Quattromog: The Original

[the german]

Snow day in Seattle!! It started dumping last night during the Super Bowl, and kept on snowing through the night. I woke up to almost 9" of snow at my house (most we have seen here since 2006), then I took the Beast Coupe up the hill a bit and found over a foot. WOOHOO!!

Enjoy the pictures








Snowplow.


It's deep!





Hill Climb!!

[youtube]https://www.youtube.com/watch?v=xKcMV0FUSJg[/youtube]

I love donuts of all kinds.

[youtube]https://www.youtube.com/watch?v=CvVMt4ZkJqE[/youtube]

[the german]

Oh! I forgot to mention that I broke the car today too. I tagged a hard curb (which I thought was a soft rolled curb) at low-speed while going up a hill sideways, and it seems I have grenaded something in the transmission. At first I thought maybe one of the axle shafts had just popped out of a CV, but on further inspection it is definitely internal (probably the front differential).

Time to swap in the 1.8T and the TIP!

[heartlessnomad12]

LOL thats one way to expedite a project

[85oceanic]

not sure if you have a cooler picked out yet, but I have this on my car as an oil cooler and its great. The fans pull a ton of air and the quality is very good. Its a really high capacity cooler.
https://www.summitracing.com/parts/der-15840

Yummy. I need something like this.

[the german]

Powertrain Swap Phase 1: the donor

I started with this perfectly good, driving b5 A4 Quattro with an AEB and TIP. I bought the car for (very) cheap due to a bad water pump which was causing it to (a) sound like a coffee grinder and (b) overheat. As I posted earlier, I already did the head gasket, timing belt, water pump, etc. on this thing so that I could make sure everything was in good working order before pulling it.



Last weekend I listed the donor car on CL for parts or for sale whole w/ title (less the parts I was using) and quickly found a buyer who I scheduled to pick it up on Thursday, for the same price I bought the car for in the first place. This was great because I wanted the car gone quickly so that it was not it the way, but it also meant I had a fair bit of work to do in two evenings.


Monday:
I spent the full evening pulling both the interior and exterior wiring harnesses. I am planning to swap in the B5 cluster plus I am doing the TIP so I had to get the TCU and all related wiring. Getting the interior stuff required pulling the full dash, console, dash support, and both front seats.




Tuesday:
Valentines day and I have a wife whom I want to keep. No car work.

Wednesday:
I spent the full evening pulling the engine, trans, and all other related bits I needed off the car. The full list includes:
-Engine (fully dressed)
-Transmission
-Airbox
-All intake plumbing
-Radiator
-Power steering pump with lines, resevour, and cooler
-Hoses for heater core
-Shifter assembly
-Intercooler
-Front section of the exhaust
-Various wiring pigtails I thought I may need





Thursday:
I came home early to meet the buyer for the donor car, who showed up right on time with truck & trailer and the whole thing was painless. Very un-craigslist like, but I'll take it.

I spent the rest of the evening working on stripping the excess wiring our of the various harnesses.

Laid out nicely (with some stripping already complete)


The resulting rats nest


Up next is some more clean up work on the harness, some maintenance on the trans, and then I'll start on Phase 2.

[vt10vt]

I know you're down the auto-swap rabbit hole but this link elaw posted made me think of your project, too bad a bike motor doesn't have enough torque for you though https://www.youtube.com/watch?v=tIIYfPxHDOk

[the german]

I know you're down the auto-swap rabbit hole but this link elaw posted made me think of your project, too bad a bike motor doesn't have enough torque for you though https://www.youtube.com/watch?v=tIIYfPxHDOk

Youre right- this totally looks like something I would make. I found some more videos of the car and that thing is hilariously awesome. My favorite parts are (1) the hand brake re-purposed into a shifter and (2) the exhaust sticking our the side of the FRONT bumper

https://www.youtube.com/watch?v=vNqqncGvb24#t=133.260217

[vt10vt]

If you tube frame the front end and get creative with the front suspension I bet you could fit an 02m/1.8t longitudinally...

[alxdgr8]

Haha, that is totally a Kirk project! We do need to find something to put a street bike motor in....something light. Stripped coupe GT? I'll start looking for a body.

[the german]

Haha, that is totally a Kirk project! We do need to find something to put a street bike motor in....something light. Stripped coupe GT? I'll start looking for a body.

My initial thought is rear-engine, RWD MK1 rabbit... what do you think?

[alxdgr8]

Haha, that is totally a Kirk project! We do need to find something to put a street bike motor in....something light. Stripped coupe GT? I'll start looking for a body.

My initial thought is rear-engine, RWD MK1 rabbit... what do you think?

Even better!

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[the german]

More work on the wiring harness. The engine harness is going in pretty much as-is, and the trans harness was very easy to strip down as the things I care about were all bundled nicely together already. The dash harness was a different story. I'm converting to a b5 cluster with the swap, so there was a good bit of work to do in stripping out what I don't want and identifying what I do.

It took an embarrassing amount of time to go from this:



To this:



My next job is to go through the b3 wiring diagrams and make an excel sheet mapping out all the connections between the b3 and b5 harnesses. Wiring has always been my least favorite part of automotive projects, but I'm forcing myself to be patient with it and so far I'm happy with the results.

I also found a b4 90 in the local Pick-n-pull from which I pulled the cast front control arms, vacuum brake booster, and manual heater conversion. My garage is getting cramped with all the parts... time to start swapping stuff so I can make some space!

[the german]

So I found this....

https://cumminsengines.com/repower


I'm sure it will be way too expensive when it comes available, but good lord it would be awesome in this car.

[the german]

Been making some slow progress, mostly boring stuff to get the engine and trans ready to swap in.

To start off, I have run into my first issue which is that one of the engine mounts I bought from the UK apparently is not correct as it does not bolt up to the engine. Based on this tread on VWvortex (http://forums.vwvortex.com/showthread.php?1774571) I bought engine mounts from a euro 2.0 Audi 80 Quattro (ABK). These are:

8A0 199 308 (Right)
8A0 199 307C (Left)

However, when I went to bolt them up I discovered that the right one (8A0 199 308) is very close but does not actually line up with the bolt locations on the block. Here is a picture of the right side ABK mount next to the stock AEB mount. Very similar.



Does anyone know which mount I actually need? I would like to find an OEM solution if it exists.

The good news is that the left ABK mount fits just fine. Here is a photo of the AEB and ABK mounts side by side. Not so similar...



And here it is installed on the engine, along with the new oil cooler and filter:





Moving on to the transmission, it was leaking before I pulled it from the A4 so I replaced all of the external oil seals (2 axle, 1 torque converter, 1 tail shaft), dropped the pan and replaced the gasket & filter, then took it outside for a bath. This took about an hour with a scrub brush and de-greaser, but it's soooo much better!



I also pulled a manual heater box from a Cabrio in the junk yard a few weeks ago, which I will swap in when I have the dash out for the conversion. As a matter of course I ordered a new heater core for it, and it's a good thing because the original was clearly leaking.

Original:


New Febi/Bilstein:


That's all for now- more to come when I figure out my right side engine mount bracket!

[Val]

I'd try right engine mount from C4 ADR or Cabrio ADR.

[alxdgr8]

I'd try right engine mount from C4 ADR or Cabrio ADR.

Cabrio ADR only work with V6 B4, not B3

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[the german]

I know that whatever I get needs to be B2 or B3 for it to line up properly, and that B4 stuff wont fit. Does anyone have first hand knowledge from a successful swap? I now I have seen B3 cars w/ 1.8T swaps, but they may have been using a 9a or ABA block.

[the german]

I'd try right engine mount from C4 ADR or Cabrio ADR.

Val- I just found another reference that suggests you are correct about the right mount needing to be from a Cabrio ADR. Does anyone have the PN for this part?

[Val]

Cabrio bracket + ford "rubber" mount.
http://www.audi-style.lv/forum/index.ph ... 1267752171
Car originally was 2.0 ABK, so that should be similar to B3 5cyl.

[the german]

Phase 2 (swap into CQ) has officially started!

The engine sold before it was pulled and is going to be swapped by a local into a CGT.

Engine out:





Harness labeled, the bits I want to retain carefully retained, and removed for the engine buyer:



To pull the complete harness and ECU I needed to pull the dash, so I swapped in the manal HVAC at the same time:





and finally.... GOOD NEWS!!!! I found a new crack pipe behind the dash!

[heartlessnomad12]

Makes me wonder if thats my old CQ that ended up down in Tacoma for a while before vanishing after the owners legal troubles.

[the german]

It's possible- how long ago did yours disappear?

[heartlessnomad12]

Sold is 6ish years ago. UrbanasaultAR's friend/acquaintance bought it and ran into some troubles from what I heard and the car faded away from our radar.

[the german]

Ok, this is a different one- it was sitting in a parking lot in Palo Alto for ~10 years before I got it, and I have history of it being in California for a few years before that.

[the german]

Picture heavy update

First off, I want to update with the correct engine mounting brackets to put a 1.8T (AEB) in a B3 chassis car. They are:

Left: 8A0 199 307C (Audi 80 w/ 2.0 ABK)
Right: 8A0 199 308J (Audi Cabrio w/ ADR)

I picked up my missing puzzle piece (the right engine bracket) while I was in Germany for work a week ago and couldn't wait to get it on the engine and test fit it to see what other problems I would inevitably run into.

Here it is on the engine:


Problem #1: transmission is huge and hits the front lift subframe cross-member. Crudely hacked it out while still in the car so that I could continue with test fitting

Problem #2: cylinder head hit the battery box, so it had to get cut back. This means the big fancy battery I just bought will have to go somewhere else. I haven't figured out what yet, but Alex tells me the B4 battery tray will bolt it. I'll have to look at that and see if it will work for me.


Problem #3: Vacuum port for the brakes runs into the master cylinder (not shown, but I already converted to vacuum boosted using a booster from a B4 I found in the junkyard). I pulled the metal tube out of the intake manifold for now and will figure that out later.


Problem #4: Transmission case hits the steering rack. Solved this by grinding down the rib on the transmission case.
[

OK, now finally getting the engine in place. Woohoo!! It fits in nicely, thought I do have to install the motor mounts after it is moved into position as the trans case is too tall to allow it being dropped down onto them.






I held the winch mount in place to see how much space I'm going to have for the radiator. Looks like there is going to be LOADS of space. Score.


Next up is transmission mounts. My wishful thinking that things might just line up was clearly not founded in reality. Not even close. LOL




So of course I fabricated a set of mounts to fit the B3 subframe. This is really the fun part. I used some 1/8" steel I had sitting in my bin of scrap metal/material.








And with that, the engine and transmission fit in the car.

Next up: shifter. Rather awesomely, Audi used the same opening size and and mounting hole pattern in the B3 and B5 chassis cars. The only real difference is the that B3 shifter assembly bolt in to captive nuts, where the B5 uses studs in the shifter box. I like the sealed design of the B5 so I just drilled the threads out of the captive nuts on the chassis and bolted it in. Something had to be easy, right?!








That done, I dropped the front subframe to deal with modifying the lift frame I hacked up to fit the transmission in. One of the issues I had with the one-piece lift subframe was that there was no way to pull the trans without pulling the engine. I am solving that by going to a 3-piece subframe with a removable crossmember. Here is what I cut out:


Made some new brackets to be welded on:






OK, now on to dealing with some damage from hitting the curb while playing in the snow. The front left control arm was badly bent, but luckily I found a set of cast ones on the same car that donated the vacuum booster. A new set of bushings and they went in.


And back into the car: