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Hi,
I've been meaning to do a 'build thread' for some time so thought I would share a little tonight
Car started as a 1990 90 20v quattro, bought the car 3 years ago with the plan to keep it stock and enjoy, that lasted about 4 weeks.
Spec before the diesel engine was
Bilstein B6 dampers all round (originally bought for my ur quattro)
Solid sub-frame mounts
Poly wish bone bushes
25mm RARB
Blue top mounts all round
B4 80 lower front ball joints
5 Bolt conversion using A4 hubs in 10v 90 rear struts and modified A6 front struts
288mm rear brake (Using C4 15mm sold front discs turned down one morning in work to 10mm)
312mm front brakes (using tt carriers and A4 callipers and discs)
B5 S4 17" avus with 215/45R17 Kuhmo KU39
Torsen Rear differential, keeping 100mm cups using spacer turned in work again
CAC stainless exhaust
Bosch injectors and adaptors
This set up was run for about 15000 miles, however I had issues with the metal gauze filter on the base of the tank blocking but finally sorted this. However on my last week of University the head gasket blew and I parked the car for a couple of months
Before the 20v went bang I had bought a 2.5tdi complete, minus pump injector and ex manifold. This was bought for my ur to build a stroker as the block cost only £80 as had striped the timing belt and bend a couple of valves. A good friend of mine convinced me to rebuild this engine rather than the 20v... Anyway a head gasket, 4 valves from a damaged 1.9tdi, exhaust manifold and turbo from a 2.0td from a 100 along a rover 200 diesel pump with the head and campmate from a A6 tdi pump and a set of injectors I had what felt like 160hp, this was with wastegate adjust on the turbo and as much fuel as I could run. The MOT then lapsed on the car and I went to the Philippines to live.
However I returned home, with a hiatus from work the car couldn't have anything done on it, but once I started working again I was focused on the car, I bought a HX27 turbo to help the engine exhaust better and produce more boost. I welded a T2 plate to the 2.0 manifold and laser cut a downpipes adaptor in work. I have ran this the past few months originally with .275 nozzles from eBay but these caused lots of smoke so returned to the .216 stock nozzles these make less power but are a lot cleaner, I think power is now at around 200hp with 1.5bar boost but really less boost is needed but injection is so long to keep exhaust clean I prefer more boost. With eBay nozzles power was more around 240hp at 2 bar boost however I wasn't happy with spray pattern and balance.
Next step is a fully rebuilt set of .280 nozzle/injector and my diy log manifold. I hope to make over 250hp with this set up after than I want to use a HE221w and aim for 300hp
Ill add pictures tomorrow
I've been meaning to do a 'build thread' for some time so thought I would share a little tonight
Car started as a 1990 90 20v quattro, bought the car 3 years ago with the plan to keep it stock and enjoy, that lasted about 4 weeks.
Spec before the diesel engine was
Bilstein B6 dampers all round (originally bought for my ur quattro)
Solid sub-frame mounts
Poly wish bone bushes
25mm RARB
Blue top mounts all round
B4 80 lower front ball joints
5 Bolt conversion using A4 hubs in 10v 90 rear struts and modified A6 front struts
288mm rear brake (Using C4 15mm sold front discs turned down one morning in work to 10mm)
312mm front brakes (using tt carriers and A4 callipers and discs)
B5 S4 17" avus with 215/45R17 Kuhmo KU39
Torsen Rear differential, keeping 100mm cups using spacer turned in work again
CAC stainless exhaust
Bosch injectors and adaptors
This set up was run for about 15000 miles, however I had issues with the metal gauze filter on the base of the tank blocking but finally sorted this. However on my last week of University the head gasket blew and I parked the car for a couple of months
Before the 20v went bang I had bought a 2.5tdi complete, minus pump injector and ex manifold. This was bought for my ur to build a stroker as the block cost only £80 as had striped the timing belt and bend a couple of valves. A good friend of mine convinced me to rebuild this engine rather than the 20v... Anyway a head gasket, 4 valves from a damaged 1.9tdi, exhaust manifold and turbo from a 2.0td from a 100 along a rover 200 diesel pump with the head and campmate from a A6 tdi pump and a set of injectors I had what felt like 160hp, this was with wastegate adjust on the turbo and as much fuel as I could run. The MOT then lapsed on the car and I went to the Philippines to live.
However I returned home, with a hiatus from work the car couldn't have anything done on it, but once I started working again I was focused on the car, I bought a HX27 turbo to help the engine exhaust better and produce more boost. I welded a T2 plate to the 2.0 manifold and laser cut a downpipes adaptor in work. I have ran this the past few months originally with .275 nozzles from eBay but these caused lots of smoke so returned to the .216 stock nozzles these make less power but are a lot cleaner, I think power is now at around 200hp with 1.5bar boost but really less boost is needed but injection is so long to keep exhaust clean I prefer more boost. With eBay nozzles power was more around 240hp at 2 bar boost however I wasn't happy with spray pattern and balance.
Next step is a fully rebuilt set of .280 nozzle/injector and my diy log manifold. I hope to make over 250hp with this set up after than I want to use a HE221w and aim for 300hp
Ill add pictures tomorrow
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