Audi 90 quattro with 2.5 TDI and 6-speed, plan B

[Dave]

Very interesting about the Pedal assembly, something i would have never of thought of.

[a_CQ]

It's like pioneer DBW setup!

Martin, I have a stock 7A fan shroud you can have, just pay for shipping. PM me your addrss, although I might already have it from the past, and I'll send it out. When FedEx charges me I'll let you know exactly how much it was.

[ralleyquattro]

Thanks Peter, I'll PM you.

Only other thing I still need to figure out is how to by-pass the stock fuel pump.
TDI does not use a fuel pump, it's pure suction via the injection pump so I need to remove the pump out of the system (including stock fuel filter) and still have it work properly when the tank gets low on fuel.

Cheers

[BlackBox]

Diesels like heavy flywheels..

I second that. I have a 2.4 5-cyl diesel in my Audi, and the gear chatter is VERY annoying. That's with a heavy NF/7A flywheel too. I'd like to get a heavier one some day.

[ralleyquattro]

Does anyone know if the electric vacuum pump from a B6 A4 would provide enough vacuum to power the booster.
I know it's there as a supplement, but not sure if it can do the job by itself.
That's another part I will have to sort out... the list is growing.

Cheers

[Lord_Verminaard]

Only other thing I still need to figure out is how to by-pass the stock fuel pump.
TDI does not use a fuel pump, it's pure suction via the injection pump so I need to remove the pump out of the system (including stock fuel filter) and still have it work properly when the tank gets low on fuel.

Cheers

I'd see if you can retrofit a PD in-tank lift pump. (or some other low-pressure pump) The wiring would already be there, and having an electric pump on a TDI will really make changing fuel filters a lot easier. Adding an electric pump was one of the best things I did on the Golf Diesel build.

Brendan

[PRA4WX]

How about just using the stock pump/wiring and a fuel pressure regulator to reg it down to 6psi or so. This is what i have in mind for gasser turned tdi car. Don't have the regulator figured out exactly but that's what i'll attempt. It will add to your fueling potential too-when you decide to turn it up! ;-)
Love the project!

[ralleyquattro]

Thanks for the tip, looked into it and yes, actually having the pump in there is beneficial in many ways.
Just need to figure out the best way to drop the pressure.
Also wondering if the stock fuel filter will like diesel going through it... never hurts having two filters..

Here is more.

Mr. Cook came by on Saturday and helped me withe the motor mounts.







I think I screwed up the driver side a bit, but nothing that a shim/spacer won't fix.

Picked up the flywheel and engine hoist today, hope to have the transmission and rest of the wiring in tomorrow and possibly the enigne itself... we'll see how the weather holds up.. it's HOT HOT HOT out there... we haven't had any rain in over 3 weeks, the grass is deed..

Anyhoo.. few more questions, any suggestions on electric vacuum pumps on a budget. I looked at the B6 and Passat pumps but don't know if they are supplemental or actually provide full vacuum to the booster, anyone know? They are only $100 and would match the OEM better than some aftermarket Jegs unit.

Cheers

[tecknoquatt]

Youre making some progress Martin!!

[Hank]

When we are hearing you Canadians complain about the heat, how hot is it actually in degrees? LOL

Looks good Martin! Should be nice!!

[ralleyquattro]

It's 95F but that's not the kicker, the humidity makes it feel like 113F.
The air feels like hot sup.

[Highlander]

It's 95F but that's not the kicker, the humidity makes it feel like 113F.
The air feels like hot sup.

37 degrees Celsius on Thursday !!!!!!!!!

[a_CQ]

It's same in Chicago here...high of 37*c in the shade! That's 97*f I think.

I saw that last picture and thought that driver's side mount looks a little high on the back end?

Martin, any way to find out how much vacuum those new OEM pumps are pulling? Otherwise, Summit sells vacuum pumps that many hot rodders use - I've looked at them when I was setting up ITBs, but it turned out that I had just enough vacuum on the brakes...it wasn't bad at all. So I think you don't need too much vacuum.

[ralleyquattro]

It's same in Chicago here...high of 37*c in the shade! That's 97*f I think.

I saw that last picture and thought that driver's side mount looks a little high on the back end?

Martin, any way to find out how much vacuum those new OEM pumps are pulling? Otherwise, Summit sells vacuum pumps that many hot rodders use - I've looked at them when I was setting up ITBs, but it turned out that I had just enough vacuum on the brakes...it wasn't bad at all. So I think you don't need too much vacuum.

Actually it's the other way around, the front end of that mount is a bit low...

I've looked at the hot rod pumps as well, but they are $300/kit almost anywhere and I rather spend $100 on an OEM unit if it works.
Anyone has one of these B6 pumps lying around and willing to test how much vacuum it can pull?

Cheers

[Lord_Verminaard]

Anyhoo.. few more questions, any suggestions on electric vacuum pumps on a budget. I looked at the B6 and Passat pumps but don't know if they are supplemental or actually provide full vacuum to the booster, anyone know? They are only $100 and would match the OEM better than some aftermarket Jegs unit.

Cheers

Don't know about the B6 vac pumps, there is this option as well for about the same price:
http://www.accuratediesel.com/shop/132.html

Might be a good idea with either option to grab an OEM vac reservoir (inner fender mount maybe?) just to be sure.

Pity there is not a provision for the ALH style vac pump off the cam, or the distributor mounted one like the old 1.6 diesels had.

Brendan

[ralleyquattro]

That looks like the standard Audi cruise control vacuum pump.
The later TDIs had the mechanical vacuum pump like 4kq/Coupe, but because the this TDI was in typ 44 car which uses hydraulic assist they felt pump was not needed, doh!

Cheers

[Highlander]

Thanks for the tip, looked into it and yes, actually having the pump in there is beneficial in many ways.
Just need to figure out the best way to drop the pressure.
Also wondering if the stock fuel filter will like diesel going through it... never hurts having two filters..

Here is more.

Mr. Cook came by on Saturday and helped me withe the motor mounts.







I think I screwed up the driver side a bit, but nothing that a shim/spacer won't fix.

Picked up the flywheel and engine hoist today, hope to have the transmission and rest of the wiring in tomorrow and possibly the enigne itself... we'll see how the weather holds up.. it's HOT HOT HOT out there... we haven't had any rain in over 3 weeks, the grass is deed..

Anyhoo.. few more questions, any suggestions on electric vacuum pumps on a budget. I looked at the B6 and Passat pumps but don't know if they are supplemental or actually provide full vacuum to the booster, anyone know? They are only $100 and would match the OEM better than some aftermarket Jegs unit.

Cheers

Looking good Martin.

Guys don't judge my welding skills in these pictures, Martin's welder didn't have enough current
to produce a nice looking weld, but the mounts are on I can assure you.

This is going to be a killer car

Cheers,

Craig

[ralleyquattro]

I sweated my bag off today, but the engine and transmission are IN... yes, it's in.
Now, it hits the hood, a LOT... But I think I can lower the assembly a bit and remove the plastic underbonnet trim and we might just squeeze in there.
Just too HOT here... I am soaked.

Pics to follow.

[my2000apb]

what do you have for oilpan to subframe clearances

[ralleyquattro]

Plenty, actually too much, so lower she can go and plenty.

Here are the shots.

Overall



Yep, she's sitting high, we can fix that NP.
Not as clean as Technoq's but this is only the DD/winter beater, so she'll get dirty in no time anyway.



All the way and some on the left side.



Right smack in the middle on the right side.



Not much space there.



Not bad, me likey.



More tomorrow.

[my2000apb]

http://www.vwparts.com/parts-outlet-center/?pg=7

bottom of page $10 oem vac pumps, cheap enough to try one

[Dave]

does that use a k24?

[ralleyquattro]

Nope, it's a K14. pretty tiny for a 2.5
My original thought were to go with a GT22V, but I rather do the go-fast bits for the '84 or the sport, this is going to be the pipe and slippers econo box.

Cheers

[gtn116]

I have a k24 and a k26 if you're interested... The comp housings are all shinied up on both.

[ralleyquattro]

Sorry, as I said not if I ever change the turbo it will be for a variable vane type like GT22V.

Thanks for the offer.