Europotvin's Big Turbo Diesel Build

[Europotvin]

Hey guys,

Heres my daily project that I have started a couple of months ago when I purchased a 04 Audi A4 1.8t with 6spd tranny. My plan is to swap my 1.9TDI ALH the was in my 2000 Volkswagen Jeta into my A4. Mecanically, the motor will bolt right in and will be perfect with the 6spd tranny.

Of course, Im not going to swap in a 90hp motor in an Audi lol So here are my plan for the engine:

CURRENT SETUP AS OF 27-01-2017

-European PD150 engine block
-Rebuilt ALH head
-GARRET GTB2260VZK (V6 TDI TURBO)
-0.280 injectors
-PD150 intake manifold
-11mm Fuel pump
-ARP head studs
-Clutch Master Fx400

This setup should be good for around 270hp and 410ft/tq. This should be alot faster than the stock 1.8t and still get great milleage.

For the car itself, Ill be going for a OEM+ look. So probably S4 bumpers and side skirts, coilovers and wheels.

So here is the car when I bought it:





The car was 100% stock when I bought it. Since then Ive done normal maintenance but also added a couple goodies like a Podi steering colum boost gauge and 19x8.5 Wheels



Ive started stripping my Jetta and will give you guys updates as I go.

Cheers !

[Europotvin]

Time for an update !

Ive gutted the Jetta of all its valuable parts and it will leaving for the junk yard this week.



I was able to sell must of my unwanted parts. Its now time to start taking my engine apart to get it all cleaned up:



For today all the accesories are off:



Next will be to remove my injection pump so I can take the head off and start cleaning everything.


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[Furly]

I'd recommend not using FX clutch. They're garbage. Otherwise looks like you're off to a good start good luck !

[Europotvin]

I'd recommend not using FX clutch. They're garbage. Otherwise looks like you're off to a good start good luck !

Oh ok lol I had read some good reviews but ok., What would you recommend ? There isnt much choice for the 6spd and good for over 400tq


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[Europotvin]

Little Update. Im still working on a cabin heat issue that Ive had since I bought the car. I have changed pretty much all the coolant system parts. Last thing was the radiator so I changed that 2 weeks ago



But unfortunately I still dont have full heat unless I beat the shit out of my car which would suspect air in the system but I can seem to get any more out.

In other news I picked up a 4.5 Cummins turbo at work last week that Im thinking of using on my TDI :



Holset HE221W that should be good for 250hp. Only issue is that it will be slower to spool than a VNT turbo but I might go this route for now to save some $$$ and maybe change my rods or my cam instead.


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[dboy021]

In for updates. LOVE THIS!

[Europotvin]

Ok so time for some much needed updates !!!

The car has changed alot since my last update so here it goes.

First off I had finished the summer with some new wheels :

19x8.5 et35 with 235/35Zr19





I them sold them and got my winter setup:

18x8 RS4 reps with 225/45R18 Nokian ( bring the snow)



Did some long due maintenance, full front control arm kit (Fcp). That was some fun ... Not !! Everything was rusted up, and that pinch bolt was a nightmare. But finally got everything done.

Since the beguinning ive lovs the S4 bumpers, so when I got a chance to buy some, I jumped on it.

Full S4 front end (bumper, grills and headlights) and S4 rear bumper :





And well since I couldnt stop? got a set of Koni coilovers for the B6 ;)



After some dialing in (daily driver height :( )





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[Europotvin]

And now the TDI updates !!!

So i decided what my final setup will be:

ASZ PD130 engine block
ALH Rebuild head
Holset He221w turbo
T25 turbo manifold
.280 Nozzles
PD150 Intake manifold
11mm fuel pump
Secondary line pump
Frontmount Intercooler

Instead of keeping my stock bottom end, I decided to beef it up a little. I pick up a ASZ block ( Europpean PD130 engine ) which is alot beefier than my Alh one



Started cleaning it up and mocking up the head to get ready for paint :



When to the junkyard to pick up an 1.8t oil pan and engine mounts :



Will get everything painted by mext week and then accesory assembly.


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[storey618]

i was just thinking about how cool this swap would be the other day! im in!

[hooligander]

What ECU are you using?

[Europotvin]

What ECU are you using?

I will be using the ALH ECU from my MK4 Jetta with a custom tune to run the wastegated turbo.

[diagnosticator]

I will be using the ALH ECU from my MK4 Jetta with a custom tune to run the wastegated turbo.

Are you planning on immo defeat? That will be required to use a Jetta ECU in your Audi. Another crucial aspect of this is if the ALH ECU has CAN capabilities.

[Europotvin]

Are you planning on immo defeat? That will be required to use a Jetta ECU in your Audi. Another crucial aspect of this is if the ALH ECU has CAN capabilities.

Yes, the immo will be deleted and the ALH ECU does have CAN capabilities.


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[Europotvin]

Little update :

Went to the junkyard to pick-up some B6 1.8t engine mounts and oil pan so I can fit my tdi in the Audi :



Decided to paint my lowers before going to Eurokracy last weekend:



So finishd up cleaning my motor and painted it and my "custom" valve cover:





So now ill will test fit my engine mounts and modify my accesory bracket. I will have my Turbo and alternator back next week. I will try to be done and ready to start the swap by the end of the month.

[Europotvin]

Ok so time for an long due update!

The project has moved along alot since my last post. I finished installing my engine mounts and pan.



I was supposed to use my holset turbo, but got a good deal on a GTB2260VZK which is from V6 3.0l TDI engine. Its the same size as the holset but is VNT, which means I will ger boost alot sooner = more torque :)



In order to install it I had to make an adapter plate to fit on an older td manifold. I got the flanges laser cut and will get them welded once the engine is in the car.

I got my injectors and installed them with the accessories





And since the project does stop getting better, I got my hands on a full Quattro Tdi drivetrain swap from a C5 A6 2.5 TDI. Its a 01E with longer 4th, 5th and 6th gear that will be perfect with my engine. I also got a Clutch Master 240mm FX400 kit to go with it.



In order to install the tranny, I need to change the subframe, tranny, shifter box and driveshaft.

So since I got all the parts, its was time to start the swap ! Started taking everything apart last weekend



And got the whole drivetrain out friday





Today I painted my "new" subframe to get it installed in the next days. Next thing to do will be to clean up the engine bay and start cutting up the harness:



Theres so much room for activities !




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[Europotvin]

Got a couple of hours tonight to work in the garage. Mounted the FX400 clutch kit to the TDI, mounted 01E to the TDI and put it in its new home with the new subframe :



Big milestone for me ! I can finlly see the project moving alond. Next is completing my coolant lines, test fitting the turbo to get my adapter welded and then work on the wiring.

Next update this weekend !


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[Europotvin]

Update time:

Got to work on the car, finished most of the tranny stuff, installed the shift tower for the 01E, bolted up the mounts and axles. Only thing that is missing is the driveshatf.

Started checking for the coolant routing. I will have to modify the rear flange since its too long



I cut the barb section off and will tap the hole and use a 90 degree barb fitting to turn before the firewall.

Also needed to cut the other steel tube since it goes to far. Will also use a barb fitting and a extra lenght of coolant hose.

Installed 1.8t power steering
Cut up some pipe to make the adapter I designed



Will try to get it welded up this week. Got the flanges laser cut.

Got to make a fuel filter bracket.
Check for the downpipe

And then jump on the wiring ...





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[AudiA4_20T]

best B6 thread in the last 5 years

[Ephry73]

Love the idea of it. I had a Golf gls 1.9TDI that had a stage 2 and muffler delete that was a beast and still got around 800 miles per tank. This will be a killer build indeed. Looking forward to more updates.


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[Europotvin]

Update !

Ive been working on the car for the past week. Did alot of wiring -_-



Stripped all the gasser stuff and put in my tdi harness. Everything is pretty much plugged in. My Ecu is getting tuned and the immo deleted tonight.

I tested fitted my turbo with my custom adapter flange



I like where the turbo is placed. I still need to finish up my stainless braided line for the oil feed and make my 3" downpipe.

For the fuelling, im still not sure what to do -_- I didnt know about the suction jet line that goes to the passenger side of the tank. I was just going to remove the in tank pump and put a hose since my engine does not require a in tank pump.


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[alexb6t]

Nice build ! Subscrib !

[heywier427]

This is nice to see.

Glad to hear you opted out for the h2221. I have it now, and its too big/laggy. Just got the 211, but have yet to install. supposed to be way better.

They now make a electric vnt controler:

http://www.ebay.com/itm/DIGIBOOSTER-...9WllLX&vxp=mtr

Gonna get this for my 1.6 and go vnt17

Instaboost!

Keep it up!

[Europotvin]

This is nice to see.

Glad to hear you opted out for the h2221. I have it now, and its too big/laggy. Just got the 211, but have yet to install. supposed to be way better.

They now make a electric vnt controler:

http://www.ebay.com/itm/DIGIBOOSTER-...9WllLX&vxp=mtr

Gonna get this for my 1.6 and go vnt17

Instaboost!

Keep it up!

Yes, thats what I was thinkng also, so when I heard about the deal for the 2260vk I jumped on it !


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[Europotvin]

Update:

Started moking up my downpipe using cardboard pipe I had laying around. 3" is sure tight !



I got all my downpipe parts so I can start cutting it up, 3" pipe, 3" v-band and 3" flex pipe



So here's how the bay is looking right now



Going to get my last laser cut flanges tomorrow and will continue finishing up my coolant and oil line on sunday. Still waiting to get my ECU back so I can try and start the motor.


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[jacobsen]

So jelly

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[Europotvin]

Update time !

Finished up the wiring, got my ECU back from the tuners and ... THE ENGINE IS RUNNING !!!



So much stress off my shoulders, this was the most complicated part of the build for me. Everything seems to be working fine, RPM, speedo, pedal etc.

So now time to finish this up, fabbed up my downpipe with help of my buddy



Im goind to be installing my exhaust cut-out after the V-band and then plug it up to the the Y-pipe.

I went to the scrap yard to pick up a Passat in tank fuel pump to replace the pump in the Audi, will install the tdi fuel filter and convert the original tank line as a return line.

Then I need to figure out my intercooler piping before I re-install the front end. Once thats done I will be able
to finish up my coolant lines and then test drive time.

I can finally start to see the end.



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[ShogunR32]

Very nice!

[jacobsen]

My favorite thread on here

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[EuroEnduro]

So the alh tdi bolts directly up to the 1.8t transe?? AND the motor mounts fit too? Next project idea...

[Europotvin]

So the alh tdi bolts directly up to the 1.8t transe?? AND the motor mounts fit too? Next project idea...

The TDI should bolt up to the 1.8t trans but I used a Euro 01E from a 2.5 TDI A6 in order to use the TDI starter. The motor mounts fit but the accessory bracket needs to be modified on an ALH.


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[SleeperAvant]

Nice build!!

[Europotvin]

My favorite thread on here

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Thanks ! I think I should try and take more pictures


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[jacobsen]

Thanks ! I think I should try and take more pictures


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Definitely and it would also be super cool if we could create diesel conversion Wiki. I really want to do this myself. I want a 6-speed Quattro TDI Audi

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[Europotvin]

Update:

Ok so got some time to work on the car tonight.

Started by dissasembling the TDI in-tank pump to install the pump in the Audi basket



Got everything installed (a real pain in the ...) Plugged everything up, put some power on it and nothing ... So ill have to pull it out to check I plugged it correctly or the pump might be bad (should of tested before -_-). Ill do that this weekend.

In the mean time I installed my TDI fuel filter I started my fuel lines



Anyways I started to reinstall my front end to check my coolant lines and intercooler piping.

I think I will install the stock intercooler on the passenger side for now. It should be fine for my base tune at 25psi. By putting it on the passenger side I will reduce to a minimum my piping so less lag. Its goig to be a little tricky since I have the S4 HID headlights but It should fit.



Cleaned up the wiring a little and this is were Im at



Next update this weeked !


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[rocket1420]

This is an awesome build. Can't wait to see the finished project.

[csosnowski]

This is pretty awesome!

[Europotvin]

Update:

Got alot of stuff done, checked the fuel pump and its fine, it was the fuse that was blown -_-. Got everything back in the tank.

Finished up the fuel filter install and the fuel lines.

Got the coolant lines figured out, had to fab up a rear coolant flange.

So this is how its looking right now



Need to finish up the coolant lines and intercooler setup and Ill be ready for a test drive.



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[19birel]

This is by far one of the coolest builds I've seen on here, too cool

[dboy021]

So jealous! Would love a tdi in my avant. Props to you sir!

[Europotvin]

Update time !

Finished up my coolant lines, intercooler piping.

For this winter, setup de stock intercooler on the passanger side instead of driver. This way I have almost no piping.



The stock cooler should do the job with my temporary tune that is at 25psi.

After winter Ill install my front mount intercooler with a rear facing intake manifold. Then I will be able to get it fully tuned at 30-32psi :)

Updated my head boltd for ARP studs



Because of my current intake routing, I had to install a baby K&N filter directly on the turbo



When I change my intake manifold, I will be able to put a bigger filter and pipe to get colder air.

Went for 2 test drives up to now. Wow does it feel good to finallly drive it after 3 months of working on it.

Pretty much everything works, I still have to adjust my shifter linkage and get my fueling adjusted.

Ill try to put up a video when I can really take it for a ride.


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