 plus shipping
              Originally posted by saltinot View Post
              Cool project Dave. You back state side again?

              I've got a couple of manual crankshafts around. Gimme a shout if you need one.

              Thanks both of you for your offers.



              Originally posted by sam80quattro View Post
              few seconds with a grinder and a bearing later and an auto block was fitted into my 90q think it might have been from a speeding-g60 thread i copied from even..

              Exactly, I think the plan for the time being is just grind it and run it stock to get the swap sorted. I'll start watching for a new bottom end that will be upgraded and built up that will eventually be swapped over when its ready and when my budget is ready!

              The goal is to have a nice sold 300+ awhp with similiar tq numbers. I want it to be a fun but somewhat practical car that can be driven on a regular basis. Not going for a monster here.

              Comment


              • #8
                If i am seeing correctly, you have a 5 lug hubs? Somebody already did conversion?

                Comment


                • #9
                  Originally posted by BosnianS2 View Post
                  If i am seeing correctly, you have a 5 lug hubs? Somebody already did conversion?
                  Yes, i used URS4 hubs machined to fit the front knuckles, and b5 A4 rear hubs in the back.

                  Comment


                  • #10
                    Nice. When i lived in States i also converted same car like yours to 3B, but i did not do conversion of hubs cause i had to sell it due to my move to Germany. There is so much more choice for breaks and wheels with 5 lug set up. I wish you lot of luck getting the swap done, there is not very many b4 cars state side without V6 engine

                    Comment


                    • #11
                      Found a buyer for the stock V6 engine, so it came out a bit sooner than expected, but i got 400 bucks for it when i thought id have a hard time getting 100 for it!









                      Picked up a steam cleaner to help clean up the junk:



                      Before:


                      During:


                      After:


                      Kinda before (i hit that small corner):



                      After:





                      a friend came over to lend a hand and yank out the 1.8t..



                      and trying to get it accustomed to its future surroundings.

                      Comment


                      • #12
                        nice project dude...
                        Polarsilber Rs2 1994

                        Comment


                        • #13
                          I stopped by Inegrated Engineering to see if I could find flywheel bolts that suited me, but no dice. I searched around on the interent and found something by ARP that fit the bill, its made for a v8 Ford, but correct length and size, and pitch...
                          and only about 40 bucks shipped


                          Installed the makeshift pilot bearing, there is a thread about converting from auto to manual, and they shaved the crank down, i did not modify the crank in anyway, my flywheel has a larger center section that allowed for it to simply be cradled inside of it.







                          Engine resting on its mounts



                          Lots of front end realestate, need to find a small intercooler now...
                          Last edited by Ruffiano; 12 March 2014, 15:03.

                          Comment


                          • #14
                            Here comes the pain:




                            Also what is this plug for? Wot switch or something?

                            Comment


                            • #15
                              Alright, I'm working on the wiring, here is what i have labeled:




                              Alright so now these are switched power things that i need to hook up through fuses. I'm trying to find a wiring diagram that shows the 90 connections to see what i can integrate from the stock harness:



                              Starter trigger (that one isn't switched, but i need to figure out where it comes from)
                              Fuel pump relay (again that one i dont think is switched)
                              Coil packs (15A and switched for sure)
                              Power for O2 sensors and MAF (15A and switched)
                              Injector power (10A and switched)


                              I believe these ones are all for integration on the internal side of things (for instrument stuff):



                              Leak Detection pump
                              Read switch for LDP (not sure about these first two and how they integrate into the stock EVAP controls)
                              Coolant Temp Switch
                              Alternator Warning
                              Oil Pressure (I'm assuming this one is also a "warning" for the autocheck)
                              Vehicle speed Sensor
                              Vehicle speed SIGNAL (these two confuse me, i'm assuming one is for the speedo, not sure what the other does)
                              RPM Tach (that one is pretty obvious, anyway to make my 90 V6 tach work with a 4CYL?)


                              Big thanks in advance for any guidance!!!

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