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conversion. 1.9tdi - 2.5 v6 tdi

Discussion in 'A4/S4 forum(B5 Chassis)' started by gavbey, Apr 4, 2011.

  1. gavbey
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    gavbey Member

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    [Apr 4, 2011]
    hi there people, i was wondering how difficult it would be to transplant a 2.5 v6 into my 1.9tdi 1997 audi a4 avant?

    i can sort the immobilizer out etc.

    what would i need?
    subframe mounts?
    would it mate with the 1.9tdi gearbox?
    ecu engine loom?

    and its FWD not quatro.

    thank you in advance


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    #1
  2. aragorn
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    aragorn "Stick a V8 in it!" Staff Member Moderator VCDS Map User

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    [Apr 4, 2011]
    It all comes down to the same old question, Why?

    It will cost you a ton of money by the time you've baught all the parts required to do the swap, then you'll have a modified vehicle thats difficult and more expensive to insure than the real thing.

    You'll be much better off just buying a 2.5, with Quattro, and swapping any nice bits over from your existing car. Take the opportunity to upgrade to facelift at the same time for all the little improvements that brings as well.

    To answer your questions though, you will need the subframe, engine mounts, engine wiring harness, intercoolers and associated pipework, ECU, possibly the fuel tank although they may be the same, radiator and water hoses. If you buy all the parts from a similar era car then it should plug into your existing harness, but it might need some electrical tweaking.
    The 1.9 gearbox will work, but the 2.5's came with a 6 speed box which will make it nicer to drive and are more suited to handling the power. If you want to use a 6 speed, you can, but you'll probably need its gearlinkages and driveshafts, and the suspension uprights as they're all beefed up for the V6 engine.
    You'll also need V6 front suspension as the motor is a lot heavier.
    #2
  3. gavbey
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    gavbey Member

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    [Apr 4, 2011]
    thank you mate, alot less than i thought to be honest.

    as for insurance its going to add £50 to my policy, its only the exstra fuel consumption that will make the big diffrance.

    i have coilovers which suport the v6 and as i say i would have a donor car beside me so its only going to cost the price of the donor car, fuel tank is the same and as for the electrics im an electrician and my other car is an mk3 ibiza cupra ( pretty much invented electrical faults ) so wiring is no problem. well ill keep an eye out for a donor car and ill be updating my thread once ive found one :)

    thanks again
    #3
  4. aragorn
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    aragorn "Stick a V8 in it!" Staff Member Moderator VCDS Map User

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    [Apr 4, 2011]
    Its even more pointless if your going to actually buy a donor car lol.

    Ditch the FWD and buy a Quattro.
    #4
  5. adamss24
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    adamss24 Well-Known Member

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    [Apr 4, 2011]
    I am about to do the exact opposite: swapping a 1.9 tdi into a v6 tdi quattro ! Dont get me wrong but aragorn is right. You will need a lot more to swap and its not wise unless you dont wanna tell the insurance company about the swap. Get his advice and buy the car with the engine you want from factory. On top of that the 1.9 tdi can be made to output similar power to a tweaked 2.5 tdi with just bolt-on mods whilst still keeping the good fuel economy ! Front uprights to take the v6 tdi driveshafts, springs/shocks, engine subframe, front slam pannel, engine wiring loom, fuel lines,ECU, clocks need codding,etc. Dont build a car you can buy, i dont know of any 6 speed 1.9 tdi quattro's arround and my v6 has all the right upgrades: 180Bhp tweaked engine,4 pot brakes,lowered suspension,6 speed gearbox with a B&M short shifter, s4 bodykit and the right kit (Bose, cruise, full DIS,leather) + just been fully painted as well ! I do love the simplicity,reliability and economy of the 1.9 tdi engine and i love the smoothness of the v6 lump (i also have a allroad with the 180 Bhp engine wich i use for towing) but i am only going to a 4 pot just because it can be made just as fast as the stock v6 tdi but without detrimental fuel consumption. I also happen to have the parts, skill but very little time but it will happen eventually !
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  6. adamss24
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    adamss24 Well-Known Member

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    [Apr 4, 2011]
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    [​IMG] Eibach springs for 1.9 tdi (bought full kit for a 4Motion passat but only fronts needed/allready eibach springs on the rear)
    [​IMG]Garrett GTB2260Vk turbo
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    [​IMG] ported head
    [​IMG] Bosio injectors
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    Had this 1.9 Tdi quattro sport 1.5 months ago and i was just about to keep-it but i could not put up with 5 speed gearbox and powerty spec. Start with a better base if you can, it makes all the difference !
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    #6
  7. Izzy1
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    Izzy1 Vorsprung Durch Technik

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    [Apr 4, 2011]
    Chris,
    How are you getting on with the TDI you took off me?
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  8. adamss24
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    adamss24 Well-Known Member

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    [Apr 4, 2011]
    Izzy, that head in the picture is off the a4 i have bought from you mate, got a turbo for it but 2 rods are slightly bent so they need replacing (ordered forged rods and oversize pistons). Good thing the AHH engine has 11mm pump as standard. I might throw the v6 tdi engine in it and use a 6 speed FWD gearbox i have spare and be done with it. It will be very cheap to insure whit it beeing a lousy 90Bhp on the logbook ! Been busy with two other cars i have bought as spares or repairs and got them running before the a4 i got from you. I am in 2 minds of what to do with my avant, have a socketed ECU with a rennsport map on it but its off a 98 AFN audi a4, the AHH ecu is a EDC15 so its OBD flashable so much easier to tune but i have a feeling that it might not work fine with my immo2 dash... Its soo much work swapping bits from one another but doable in everz respect.
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  9. Izzy1
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    Izzy1 Vorsprung Durch Technik

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    [Apr 6, 2011]
    Keep up the good work Chris,
    Let me know how you get on.
    #9

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