80 Cabriolet Tdi conversion

Posted: Sat Jan 07, 2012 2:53 pm

Photos for the bulk head will be a couple of weeks as put the car in storage. Cabriolet TDI aircon is in pic below. Just watch as some times the pics are LHD. On the V6 the AC comp is on passenger side of engine on the TDI its on the drivers side. But rest looks similar to my Cab aircon other than the bulkhead hole which looks LHD in the pic below.

Audi Nut Joined: Dec 01, 2011 Posts: 96 Location: Lanark

Ta, think I've got the tank sorted out (in my mind anyway Wink

)

Air-con

Managed to get a setup of a v6 so I suppose there is no excuse not to put it in! The compressor bracket is the thing thats going to be tricky to get. Think it was only on the 80 tdi and the a6 95-97 with the 1Z tdi engine so prob not many of them about, and if there are some, it'll be a part that never gets asked for so will be thrown straight into the scrap skip. Ho hum!!

Think i'll put the air-con heater box and wiring in then bide my time for the rest of it unless a bracket turns up. I suppose I could use a bracket off an A4 though I'd mean changing alternator brackets and everything else as well.

Audi Nut Joined: Dec 01, 2011 Posts: 96 Location: Lanark

I really fancy cruise control and trip computer for this build!!

So........

I sent a pm to Jas11n and he sent a message back saying that the earlier ECU which I have is no good Crying or Very sad

He did say though that the 80 tdi built from july 1994 it was fairly simple Smile

So........

Last friday found a late August 94 assembled 80tdi in a scrappy near Stirling
so.....

1st one took a couple of days to get the loom out of
2nd one a day
This one 5 hours to get the wiring looms, ecu, injector pump, etc out.
hope I've got all the bits I need, now i need to find out how to Laughing

Posted: Tue Jan 10, 2012 5:44 pm

Could you add 4x4 quattro Cool

.
Maybe climatronic as well .

http://www.audicabrio.info/support/index.php?action=artikel&cat=25&id=68&artlang=de

I thought it was 1992/1993 that they went over to the TDI. It was TD before 1992 and they did not have the electronic pump. I planned to fit it to my 1993 Audi 80 just never got round to it. Could be wrong.

You will need VAG-COM to reprogramme the ECU. Just fitted cruise to my B5 A4. It is relatively straightforward. There are photos on the A4 pages.

Posted: Tue Jan 10, 2012 10:31 pm

There are a couple been done I know of, meant to be a PITA though. Gav had one, Kim Collins has one I beleive, there is one recently converted on motorgeek.

Posted: Tue Jan 10, 2012 11:19 pm

If there is a 4x4 B4 cabriolet with TDI out there I will buy it! Even if its petrol are there any links or photos?

Posted: Tue Jan 10, 2012 11:32 pm

http://www.motorgeek.com/viewtopic.php?f=6&t=9349&hilit=cabriolet

Posted: Mon Jan 16, 2012 8:04 pm

Cool links. Dream would be 1.9 TDI 4x4 Cabriolet. Not sure if you could build one from A4 bits TDI bits and a B3 rear end.

Anyway the 2 wheel drive conversion looks hard enough!

Audi Nut Joined: Dec 01, 2011 Posts: 96 Location: Lanark

4x4 tdi cabrio...... maybe next time!

So, what've I been up to?

Just been gathering bits n bobs for the toys to go in the cab Smile

Audi Nut Joined: Dec 01, 2011 Posts: 96 Location: Lanark

Did start to the air con, just to see if it would fit....
Thought I'd need to get out a can opener Laughing

Typical Audi....already had the hole in the bulkhead with a bit of tin covering it!! Just pressed it out with a screwdriver( and a wee bit assistance from a hammer) and Bobs your uncle...(Well he is mine Wink

)

Posted: Sat Jan 28, 2012 11:05 am

Looking good...Whats the plan with the exhaust? The Audi 80 has that indestructable stainless system that silenced it to a nice level. Not sure if it will fit but I would try.

Another odd differenece I notice on my 2.8 is that the underbelly sound absorber under the drivers area is not fitted. (the one under the engine is fitted). You might need it on the TDI to keep the noise reasonable particularly with the roof down.

Audi Nut Joined: Dec 01, 2011 Posts: 96 Location: Lanark

Exhaust, going to use the petrol one to get it up and running. I am going to use the tdi downpipe and cat then at the next joint swap to the 2.3's exhaust. Don't know whether the petrol engine's exhaust is as free flowing as the diesel. Will try anyway (easiest option for the moment)
I've got a 2010 A4 tdi S-line and the exhaust tail pipe is kinda sporty and points straight out, only problem is that the rear end of it does get a bit sooty... There is a lot to be said about the old 80 tdi exhaust with the double tails that point down....

If when I get the tdicab on the road, if it starts to soot up the back end then I'll just put the tdi exhaust (double downpoint tails) in the cab...the cab does look good with the big oval tailpipe though.......

Soundproofing

It'll be a hassle to put in the soundproofing on the underside,,,,, so for the moment I'll just go with the interior bulkhead soundproofing. Its about an inch thick and goes from windscreen height to past the gearlever!! The 2.3 didn't have it......so it may be quieter than the 2.3 when I'm finished!!!

Always found out that with the diesel scimitars I had they were just as quiet as the petrols when you were driving them. It's only at idle when diesels are noisier than petrols..........though I'm probably deaf anyway,,,,or was it that I don't listen? Laughing

More to follow! It's going slow at the moment, life is getting in the way of fun Rolling Eyes

Audi Nut Joined: Dec 01, 2011 Posts: 96 Location: Lanark

Sorry about the delay, there has however been some progress Smile

Finally got the engine back together, new belts, seal, gaskets etc. Hopefully leak free! time will tell.

Also started to rebuild the rest!!

Wiring looms in. And for future goodies I ran some 7 core wire to the front of the engine bay from inside the car, also a cable from front to the boot and one from left to right inside the bulkhead to the footwells. (Just in case)

Next, thought I'd better try the air-con set up in!! bu**er Shock

Ok, thought it'd be no probs and everything was ok.... and it did actually go in fairly easily....apart from the drain tube from the cooling radiator. Still to sort that out. I took the grommet on the engine bay of the car off, though in the car the bulkhead strengthener is in front of the grommet Confused

If someone has got an aircon cab could you have a wee look at where this hose goes to get out of the car. ie will I need to savage the strengthening to get the hose out?

Audi Nut Joined: Dec 01, 2011 Posts: 96 Location: Lanark

Carpet in. Another few strange words.

To help you if you take one of these to bits. Put the carpet in before you put the pedal box in.... I didn't Mad

So it's starting to look a bit more like it now, also tried the intercooler and airbox in place. Phew!!

Next time The engine will sitting in on the engine mounts!!

I do have a problem with the subframe though Shock

The 2.3 cab has 10mm bolts and the tdi subframe has 12mm.
Anyone got any ideas??

Site Moderator Joined: Jan 31, 2003 Posts: 9144

could you not fit new bushes to the subframe for the 10mm bolts ?

Audi Nut Joined: Dec 01, 2011 Posts: 96 Location: Lanark

Probably, though being a mean spirited scotsman that would mean letting a few of my moths out of the wallet!!! I'm going to cut off the gearbox mounting from the tdi subframe then weld it to the cab subframe. The tdi subframe is rusty anyway, and that should be good enough!!

Audi Nut Joined: Dec 01, 2011 Posts: 96 Location: Lanark

Busy day on the cabtdi!!

Needs to get out more Joined: Jun 11, 2008 Posts: 183

great progress!

Audi Nut Joined: Dec 01, 2011 Posts: 96 Location: Lanark

Well....... it starts.........for a second........then stops.....

Just temp put the wires in the fuse box and relay box/ junction box just to see if I could start it.

It runs for a few seconds then stops!!

I think it's an immobiliser that the pump has that came with the ecu!
I got the steering lock though no key so will need to go back to the scrappy to see if I can get one, or get the serial number and go to Audi and get a new one....

Oh and I put the exhaust together as well, so a busy day!! I used the tdi downpipe and cat and then the cab exhaust. The only difference was that the cab exhaust is a slightly larger diameter. No probs, I just cut a bit of the end of the cab cat tail pipe, hammered it onto the tdi cat tailpipe then welded it!! Perfecto Very Happy

.... well apart from my welding Wink

Audi Nut Joined: Dec 01, 2011 Posts: 96 Location: Lanark

No news is good news!!

Yet again life has interupted fun!!

Still haven't got the immobiliser problem sorted,,, though I'm getting a chip coded next week, so here's hoping!!

Started to rebuild the front end.

Got all new brake discs, pads, wishbone bushes and bottom ball joints so will be having a go at them in the near future.

It'll be on the road in may.............. Liar

Posted: Sat Mar 17, 2012 12:49 pm

Great stuff Jim ! Shes certainly getting there Cool

Finished just in time for the summer (if we have any Rolling Eyes

) ?

The good looks of a cabby with diesel economy, great project !

Audi Nut Joined: Dec 01, 2011 Posts: 96 Location: Lanark

Bit of progress today!!

Finally welded the gearbox mount from the tdi subfame onto the Cab subframe. then primed then painted......then offered up and......success! it fits Very Happy

Bolted up good and tight.

New brake discs and pads on the front. pretty tricky to get the caliper cylinder retracted far enough to get over the new bits!! Got it though.

New wishbone bushes and ball joints on as well!

( Anyone know somebody in the central belt of Scotland that knows how to align and set the camber/ caster on these?)

Audi Nut Joined: Dec 01, 2011 Posts: 96 Location: Lanark

More progress!!

Lights and started to put the front bumper on!!

Site Moderator Joined: Jan 31, 2003 Posts: 9144

For alignment I've been using CLCM in Edinburgh

Audi Nut Joined: Dec 01, 2011 Posts: 96 Location: Lanark

Do I need to say any more!!
Finally got it starting and running after getting a couple of immobilizer chips made. Think its off timing though as it runs a bit rough and hunts a bit!! Need to slacken the bolts on the pump and give the pump a wee shove (technical term Wink

) to see if it steadies,,, if not.. Bl**dy electrics......

Brakes, new discs and pads all round (and now on), driveshafts on (new outer couplings on).

Phew!!

Audi Nut Joined: Dec 01, 2011 Posts: 96 Location: Lanark

And I thought I'd get up to Crieff on sunday to see all things Audi and annoy people and ask questions, but, didn't finish work till 2 so no go.......BUT Very Happy

I'll let the photos do the talking Wink

.........

Audi Nut Joined: Dec 01, 2011 Posts: 96 Location: Lanark

Well, that's the easy bit done! If only I could go and mot it, though I've a wee bit electrical work to dooooo.....
Shocked

I'll get there though

Site Moderator Joined: Jan 31, 2003 Posts: 9144

top work

Posted: Wed Mar 28, 2012 7:14 pm

how have I missed this? Confused

EXCELLENT project..... any objections to putting a "mention" of it on the homepage?

Well done so far; as a mute point (something Bladerunner mentioned in a post (RIP))- the Cat isn't a legal requirement on diesels and may help improve breathing (and give a few more ponies!) Cool

-something for you to think about.

I'm sure there was something else... but can't remember... for now...

Keep up the good work Very Happy

Audi Nut Joined: Dec 01, 2011 Posts: 96 Location: Lanark

no probs about a mention.
Cat, It's on at the moment though may give it the straight through conversion in the future.

Thanks for the comments, I feel as if I'm actually getting somewhere with this.
It's the little things that take time. Last night thought I'd better sort out the immobilizer chip reader loop ring!! (The cab didn't have a factory immob though the 95 tdi wiring that I used did..

So.... angle grinder to the metal ring at the end where the key goes in to the lock. Find the locking spring and pull out the spring.

Next get the chip reader off the lock/switch assembly without destroying it (using angle grinder, hammer, chisel)

Now the easy bit. Put the plastic chip reader onto the lock assy!!

Ehh... how do you do it without losing sanity.... Crying or Very sad