2003 B6 Audi a4 convertible 3.0 petrol conversion to 1.9TDI
Discussion
Hi im planning on buying a silver 3.0 petrol 2003 B6 Audi a4 convertible for £950.00
and converting it to a set up that i think is the best but very difficult to find in 1.9 130 TDI 6 speed format all the small tdi engine convertibles are over 4k even for a old one,
why the 1.9 tdi engine you ask?
the 1.9 TDI engine incorporates more reliable PD injectors and 55mpg and no DPF,s etc, .
also the bullet proof 6 speed manual gear box thats used in passat and used in the saloons and estate a4 and a6 models.
by using this power train i should be able to keep my costs down by using a stock pre face lift B6 saloon donor car around 2002-3 era in the same color silver, so i don't have to paint any thing.
B6 saloons 1.9 TDI 130,s are now going for as little as £750 on ebay and less if they are non runners etc,
so hear goes
summery
patient car
3.0 petrol auto 2003 B6 Audi a4 2wd convertible pre face lift 110k mile 17in stock 5 spokes £950.00
is a good color "silver" and has a gray/cloth interior and back dash so it has the best type of interior for a older car and ages better than leather that cracks and gets shinny with age.
The convertible chassis only has 110 k miles, it has slight front end damage to the OSF wing bumper and front panel but its unrecorded and that the reason its going cheap, no air bags have gone off and inner wings are ok and not damaged,
donor car
1.9 tdi 130 6 speed manual 2002 silver B6 Audi a4 2wd saloon pre face lift B6 saloon donor car 165k miles 16in stock 5 spokes £850.00
silver
so my plan is use my mates garage who has X2 2 poster ramps side by side
then.
place both cars on each ramp,
support the engine with engine support host lift the donor car in the air about 3 foot
remove the front panel in full detach air con pipes coolant hosts
remove all plastic covers
disconnect all wires and cables on the engine
remove all heat shields and exhaust
undo the top suspension struts from the body
lift the donor car in the air about 5 foot
undo all sub frame bolts make sure engine support host can take the load of the engine and transmission. (keep a few bolts in place and check the load when car i lowered to the ground
if all goes to plan the entire engine transmission and drive train should be supported by the engine support host when the car is lowered to the ground and the engine support is removed and the car lifted back up in the air the drive train should be free from the chassis wihh the front wheels still attached.
use a full size engine hoist to drag all the drive train out form under the donor car ramp area
the next thing i would to to keep things simple is perform the same procedure to the patient car but with a few extra steps regarding removing the wings.
1.support the engine with engine support host, lift the patient car in the air about 3 foot
2.remove the bumper & front panel in full detach air con pipes coolant hosts
3.re move the wings and bonnet,
4.remove all plastic covers
5.disconnect all wires and cables on the engine
6.undo the top suspension struts from the body
7.lift the donor car in the air about 5 foot
8.undo all sub frame bolts make sure engine support brace can take the load of the engine and transmission. (keep a few bolts in place check the load on the engine support brace when car is lowered to the ground,
if all goes to plan the entire engine transmission and drive train should be supported by the engine support brace,
when the car is lowered to the ground remove engine support brace lift the car back up in the air then drive train should be free from the chassis on on the floor with its wheels attached
use a full size engine hoist to drag all the drive train out form under the patient car and put it on ebay at 99p
now focusing on the donor car again,
remove all the auxiliary components in the engine bay like abs pump ecu,s pressure valves etc,
remove the wiper mechanism and disconnected any engine looms from the interior of the car
remove front seats (for space to work)
remove steering rack
remove the center console
remove clocks and engine ecus
remove steering column (you might need the receiver for the immobilizer round the lock if this cant be swapped round if not swap it round)
remove the dash board in including all radio and climate control modules
remove air blower box and air ducts if different to the one in the patient car (its possible as the dash is different in patient car)
remove manual peddle box
remove all heat shields and exhaust
clean and place all the 1.9tdi parts some where safe as all this will be going in the patient car
now focusing on the patient car (rinse and repeat)
remove all the auxiliary components in the engine bay like abs pump ecu,s pressure valves
remove the wiper mechanism and disconnected any engine looms from the interior of the car
remove front seats (for space to work)
remove steering rack only if different
remove the center console
remove clocks
remove steering column
remove the dash board in including all radio and climate control modules
remove air blower box and air ducts if different to the one in the patient car (its possible as the dash is different in patient car)
remove auto peddle box
remove all heat shields and exhaust
place all the parts some where safe not to mix up with other parts off the patient car as some of this might be reused in the patient car
at this sage both cars are totally stripped and the patient car has no wings or bonnet on,
on the tdi engine i would probably fit a new head set £60 off ebay
cam belt and water pump kit £90 quid off ebay
remove and power wash the manifolds while the engine is out of the car and inspect the cams and lifters £160
check the DMF and clutch and replace that if required £160 off ebay
(but lets say its a good setup already and only need a cam belt,fitting).
so this is the order i would start re building my patient car 2003 B6 Audi a4 convertible back up
1.install 1.9TDI heat shields and exhaust
2.install 1.9TDI ecu modules behind dash (note the ecu module for the roof is located in the rear of the patient car and would not be affected buy removing the dash and engine ecu, they might be a setting in vag com that needs to be activated but i would cross that bridge and run tests after the car was built back up)
install donor car 1.9TDI blower box and air ducts if different to the one in the patient car (possible as the dash is different in patient car)
3.install donor car 1.9TDI wiring looms behind dash
4.install donor car 1.9TDI steering rack if different!
5.install donor car 1.9TDI abs pump if different!
5.install donor car 1.9TDI peddle box
6.install donor car 1.9TDI dash board in including all radio and climate control modules
7.install donor car 1.9TDI clocks and engine ecus
8.install donor car 1.9TDI the center console
9.install donor car 1.9TDI steering column
10.install donor car 1.9TDI wiring looms from the interior of the car
11.install wiper mechanism probably the same on both cars!
use a full size engine hoist to drag all the 1.9tdi drive train under the patient car remember the wheels are still attached so this could be done with 2 people,
12.lower the patient car to the ground marrying the 1.9 TDI drive train to the patient car chassis
13.support the engine with engine support host
14.tighten suspension struts to the body
15.lift up 3 foot in the air and re bolt up sub frame to the patient car chassis
16.lower back down and remove the engine support brace
17.reconnect all wires and cables to the engine and transmission
18.refit all plastic covers
19.remove wings from donor car and refit to patient car (fit loose untill bonnet is on)
20.remove bonnet from donor car and refit to patient car
21.refit the donor car 1.9 tdi front panel donor car bumpers (align properly)
22.reattach air con pipes coolant hosts re gas and fill all coolant and hydraulic systems
23.use Vag com to run abs tests and check for errors
24.test engine starts and abs works & and roof opens and closes
25.swap the os ns door lock barrels round from the donor car or live with 2 keys but the central locking should work but this can be re programmed with a MPV key programmer or vag-com that i both have any way,
26.last but not least use vag taco USB to set the mileage of the 1.9 tdi clocks to patient car 110K
and get the key code off the ecy
In theory this engine setup should start, as all the engine ecu,s keys,key receiver locks & clocks, dash HVAC systems are off the donor 1.9 tdi car
so hopefully the original convertible drop top roof ecu and air bag ecu would still work independently as long as the years are roughly 2002/2003 on both cars,
after all that you would have a very desirable 2003 silver a4 convertible 1.9 TDI 2 wheel drive, with gray cloth interior amd 17in stock 5 spokes
and a s
t load of spares
plus wiht all the bits you could re coop half the cost of the donor car back
and you still have the original NS convertible undamaged wing and bonnet so after you sell all the bits on ebay that car migh have cost you about 1200 quid,
and will be worth 3500 easy because of the desirable ness of that engine setup and color scheme
i cant seem to find a 1.9 TDI A4 convertible any where they are all
3.0 petrol drinks fuel
3.0 TDI v6 drinks fuel unreliable and a night mare and expensive to fix
2.5 TDI v6 drinks fuel and a night mare to fix
1.8 T petrol drinks fuel and blows up
2.0 T petrol drinks more fuel and blows up
or 2.0 TDI @ 6 grand and above, with all the problems of the 2.0 TDI engine brings and expensive to fix
and converting it to a set up that i think is the best but very difficult to find in 1.9 130 TDI 6 speed format all the small tdi engine convertibles are over 4k even for a old one,
why the 1.9 tdi engine you ask?
the 1.9 TDI engine incorporates more reliable PD injectors and 55mpg and no DPF,s etc, .
also the bullet proof 6 speed manual gear box thats used in passat and used in the saloons and estate a4 and a6 models.
by using this power train i should be able to keep my costs down by using a stock pre face lift B6 saloon donor car around 2002-3 era in the same color silver, so i don't have to paint any thing.
B6 saloons 1.9 TDI 130,s are now going for as little as £750 on ebay and less if they are non runners etc,
so hear goes
summery
patient car
3.0 petrol auto 2003 B6 Audi a4 2wd convertible pre face lift 110k mile 17in stock 5 spokes £950.00
is a good color "silver" and has a gray/cloth interior and back dash so it has the best type of interior for a older car and ages better than leather that cracks and gets shinny with age.
The convertible chassis only has 110 k miles, it has slight front end damage to the OSF wing bumper and front panel but its unrecorded and that the reason its going cheap, no air bags have gone off and inner wings are ok and not damaged,
donor car
1.9 tdi 130 6 speed manual 2002 silver B6 Audi a4 2wd saloon pre face lift B6 saloon donor car 165k miles 16in stock 5 spokes £850.00
silver
so my plan is use my mates garage who has X2 2 poster ramps side by side
then.
place both cars on each ramp,
support the engine with engine support host lift the donor car in the air about 3 foot
remove the front panel in full detach air con pipes coolant hosts
remove all plastic covers
disconnect all wires and cables on the engine
remove all heat shields and exhaust
undo the top suspension struts from the body
lift the donor car in the air about 5 foot
undo all sub frame bolts make sure engine support host can take the load of the engine and transmission. (keep a few bolts in place and check the load when car i lowered to the ground
if all goes to plan the entire engine transmission and drive train should be supported by the engine support host when the car is lowered to the ground and the engine support is removed and the car lifted back up in the air the drive train should be free from the chassis wihh the front wheels still attached.
use a full size engine hoist to drag all the drive train out form under the donor car ramp area
the next thing i would to to keep things simple is perform the same procedure to the patient car but with a few extra steps regarding removing the wings.
1.support the engine with engine support host, lift the patient car in the air about 3 foot
2.remove the bumper & front panel in full detach air con pipes coolant hosts
3.re move the wings and bonnet,
4.remove all plastic covers
5.disconnect all wires and cables on the engine
6.undo the top suspension struts from the body
7.lift the donor car in the air about 5 foot
8.undo all sub frame bolts make sure engine support brace can take the load of the engine and transmission. (keep a few bolts in place check the load on the engine support brace when car is lowered to the ground,
if all goes to plan the entire engine transmission and drive train should be supported by the engine support brace,
when the car is lowered to the ground remove engine support brace lift the car back up in the air then drive train should be free from the chassis on on the floor with its wheels attached
use a full size engine hoist to drag all the drive train out form under the patient car and put it on ebay at 99p
now focusing on the donor car again,
remove all the auxiliary components in the engine bay like abs pump ecu,s pressure valves etc,
remove the wiper mechanism and disconnected any engine looms from the interior of the car
remove front seats (for space to work)
remove steering rack
remove the center console
remove clocks and engine ecus
remove steering column (you might need the receiver for the immobilizer round the lock if this cant be swapped round if not swap it round)
remove the dash board in including all radio and climate control modules
remove air blower box and air ducts if different to the one in the patient car (its possible as the dash is different in patient car)
remove manual peddle box
remove all heat shields and exhaust
clean and place all the 1.9tdi parts some where safe as all this will be going in the patient car
now focusing on the patient car (rinse and repeat)
remove all the auxiliary components in the engine bay like abs pump ecu,s pressure valves
remove the wiper mechanism and disconnected any engine looms from the interior of the car
remove front seats (for space to work)
remove steering rack only if different
remove the center console
remove clocks
remove steering column
remove the dash board in including all radio and climate control modules
remove air blower box and air ducts if different to the one in the patient car (its possible as the dash is different in patient car)
remove auto peddle box
remove all heat shields and exhaust
place all the parts some where safe not to mix up with other parts off the patient car as some of this might be reused in the patient car
at this sage both cars are totally stripped and the patient car has no wings or bonnet on,
on the tdi engine i would probably fit a new head set £60 off ebay
cam belt and water pump kit £90 quid off ebay
remove and power wash the manifolds while the engine is out of the car and inspect the cams and lifters £160
check the DMF and clutch and replace that if required £160 off ebay
(but lets say its a good setup already and only need a cam belt,fitting).
so this is the order i would start re building my patient car 2003 B6 Audi a4 convertible back up
1.install 1.9TDI heat shields and exhaust
2.install 1.9TDI ecu modules behind dash (note the ecu module for the roof is located in the rear of the patient car and would not be affected buy removing the dash and engine ecu, they might be a setting in vag com that needs to be activated but i would cross that bridge and run tests after the car was built back up)
install donor car 1.9TDI blower box and air ducts if different to the one in the patient car (possible as the dash is different in patient car)
3.install donor car 1.9TDI wiring looms behind dash
4.install donor car 1.9TDI steering rack if different!
5.install donor car 1.9TDI abs pump if different!
5.install donor car 1.9TDI peddle box
6.install donor car 1.9TDI dash board in including all radio and climate control modules
7.install donor car 1.9TDI clocks and engine ecus
8.install donor car 1.9TDI the center console
9.install donor car 1.9TDI steering column
10.install donor car 1.9TDI wiring looms from the interior of the car
11.install wiper mechanism probably the same on both cars!
use a full size engine hoist to drag all the 1.9tdi drive train under the patient car remember the wheels are still attached so this could be done with 2 people,
12.lower the patient car to the ground marrying the 1.9 TDI drive train to the patient car chassis
13.support the engine with engine support host
14.tighten suspension struts to the body
15.lift up 3 foot in the air and re bolt up sub frame to the patient car chassis
16.lower back down and remove the engine support brace
17.reconnect all wires and cables to the engine and transmission
18.refit all plastic covers
19.remove wings from donor car and refit to patient car (fit loose untill bonnet is on)
20.remove bonnet from donor car and refit to patient car
21.refit the donor car 1.9 tdi front panel donor car bumpers (align properly)
22.reattach air con pipes coolant hosts re gas and fill all coolant and hydraulic systems
23.use Vag com to run abs tests and check for errors
24.test engine starts and abs works & and roof opens and closes
25.swap the os ns door lock barrels round from the donor car or live with 2 keys but the central locking should work but this can be re programmed with a MPV key programmer or vag-com that i both have any way,
26.last but not least use vag taco USB to set the mileage of the 1.9 tdi clocks to patient car 110K
and get the key code off the ecy
In theory this engine setup should start, as all the engine ecu,s keys,key receiver locks & clocks, dash HVAC systems are off the donor 1.9 tdi car
so hopefully the original convertible drop top roof ecu and air bag ecu would still work independently as long as the years are roughly 2002/2003 on both cars,
after all that you would have a very desirable 2003 silver a4 convertible 1.9 TDI 2 wheel drive, with gray cloth interior amd 17in stock 5 spokes
and a s
t load of spares plus wiht all the bits you could re coop half the cost of the donor car back
and you still have the original NS convertible undamaged wing and bonnet so after you sell all the bits on ebay that car migh have cost you about 1200 quid,
and will be worth 3500 easy because of the desirable ness of that engine setup and color scheme
i cant seem to find a 1.9 TDI A4 convertible any where they are all
3.0 petrol drinks fuel
3.0 TDI v6 drinks fuel unreliable and a night mare and expensive to fix
2.5 TDI v6 drinks fuel and a night mare to fix
1.8 T petrol drinks fuel and blows up
2.0 T petrol drinks more fuel and blows up
or 2.0 TDI @ 6 grand and above, with all the problems of the 2.0 TDI engine brings and expensive to fix
The 1.9 TDI sounds like a tractor, not very desirable in a convertible IMO.
The 3.0 V6 TDI is a very reliable unit, as is the 1.8T. The only issues with the 1.8T seem to be oil pick up pipes blocking (due to lack of oil changes) and failing coil packs (should now be ok since the 'recall' workshop fix a couple of years ago).
You must have a lot of spare time on your hands.
The 3.0 V6 TDI is a very reliable unit, as is the 1.8T. The only issues with the 1.8T seem to be oil pick up pipes blocking (due to lack of oil changes) and failing coil packs (should now be ok since the 'recall' workshop fix a couple of years ago).
You must have a lot of spare time on your hands.
Edited by Maracus on Thursday 31st December 08:16
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