Project 160+ HP Top Spec TDI

[Cameron Waters]

So to start off I bought my long termer back in the summer, One The best spec TDI’s I’ve ever seen and I’m lucky enough to own it. It’s a Fully Loaded SE 75. Options include, Working OSS Sunroof, 5 Seater Heated Full Leather Interior, Cruise Control, Double Din Dash, Rear Cupholders, 4X Electric Windows, Crazy Rare Headlamp Washer Front Bumper, Auto Dim Rear View Mirror, False Floor, 12v Socket in the Boot, Heated Washer Jets…

After Owning 7 A2’s since 2016 I’ve always wanted to improve on the power delivery of the car and driving a 90 compared to a 75 TDI the difference in refinement and drivability is night and day (in my opinion) The VNT Turbo spools up so much faster making the powerband far more usable on the 90 which gives it that PD130 type feeling alongside the DMF which reduces the harshness and vibration of the little 3 cylinder engine. With a bit of experience and knowledge from Building a 250hp / 500NM A3 8L PD130 Quattro last year I set about improving the A2 and making its performance on par with cars from the modern era.

 

[Cameron Waters]

To Begin with I Sourced a GT1749VB Turbocharger from a PD150 1.9TDI MK4 Golf. This has a billet compressor wheel and uprated thrust bearing to aid spool time and greater boost pressures. I had the extra cylinder branch on the exhaust manifold chopped off and welded up to make it compatible with the 3 Cylinder motor.

I then sourced an ATL TDI 90 Engine from a Rolling Shell Donor Vehicle I bought from a lovely Chap called Andy who’s local to me down in the south east. After doing some research on the ATL Engine I felt it was the best thing if I’m after extra power as I read they have lower compression pistons to cope with the extra boost a 90 runs so this would help me run more boost safely. Plus I know they have the Larger Oil Cooler and 550cc Injectors and Stronger Headbolts from an ARL PD150 engine so it made sense while pulling the AMF 75 engine out to change it for the strongest alternative.

Next Task Was the Gearbox, after having 2 JDD gearbox converted TDI’s and loving them I wanted a change so set about getting an MYP 6 Speed a manual Gearbox from a Passat B7 1.6TDI. After doing more research I established a 90 has a larger diameter clutch than a 75, the same as a 2.8 VR6 Golf so figured it will be able to cope with way more for so decided on running a new OEM LUK kit and seeing how I get on. As I Previously had a CG Motorsport stage 3 clutch which I found a bit grabby.

For the Downpipe I’m going go be using a Standard 90 Downpipe Which uses the same Flange fitment as the PD150 turbo I’m going to be fitting as there’s no aftermarket alternative that fits unless it’s custom made so I’m just going to DECAT the system for improved flow.

The next hurdle is converting a 75 to run a VNT (Variable Geometry) style turbo as in original form they just have a wastegate style turbo like a petrol car. TDI 90’s run a vacuum box system like a Fabia VRS but a 75 Uses a N75 Valve. I decided to keep the N75 System and just get a valve that was compatible with VNT from an old MK3 Golf TDI AFN. Part Number 1H0906627A has the same square plug as an original A2 valve so is plug and play with no loon adaptations or chopping wires.

For Front Brakes I decided on 312mm Discs and Calipers from a TT MK1 225. In order to fit these to an A2 you need Fabia VRS MK1 Hubs which have the Bolt On Style Caliper Carriers unlike A2 hubs that have the carrier as part of the hub assembly, so brake upgrades can’t be done.

For Rear Brakes I sourced a Disc Brake Rear Axle from a TDI 90 / 1.6 FSI with the necessary brake pipes and handbrake cables.

Suspension Wise I decided on SPAX 25mm Lowered Springs, Bilstein Shocks and new top mounts.

For the Intercooler I have a Custom PRO-Alloy Cooler which fits in the standard location and utilises the OEM Airducting. These were made in a batch of 50 and were from Tom Cunningham from A2OC. This will eliminate the boost leak issues the oem plastic ended coolers. I will be running a 4 BAR Map Sensor also.

An Ecu Remap is also being done once the car is finished so make sure everything is calibrated properly and the car will be live data tuned on the road.

 

[Cameron Waters]

Here are some photos of the car before the work, Did a 4500 mile round trip to southern Spain in august 2022

 

[Cameron Waters]

Some Pictures of the Pro Alloy Custom Intecooler…

 

[Cameron Waters]

The GT1749VB Hybrid Turbo with the Chopped Cylinder Branch…

 

[Cameron Waters]

The TDI 90 Rolling Shell with Running Gear I picked up as a Donor Car for the Build…

 

[Cameron Waters]

The 312mm Front Brake Upgrade vs Standard A2 Brakes…

 

[Cameron Waters]

New (OLD) N75 Valve to be fitted…

 

[Cameron Waters]

A Gradual Process of Removing the radpack, old engine and gearbox, front suspension, rear axle and suspension along with cleaning, prepping and painting parts ready to be re installed.

 

[Cameron Waters]

A Gradual Process of Removing the radpack, old engine and gearbox, front suspension, rear axle and suspension along with cleaning, prepping and painting parts ready to be re installed.
View attachment 102876

A Gradual Process of Removing the radpack, old engine and gearbox, front suspension, rear axle and suspension along with cleaning, prepping and painting parts ready to be re installed.
View attachment 102876

 

[dj_efk]

Congratulations on owning the only A2 that Audi made money on when they sold it!!

Smashing project and write-up. Very interesting, especially the engine modifications

 

[Sylvester]

Here are some photos of the car before the work, Did a 4500 mile round trip to southern Spain in august 2022
View attachment 102855

Are those the famous Fat Fives? I think they look superb, if I'd chose any wheels for my A2, it'd be these on 17" in polished or Suzuka Grey.

 

[A2Steve]

Looks to be a great project Cameron, thanks for sharing the photos.

Love the attention to detail with all the prep work going on as you go along.

Should make for a really great driving A2.

I’d suggest changing the rear axle bushes while the axle is out. Even if you just change them for the standard bushes, the difference it makes to the ride quality is night and day.

 

[birtyA2]

Are those the famous Fat Fives? I think they look superb, if I'd chose any wheels for my A2, it'd be these on 17" in polished or Suzuka Grey.

Wow!

These are indeed the fat fives, which to my eyes are the best design wheel from VAG and look fantastic on any car I have seen them fitted to and do look great on an A2 as well

That is one hell of a car

J

 

[Cameron Waters]

Ingratiations on owning the only A2 that Audi made money on when they sold it!!

Smashing project and write-up. Very interesting, especially the engine modifications

Thank you much appreciated

 

[Cameron Waters]

Are those the famous Fat Fives? I think they look superb, if I'd chose any wheels for my A2, it'd be these on 17" in polished or Suzuka Grey.

They are indeed, mirror polished, no lacquer Just metal

 

[Cameron Waters]

Wow!

These are indeed the fat fives, which to my eyes are the best design wheel from VAG and look fantastic on any car I have seen them fitted to and do look great on an A2 as well

That is one hell of a car

J

Thank you

 

[Cameron Waters]

Looks to be a great project Cameron, thanks for sharing the photos.

Love the attention to detail with all the prep work going on as you go along.

Should make for a really great driving A2.

I’d suggest changing the rear axle bushes while the axle is out. Even if you just change them for the standard bushes, the difference it makes to the ride quality is night and day.

Will do thanks Steve

 

[2work]

Morning Cameron,

Really interested in this thread. Cannot wait to see how it progresses. I’m always amazed reading the various project threads hosted on here following what members do to their A2s.

Agree that the Fat 5s always look stunning but even more so when polished.

Good luck with all that you’re embarking on.

Kind regards,

Tom

 

[simon martyn]

Greatly looking forward to the continuing tale of you Fabuuuulous coversion!