Upcoming AHU 1.9 tdi into Doka

[T3Aljezur]

Hi all
Been trawling around for a few weeks now, getting info together for my upcoming change over
Currently have a 1.6 cs with not enuff power to pull the skin off a rice puddin'
Have an A4 completely stripped (just finished chopping it up with angle grinder today ready for recycling)
I am using the engine, but keeping the old box (for now) until funds permit better box.
Only ever drive local up some big hills so grunt is more important than speed. Can live with it for a bit.
Bear in mind I have done a tdi conversion on my T4, so have a little experience, but fairly new to T25. (Learnt to drive in splitty tho)
Couple of questions I need to clear up.

1. I want to use the orignal flywheel, saves messing, from the 1.6. I will of course have a new clutch spigot and seals. Is this possible, and what should I beware of ?

2. I have read the engine will need a new mount fabricated for one of the mounting points ? Any tips ? Also I read someone has done it using existing ahu mounts and cs mounts. Is this possible ?

3. Starter motor. If I keep the original flywheel and clutch then I don't need the adaptor as will be using the original cs starter. Correct ?

4. The sump needs to have a oil feed adaptor for the turbo. My A4 AHU has the oil feed for the turbo coming from the side of the engine block, or is this the return. Also I need to change the oil pick up and keep the cs sump ?

I want to try and do a photo guide as I go for the wiring, as this seems to be lacking around here, and always seems to be an issue with knowing what to do.

Anything alse that you bods can offer in tips advice and general help would be much appreciated.

Thank you all in advance,
Dic

[randolph57]

Not speaking from AHU experience as i chose a different configuration on my TDI conversion but as i see it :-

1. Original clutch known to be a little 'weak' and prone to slipping -not necessarily a problem being a Doka ( unless fully loaded )

2. left hand mount is a straight swap- RH mount i think is only a problem on Audi donors or the AFN engines but i may be wrong-RH mount is available on ebay .de at a premium but would recommend making your own if you have the capability as they are very rough and ready!

3. Yes and Yes

4.IF you are using the AHU manifolds there may be clearance issues around the LH mount -common conversions on TDI'S use a JX exhaust manifold, adaptor plates for the donor turbo and standard JX exhaust-This tends to keep everything fairly VAG 'standard'.I am assuming you are ditching the weasel standard exhaust system If you move the turbo to a JX manifold you will need a new oil feed (flexi is best) and a sump adaptor /drain pipework anyway for the oil return.
oil pump is a straight swap over but again you may want to renew - i dont know condition of your CS engine.

advise maybe contacting Tim shettle (Trader) on 07810320464 as he may well be able to supply various exhaust adaptors and has a wide spectrum of Knowledge and good advice (free ) before you start.

Good luck

[keith]

would be good to see some pictures when you get going.

[T3Aljezur]

Firstly many thanks for info Randolph.
Will see how it goes with clearance issues. Have a big hammer
well, lets see if this works, pics that is
probably not the best convertible in the worls, but it is getting recycled

The beast, also know as Jelly, cos it's a 1.7 KY
and it's alternative uses


all the rest are the engine loom, before it enters the cabin.
connections are simple on the engine, but need to dismantle the cabin side now, pictured, and keep what I need.
I am for now keeping the binnacle as the immobiliser is buried in there somewhere, and until I either delete it, or find and alternative (golf 3 setup) then I gotta keep it.
Will keep notes and take pics as I go



on the second pic, on bottom left, this is the connections into engine bay. I cut the red and black in frustration, trying to get it out, but they go to the main board inside and the engine loom, so easy fix.

The engine loom is seperate, and no photos at the mo, but all labelled up, and easy to refit

[T3Aljezur]

sorry to avoid confusion
Jelly was named when we bought her, thinking it was a 1.7KY
Found afterwards someone has put a 1.6CS in it (Not for long)

[T3Aljezur]

OK
Had a bout 3 hours at the cab side of wiring.
Just picking out the wires that go into engine bay inc, immobiliser, glow plugs etc etc.
The connectors can easily be unplugged and then put back together which has made things really easy, along with wiring diagrams for an A4
I am making things more difficult cos I want to keep the cruise as well, then make a switched cruise unit on the dash later
I have some pics of what I've been doing and will upload this weekend, along with a list of what I have learnt, and why, with patience, anyone can do it.

As a bonus, have just sold the 1.6cs lump (when removed) to a local chap who has 16 T3´s that he's going to be renting out to holiday makers from next year. Sounds like a good Algarve holiday to me............