Kenny' s Coupe/AAN engine build thread

[morris400]

This thread was originally for a Holset project on my 94 S4. That build finished with a Volvo k24 7400 instead

The goal of this next project which im getting extremely lucky on as a really good friend of mine has decided to sell to me, is to build the car to around 400awhp. Nothing crazy. Im picking it up next Sunday and the plan for the build is as followed:

1990 Audi Coupe Quattro
Turbo: EFR 6258
Exhaust manifold: Wagner cast (real)
Injectors: 630cc Deka
Tune: EFI express Chip set on AAN ECU.
Downpipe: EFI express 3 inch
Exhaust: custom build.
Fuel pump: Walbro
Stock MAF: AAN
Drive train mounts: HPR/034/Stock
AFR, Boost and Water meth gauges: Innovate/Podi/Snow performance
Oil lines: EFI
Brakes: Stock.....for now.
Wastegate: stock rebuild from EFI with 1.9 bar spring.
Head: AAN rebuild with Ferrea valves.
Block : AAN 81mm stock
Cams: 7A
Pistons: 81mm stock coated
Rods: Forged Rods (DM)
Crank: Stock AAN
Damper: Issam Fluid Damper
Shifter: 034 Billet
Intercooler: S2/Rs2 Audi
Clutch: Southbend Stage 4 disc, stage 2 PP
Flywheel: 034 LWFW
Wheels and tires: Audi S4 Fuchs with Indy Firehawks.
Breather: issam breather with Provent Catch Can
Intake Manifold: 3B
Water Methanol: Snow performance
Hardware: ARP/OEM main bolts.





I'm going to use this thread to update my project as it procedes and will include pictures as they come. This is going to be a hell of a project and will test me in every possible way. Lucky for me, my friend im buying it from has colected most of the parts required to build the car i just need to assemble.

My goal is to have it all complete and driveable by April this year. If that happens ill consider it a win. Time will tell. Big factors right now is getting the block machined for 83mm pistons and sourcing a 83mm Headgasket.

Pictures to come once i take possession of it all, its a lot to move and logistically its a challenge.

[jcarrick]

Sounds like a fun project. I built an urS4 with an Hx35/40 and it was super fun. It was a bit laggy, but when it lit, it pulled like a freight train. I would be concerned about stock rods with that turbo though. It is capable of way more than 340whp...

[morris400]

Sounds like a fun project. I built an urS4 with an Hx35/40 and it was super fun. It was a bit laggy, but when it lit, it pulled like a freight train. I would be concerned about stock rods with that turbo though. It is capable of way more than 340whp...

I know the turbo can handle more. That's why my plan is to run it conservative and limit the power. Just a fun DD. Unless I win the lottery then I'll go balls out lol.

[PRY4SNO]

Build's coming together quickly from when you first texted me. Good job so far, it's as good a place to start as any. Slippery slope, and all.

[dana]

I think you turbo is too big for your power goals. I think you be better served with an hy35 or something else a bit smaller.

I would either go smaller turbo, or put some rods in the engine and be able to get some of the payback you deserve for all the lag.

[88a5tq]

Hey you wanna trade lol
I love it it's gonna look awesome and run awesome

[morris400]

I think you turbo is too big for your power goals. I think you be better served with an hy35 or something else a bit smaller.

I would either go smaller turbo, or put some rods in the engine and be able to get some of the payback you deserve for all the lag.

It's gonna lag for sure...but rods and a full build are not in the budget. The lag I think I can deal with. I won't be driving the car daily...more of a weekend summer fun car.

[chaloux]

I would advise changing the head gasket...

[dana]

I think you turbo is too big for your power goals. I think you be better served with an hy35 or something else a bit smaller.

I would either go smaller turbo, or put some rods in the engine and be able to get some of the payback you deserve for all the lag.

It's gonna lag for sure...but rods and a full build are not in the budget. The lag I think I can deal with. I won't be driving the car daily...more of a weekend summer fun car.

I'm really not trying to be preachy, but aren't rods like 400-500 bucks? You are going to need to upgrade injectors, intercooler, piping, ECU/tune, clutch etc, and it doest really cost you any more to go bigger on any of those. So really you are really only 500 bucks away from being able to get at least another 100hp.

You are going to spend a few grand to make the setup you have work, what is another $500? Maybe another month or two of time to complete the build? Worth it in my opinion, or get a smaller, more responsive turbo.

$5 per hp is about as cheap as it gets.

Its your car, its going to be cool either way, just wanted to throw that perspective out there, not trying to be preachy, I have just made the same types of decisions on projects and regretted it in the past.

[955urs6]

Looks like a fun build! I second the tradeoff for spool. Unfortunately, we don't live where there is an autobahn so most of our fun is getting up to the speed limit(ish). For 340wheel, maybe a gtx3076 or the equivalent? Although I"ve heard that compressor is mismatched... I wish you luck!

[morris400]

Updated the first post with a new direction for this build.

[PRY4SNO]

LOL adapting an old thread makes the first few replies hard to follow but the picture sure is purdy.

Maybe we can help each other with the wiring. Figure out one and do the other that much more quickly.

Sad to see Lars give up, but he's on to bigger things and nice to see such a good chassis find an ideal home!

[morris400]

Lol, well the old thread went no where this one will. I dont think he gave up, life takes you in different directions all the time. He said he had fun planning and collecting everything over the years but has new goals and plans. He opted to sell all the 20vt parts in one shot rather the part it out cause he does want it to be build.

The wiring wont be as bad (for me) im getting a complete new wiring harness with the build. Just need to pull out the 7A harness and put in the new one.

[PRY4SNO]

life takes you in different directions all the time

Tell me about it, lol. I'm still too stubborn to throw in the towel.

I'd forgotten Lars picked up a new S2 harness from Norbitron. Clever bastard. I might want to reference off of it before you do the install.

[morris400]

Better come by quick...cause that harness goes in quick...im really hoping to have it running by Apr.

[jbrentd]

Nice that you were able to get a bunch of the stuff to come with the car. I'll be following along and have a parallel swap of my own, but I have a feeling you'll be done way before me. lol

[morris400]

Nice that you were able to get a bunch of the stuff to come with the car. I'll be following along and have a parallel swap of my own, but I have a feeling you'll be done way before me. lol

Its a project for sure, i just have a bad habbit of building really quick to get it done lol. I will build it from the min i get home until 4am...sleep 2h and go to work.

April is a really aggressive time line but if i dont set one ill never finish. I finished my S4 turbo swap and head build on the exact day i planned to lol. Managed to cut 0 corners either.

Just want it running by April. Ill try to update as much as i can

[morris400]

True to my word, today i picked up the Project Coupe quattro....and the boat load of parts that came with it. The list above is only a small amount compared to what i got today. There are more parts then i think i even know what to do with. A proper inventory is required and i also need to make more shelves in my garage to store the parts until i get to that part of my build.

Staying optimistic, i want to keep to my April time line but only tonthe effect that the car will be ready for an engine. I want the interior and wiring done, HVAC done and battery relocation done by Apr. Then ill aim for June 30th to get the engine in and running. I hope 5 months is enough.

On to the pictures. Its a solid start thats for sure.

[jbrentd]

Looks like you just have a big LEGO set to put together now. :-) With all of the tear down done, it’s nice on one hand, but on the other...that’s part of the learning process and helps me figure out how it all goes back together.

[morris400]

Trying to get some so my ducks in a row here, getting some shelves made up tomorrow so i can organize my parts into C4 and B3 psrts as well as AAN and 7A parts as well. Need to get a start on this soon.

Im waiting on my harness to come back from my buddy as hes using my Norbitron S2 harness and copying it for his coupe project.

Question on AC, is it physically possiable to keep the AAN serp belt and the AC compressor on the small chassis? Will either 7a or AAN compressor fit on the dvr side as per AAN? What is required to make this work?

I do have a 7A harmonic balancer and i know the v belt setup is easy to accomplish and i can relocate the oil drain for the turbo i have all the parts. BUT...i have a AAN fludi damper from Issam and would hate to not be able to use it.

[PRY4SNO]

I'm just going to leave this here for reference:
https://www.s2forum.com/forum/technical ... 7a-108-112

[morris400]

Wheels and have been decided. S4 Fuchs with indy 500 firehawks

[morris400]

83mm Head gasket has arrived!

[Afterthought]

What a bad ass parts pile .
I ran serpentine in my CQ and really liked it but I didn’t run the AC with it , I’m not sure why there is anything that would get in the way of that though. With a b3 with a front mount ic

[morris400]

Im thinking ill be deleting the AC just to make things easier....that and incan seem to find an AC compressor in the garage anyway lol. Hoping to get the 5x112 swap done nedt week if i can get the hubs machined and ger bearings.