How hard - B4 TDI engine into dead S2 ?

[macspring]

1. How hard is the above and what's involved, with any awkward things to be aware of ?

Are there any expensive dealer only part issues ?

We'd have access to a dead B4 TDI.

2. Should we wait and look to increase the budget to a more modern TDI from say an 04 Audi A4 from a breakers, or is that a step too far in expense and difficulty ?

3. Lastly, don't think this is a runner due to expense, but what about the 2.5L five cylinder diesel engine, which car is the engine in and what's involved ?

I appreciate it is three questions in the one post, but any replies would be greatly appreciated.

The above queries relate to a good mate, rather than my cars.

Thanks in advance.

[s2_wot]

David I don't have all the answers but..

2. The B5 A4 / passat AHU TDI is a bombproof 90bhp that can be chipped. Longitudinal installation in both cars so you might get lucky with the installation. I'd be happy to help with measurements if you want.

3. AAT is a good code I think from a C4 chassis audi 100. Not too many of them over here though to source a donor.

This link has some basic information:

http://www.new-car-model.com/audi/100/audi_100_c42.5_tdi(587)/

[Acidburn]

if your going to use the b4 tdi you need the following:

pedal box
wiring
engine
downpipe
all pipework under the bonnet.

If you have a look for posts on here by john (can't remember his new username) he fitted a b4 tdi into a 20v quattro saloon and has it running. I'm slowly helping someone do this with a b4 coupe fwd.

not too hard to do and all bolt on no mods to chassis etc.

[b3robo]

After your done will you sell it to me?

[prj]

S2 dag dag


In my country one guy converted a UrS6 to 2.5TDI...
He did have a bit of trouble explaining it at the car registration center though.

[Acidburn]

aronmatic2 on here did the conversion as well, there's a thread on here about it.

[prj]

You will need to change the gearbox too, otherwise your revs will be too high on the highway.

[gunman]

If you're going the 5 pot diesel I wouldn't use the AAT, Use the AEL as it's 25 BHP more (140, chippable to 170 odd), also they made an AEL engined A6 (C4) in quattro so a 4wd gearbox with the right ratio would be available (not sure if it would physically fit mind you).

[s2_wot]

If you're going the 5 pot diesel I wouldn't use the AAT, Use the AEL as it's 25 BHP more (140, chippable to 170 odd), also they made an AEL engined A6 (C4) in quattro so a 4wd gearbox with the right ratio would be available (not sure if it would physically fit mind you).

Good information there, I pulled the AAT code from a google search. Was the AEL only used in the c4 or did it feature anywhere. The exhaust could be tuned to make an angry 5 pot noise too.

[gunman]

I think the AEL was only in the C4 and the A6 variant at that, not the 100 which was all AAT I beleive. The same engine I think was used in the Volvo V70 as well but I think it may be a different engine code, still 140BHP tho.

I have an A6 avant with the AEL and had a quattro once last year for a while too. Decatted and chipped they aren't a bad drive.

[topsparky]

vw transporter engine 2.5 tdi stock internals
300bhp
click here
i think its shadowmaker on the tdi forum

[raymor]

Have a look here... http://forums.tdiclub.com/forumdisplay.php?f=63 there are a lot of conversion projects, no blueprints for an S2 Tdi. But the information you need will be here.

The 5 pot diesel AAT/AEL would be the best to go for a shed load of reasons.

Mechanical fit - straightforward - ok you've got gearing and drive by wire bits to address but a standard S2 IC will be fine, same with airbox. You need to do the fab work to connect them, but they're all good up to and beyond 280bhp.

Heritage connection - 5 pot

Power output potential with 2461cc Tdi. With decent VNT 2260V or 2056V on standard nozzles should be around standard S2 power wth better torque. 2260V will give bigger power. Volvo branded AEL's have done 280bhp wth larger nozzles, little smoke and the same or better fuel economy.

Have a look on the Power enhancement section. There's a few AAT/AEL upgrades happening at the moment, including mine as linked below.

There's an interesting one using a standard S2 K24 turbo that appears to have good results, although IMHO VNT will always give better response.

An S2 5pot TDi would be cool. With careful mods you would have the same or maybe even better midrange than the donor. With easily double the mpg when you didn't want to play.

[s2_wot]

Have a look here... http://forums.tdiclub.com/forumdisplay.php?f=63 there are a lot of conversion projects, no blueprints for an S2 Tdi. But the information you need will be here.

The 5 pot diesel AAT/AEL would be the best to go for a shed load of reasons.

Mechanical fit - straightforward - ok you've got gearing and drive by wire bits to address but a standard S2 IC will be fine, same with airbox. You need to do the fab work to connect them, but they're all good up to and beyond 280bhp.

Heritage connection - 5 pot

Power output potential with 2461cc Tdi. With decent VNT 2260V or 2056V on standard nozzles should be around standard S2 power wth better torque. 2260V will give bigger power. Volvo branded AEL's have done 280bhp wth larger nozzles, little smoke and the same or better fuel economy.

Have a look on the Power enhancement section. There's a few AAT/AEL upgrades happening at the moment, including mine as linked below.

There's an interesting one using a standard S2 K24 turbo that appears to have good results, although IMHO VNT will always give better response.

An S2 5pot TDi would be cool. With careful mods you would have the same or maybe even better midrange than the donor. With easily double the mpg when you didn't want to play.

Is your project s2 / b4 related, I'd be interested in a link. It would be great to have some s2's burning satan's fuel of choice.

What do you think about the later 2.5 v6, 3.0 v6 or even the 4.2 v8, is there any benefit to the later engine management systems?

edit: Found your thread

http://forums.tdiclub.com/showthread.php?t=291269

edit2: Donor here for you David and another one here look at the mileage on these things already, wow

[macspring]

To All to date,

Thank you for the feedback, just digesting it and doing more research before any plan is decided upon, only want to do it once and hopefully correctly.

Shane, thanks for the links, is the Volvo diesel engine block identical to the 2.5 AAT AEL block that people want to use to make petrol strokers in an S2? I thought Volvo blocks were aluminium, or is that just the petrol ones ?

"What do you think about the later 2.5 v6, 3.0 v6 or even the 4.2 v8, is there any benefit to the later engine management systems?"

No idea on this, but hopefully others will be able to advise.

Thanks again.

[spink]

[QUOTE=David in Dublin;546493]
Shane, thanks for the links, is the Volvo diesel engine block identical to the 2.5 AAT AEL block that people want to use to make petrol strokers in an S2? I thought Volvo blocks were aluminium, or is that just the petrol ones ?

QUOTE]

just about,its an audi engine that was sold to/licenced to volvo,iron block and yes the petrol ones are alloy

dont think volvo have an aat version,just the ael although all that is different is the injector nozzles and the mapping,easy to turn an aat into an ael