George's ABZ'd B4 90

[Grillage]

AWSOME!

I'd LOVE to see this thing at Carlisle

[lorge1989]

Sweet!! Nice work!

Those rubber harmonic balancers are notorious for shifting their timing marks. I had to re-mark the one on my engine as well.

Yeah I hadn't even heard of this issue, until my friend randomly stumbled upon it. Fortunately I don't think any damage was done.

AWSOME!

I'd LOVE to see this thing at Carlisle

Yeah, I'm really going to push.

List goes:
-Get an exhaust on it, so I dont get harassed by the police in my neighborhood/get in trouble with the neighbors...
-Coolant temp sensor, standalone or figure out how to use the V8 one (just going to do standalone for now most likey)
-Fan operation, I need fans hooked up. I am quickly going to try to use the factory thermo switch and relay. I think all I need to do there is connect up a few things but once again might just put it on a switch for now. That will get me to Carlisle at least.
-Alternator belt, need to measure up and get an alternator belt. I hope my mount works well and I dont have any misalignment issues, but we will see.
-Heat shield/longer intake pipe

I think if I get all those things done I can make it to the show. Having a day job sucks.

[90quattrocoupe]

Nice work.

Greg W.

[Aktapod]

Awesome man. Sounds fantastic! Hope to see it at Carlisle!

[DE80q]

This is great! I'm working on an ABZ'd B3, so it will be great inspiration to see this make it to carlisle.

[lorge1989]

Thanks for the kind word everyone. Drove it maybe 30 miles last night. Not real issues. I need to put the hood latch on, bumper, new exhaust clamp and then I'm going to send it!

[lorge1989]

It was great meeting some of you! Car ran well, some issue still left to figure out, but 5 hours there and back without any really problems made me feel good!

[AudiSport4000]

Didnt get to meet you but checked this thing out. Nice work! Hope to see you back next year.

[Grillage]

Glad you got there and back - that's step 1!

[PRY4SNO]

Car looks like a total sleeper, love it!

[pete82]

Cars looking good, what other plans you got for it?

[the german]

awesome, great result!

[lorge1989]

Didnt get to meet you but checked this thing out. Nice work! Hope to see you back next year.

Ill be back!

Glad you got there and back - that's step 1!

Hell yeah. Great meeting you and talking to ya!

Car looks like a total sleeper, love it!

Thanks

Cars looking good, what other plans you got for it?

Thanks, I have bunch of stuff to do still. Runs and drives, but many things can be and will be improved.

awesome, great result!

My to do list never seems to get shorter. Although the fact its running and drivng now means I can just check things off the list one by one.

-Fix exhaust leak, possibly add flex pipes depending where the leak is
-mod and install airbox
-Troubleshoot TPS
-Reverse lights, for inspection
-Wheels and tires to pass inspection
-new ecu with chip mod to hopefully solve some WOT issues.
-get all gauges working
-move rad fans to push instead of pull
-install ac components
-install ps pump and lines, need to make mount
-radio/speakers
-oil cooler w/thermostat
-Springs all around, maybe front coilovers (the car is too low)
-Poly front control arm bushings

That is not really in any particular order. But it would be nice to get the car inspected so I dont have to worry about getting pulled over.

Stole these from Ben:

[90quattrocoupe]

These are the fans I used in front of my radiator. This is just a reference. Mine is a Gate brand. They have held up well.



https://www.ecstuning.com/b-acm-parts/a-c-condenser-fan/4b3959457~acm/



As for an air cleaner, an adapter to the stock B4 air box works well.



Greg W.

[lorge1989]

^thanks!

I have a big boy I got from the junkyard im going to try first. But my problem also is my thermo switch doesn't turn the fans on until 210 or so, sometimes 215 as logged by VCDS. Looking into this more, it seems like these switches are notorious for letting the engine get a bit too hot. Looking around, I see some switches are designed to come to function between 113-118c, which seems crazy hot to me.

German Auto parts had a lower temperature switch offered, so I ordered one of those. I think with the fans on the front and the switch at a lower temp I will have no issues, not that i have any huge ones now.

I made up an intake quick with a factory a8 hardpipe, factory boots and factory velocity stack. Then I added a screen filter, yeah I know not the best, but most importantly I made up a heat shield that bolts to the block and hangs over the exhaust manifold, should keep my intake temps down and prolong the life of the wiring over there too. I should probably make another one to protect the battery on the other side.

[lorge1989]

So I have been dailying this, as the old truck I just bought developed a rod knock. I spent extra on a 'nice' truck so I wouldn't have any problems.

Since I'm dailying it, I haven't really had a chance to fix anything. The only issues I have are :

-Partial and full throttle is weird, low on power and sometimes will go into a limp mode if not careful
-Suspension is too low and very bouncy
-Leaking a good bit of oil
-Exhaust leak
-Fans sometimes rub
-No power steering
-No reverse lights, speedo or tach



Currently I am pressing in some new bushings and cleaning up a set of front control arms, have new springs and struts to go in. Also have some different wheels with brand new tires to go on! That should solve my ride issues.

A friend of mine picked up a 1999 ABZ ecu from the junkyard. I put it in this morning and the partial throttle issues are gone and it drives awesome. Currently getting the ECU socketed and the manual trans/s6 chip soldered in!

I'm hoping I will have some time this weekend to get the suspension all sorted, my speedo and reverse lights working as well as get my fan setup fixed. I have to figure out the oil and exhaust leaks as well. I should finally be able to get the car inspected which would be nice since its about 2 months over due.

Lots of talking not so many pictures, next time I'll have pics.

[pete82]

Check the plug on the gearbox, it might need a wiggle or a clean.

[DE80q]

I agree with Pete. That's what happened to mine and had no reverse lights.

[lorge1989]

I never wired them in

They came out with the V6 harness as well as the speed sensor, just have to re-install.

[pete82]

lol that will be why

[lorge1989]

Wheels still don't fit, going to need a spacer...

Chip got soldered in, installed, started then died. I forgot the chip I got from Reflect tuning states its a euro chip, therefore an Immo defeat is needed. I'm hoping my ebay special works.

IMG_20170703_080851524 by George, on Flickr

[pete82]

what wheels you got (sorry if I missed them earlier in the thread)

[lorge1989]

what wheels you got (sorry if I missed them earlier in the thread)

Some Racing Dynamics 16 inchers. I put some new 225/50 BF Goodrich G-Force tires on them a month ago. Didn't check the bore size and I needed some hubcentric rings. When I did that test fit it was on the back. When I got around to putting the wheels on a second time with the rings I tried a front wheel, just to find out I needed a spacer because of tire interference on the strut housing. I'm just hoping I can get away with a 10mm spacer, so the wheels still sit nice.

Only pic I have at the moment.

IMG_20170608_165244366 by George, on Flickr

[lorge1989]

My ebay immo defeat device works well. I just wired it in with the OBD connector. I'm 99% sure I still have communication with the ECU with the immo installed, I have only tried a bluetooth adater and it was iffy, but thats probably the adapter.

IMG_20170707_182330077 by George, on Flickr

I installed the new lower temp thermo switch:

IMG_20170714_192522762 by George, on Flickr

AC condenser and radiator mated with fans:

IMG_20170714_192515808 by George, on Flickr

I am modifying the upper mount just a bit so they tilt slightly back for more fan clearance, also on the oil cooler loop side I'm going to be adding an aux radiator just to be sure I have enough cooling capacity.

B5 A4 power steering pump bolts up, and the pulley is aligned perfectly.

IMG_20170714_192426929 by George, on Flickr

IMG_20170714_192449778 by George, on Flickr

The AC compressor from the V6 also bolts up to the V8 stock mount with two holes. I drilled out the compressor so I can use the locating pins on both of those mounting holes. A bracket will be needed to catch another hole on the compressor but that shouldn't be an issue.

Using the factory V6 compressor would be awesome, no wiring change, its in nearly the same location so I believe the lines will work etc. Problem is the pulley sits back slightly. I am investigating how and if I can push the pulley out with a spacer. ButI have never taken one of these apart before....

IMG_20170714_192433767 by George, on Flickr

[lorge1989]

Pulling apart the compressor wasn't too bad. People say they have used a few screwdrivers to pry the clutch off, but I didn't like that idea. I drilled 3 holes in a big washer and bolted to the clutch face. Then I reinstalled the center bolt, loosely, and used a 3 jaw pulled to break the clutch free. Once that was loose, I made sure I didn't lose any spacers and just removed the other two snap rings.

After doing this, it was evident I wasn't going to be able to spaced out the assembly. The snap ring grooves prevent that. I guess now its time to source an A8 AC compressor and get some custom lines made. For now, Im going to installe the condensor and leave everything else out. I want to get this up and running, I think I can deal with no AC for the rest of my Buffalo, NY summer. (it was 74F yesterday )

I removed the exhaust and welded in two flex joints on the downpipes. The are not used from the factory, but with my vbands, I think its necessary. After inspecting the face of the vbands I do believe i had a small leak on the passenger side. Drivers was sealed up perfectly though. Just have to make a skid plate or something so the flex pipes don't get destroyed.

Working on bending the PS line on the rack towards the drivers side so i can use all the factory lines. My B4 lines bolt up to the B5 pump.

Also have to add an aux radiator and possible re-do my oil lines with some higher quality fittings/lines, I'm sick of leaks.