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Audi Coupe B4 1.9 TDI
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.
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_o...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
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:
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=HGUAl...1&feature=plcp
And here's a video of testing a little with no exhaust.
https://www.youtube.com/watch?v=4B59...e_gdata_player
EGR Was removed, MAF was removed.
Friend of mine gave a gift from Audi Museum in Germany: ^^
Bought S2 front bumper.. Will buy RS2 in future
There was a 60 mm straight exhaust pipe built for this project so, it was quite loud, so I had to make sound suppressor:
Now its not that loud
Since 2nd gear of my Q gearbox broke, i took my gearbox to a Gearbox specialist, who swapped the Gears. Now i have 1st and 2nd gears from B5 2.8 gearbox and 3;4;5 gears from 1.9 TDI gearbox (2100 +/-50 RPM on 100km/h
Currently HP:
Something between 170-190hp, dunno yet.(currently working on ECU Mods)
Current Turbo MAX boost - About 1.8 BAR, wich is a bit too much.(working on it)
HP planned - 200+
Future plans:
S2 headlights,
RS2 front bumper,
RS2 mirrors,
RS2 front grill,
Repainting whole car in different color. (RS blue)
Original Air Conditioner,
Install some extras (Maybe Leather seats, S2 steering wheel, and other stuff)
6 Gear Q gearbox,
Replacing 2.5 tdi nozzles with R520 Nozzles,
Replacing 2.5 TDI turbo with Volvo turbo GT2056VL
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.
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_o...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
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:
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=HGUAl...1&feature=plcp
And here's a video of testing a little with no exhaust.
https://www.youtube.com/watch?v=4B59...e_gdata_player
EGR Was removed, MAF was removed.
Friend of mine gave a gift from Audi Museum in Germany: ^^
Bought S2 front bumper.. Will buy RS2 in future
There was a 60 mm straight exhaust pipe built for this project so, it was quite loud, so I had to make sound suppressor:
Now its not that loud
Since 2nd gear of my Q gearbox broke, i took my gearbox to a Gearbox specialist, who swapped the Gears. Now i have 1st and 2nd gears from B5 2.8 gearbox and 3;4;5 gears from 1.9 TDI gearbox (2100 +/-50 RPM on 100km/h
Currently HP:
Something between 170-190hp, dunno yet.(currently working on ECU Mods)
Current Turbo MAX boost - About 1.8 BAR, wich is a bit too much.(working on it)
HP planned - 200+
Future plans:
S2 headlights,
RS2 front bumper,
RS2 mirrors,
RS2 front grill,
Repainting whole car in different color. (RS blue)
Original Air Conditioner,
Install some extras (Maybe Leather seats, S2 steering wheel, and other stuff)
6 Gear Q gearbox,
Replacing 2.5 tdi nozzles with R520 Nozzles,
Replacing 2.5 TDI turbo with Volvo turbo GT2056VL
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