non duramax diesel build

M

mainer

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Nov 11, 2008
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well i havent been on here much in quite a while, trucks been running well (knock on wood) and i've been working 45 hours a week and taking 5 classes (dont recommend it)

anyways here is my latest project, when its done maybe i'll get to work on the truck some more since it wont be a dedicated daily driver.


99.5 audi a4 quattro 5spd manual with a 1.8t thrown rod

swapping in an vw 1.9 tdi (ahu) 90hp stock 155tq

cant leave it stock though so the following parts are on hand

turbo: vnt17 and appropriate manifold
bosio power plus 520 nozzles
2.5" full exhaust with no mufflers
2.5" intercooler piping
large front mount intercooler
in tank gas fuel pump regulated to 7psi
southbend stage 4 OFE clutch rated at 450ft/lbs
audi 80 single mass flywheel

h/r race springs 1.75" lower than stock

a local friend is running a similar setup in a jetta and made 185whp and 375tq which should be pretty awesome in a 3300lb awd car

i'll try and keep this updated with pics as the swap/ build progresses

hopefully have less than 4k into the car when all said and done....


IMGP2424.jpg
 
RENODMAX

RENODMAX

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Mar 4, 2008
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Foster what'd that motor and car cost you? I've been working on my brothers Audi and thinking of doing the same
 
M

mainer

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Nov 11, 2008
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jordan,

paid 1500 for the audi

paid $700 for the tdi (complete car), ( my neighbors bought it new in 98, and i did $700 worth of work on it for them about 6 months ago)

at the same time i bought the donor car i bought another tdi complete car for $300, beat to hell but it ran, sold it 2 days later for $1150... so i really only have $1500 in the audi and the tdi was free:rofl:
 
Durasizzle

Durasizzle

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Oct 3, 2008
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Stony Plain. Alberta
My cousin has a 98 Audi A4 with the 1.8 turbo (gasser) and man does his car go, i think he dynoed something like 200+ horsepower at the wheels.

With the 1.9 TDI in it the torque should be able smoke all 4 tires in that thing.

Are we going to see some coal rolling from this car? :D
 
M

mainer

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Nov 11, 2008
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made some more progress today

cleaned up the drivers side of the block, swapped the oil cooler and and stand and oil pickup tube and put on the audi oil pan


painteddrivers2.jpg


painteddriversside.jpg
 
RENODMAX

RENODMAX

Dead Wrong
Mar 4, 2008
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So how do the electronics mate up for this foster? Do you need the vw cluster etc or can you splice it to work with the audi stuff. this is what my lady may wind up getting
 
M

mainer

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Nov 11, 2008
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jordan, i typed out a long winded reply on the electronics info but somehow it didnt post and i lost all i typed, i'll retype it when i get a chance later in the week.



Turbo and piping came, cleaned the turbo and the manifold , need to finish the manifold in blasting cabinet when i get home

0 shaft play and really no rust so i cant complain for $350


vnt17.jpg


turbopiping.jpg
 
M

mainer

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Nov 11, 2008
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well since i havent updated this in a long time i'll add some details


car is up and running, since may i guess, put almost 10k on it so far.

blew the first turbo up because i didnt have a boost gauge and the way the vnt is controlled on tdi's is retarded... making over 30psi on a turbo that shouldnt see more than 22, and a headgasket that shouldnt like more than 26 but seems to be holding still.

so anyways i got another used turbo and have it turned down to 22psi now.


picked up some massive front brakes 345mm rotors and 6 piston brembo's off a touareg/ cayenne, made adapter brackets, but i still need to find 18" wheels to fit them under. have 17's on the car now so i'll wait till spring time to find some 18's

IMGP2935.jpg



i also swapped in a complete 2001 s4 drivetrain, front axles, 6spd transmission (the reason for the swap) drive shaft, rear 4.10 diff, rear axles and rear brakes, rear brakes are .5" (269mm i believe) bigger and have vented rotors. when i get the brembo's on the front i'll upgrade to 300 mm's in the rear as its a cheap upgrade.


i have a bunch of other things i've accumulated but havent had time to put on yet.

11mm injection pump off automatic tdi (good for 10-15hp) and needed for better atomization with bigger nozzles

european 150hp tdi intake manifold, flows more/ much larger. 2.5" intake piping, so i can loose a few hose clamps and have .5" bigger piping.

hx35 so i can build some twins and see how good this stock headgasket is

now i just need work to slow down a bit so i have time to work on it, guess i shouldnt complain about being busy with work and having $ to buy parts for toys

i'll get some updated pictures and maybe a video of some axis spins if we get some more snow
 
duratothemax

duratothemax

<--- slippery roads
Aug 28, 2006
7,139
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Wyoming
mainer said:
well since i havent updated this in a long time i'll add some details


car is up and running, since may i guess, put almost 10k on it so far.

blew the first turbo up because i didnt have a boost gauge and the way the vnt is controlled on tdi's is retarded... making over 30psi on a turbo that shouldnt see more than 22, and a headgasket that shouldnt like more than 26 but seems to be holding still.

so anyways i got another used turbo and have it turned down to 22psi now.


picked up some massive front brakes 345mm rotors and 6 piston brembo's off a touareg/ cayenne, made adapter brackets, but i still need to find 18" wheels to fit them under. have 17's on the car now so i'll wait till spring time to find some 18's
Click to expand...

345mm brakes wont clear 17's? Mine has 345mm front brakes and I was almost positive my spare tire/wheel is 17"???
 
M

mainer

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Nov 11, 2008
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check your spare ben i'd be surprised if it was 17, but its possible i guess, but the porsche/ brembo calipers are fairly low profile.


i've debated getting some 330mm c320 rotors so i could just keep my 17's
 
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