Pearl white coupe revival

[ottawa coupe]

Right, engine mounts are done. Need to measure where the output flanges of the 01a sit and swap boxes for the 01e and get those mounting arms made up. Hopefully by the end of this weekend i've got all the mounts done (ok, not the 3rd engine mount up front) and passenger frame rail cleaned up and closed up (it's taken a small beating for the exhaust manifold). Mk4 rad and ac condenser arrive next week so i'll get on with the plumbing. The last mechanical part will be the throttle pedal. Then wiring. Again. Sigh.

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[ottawa coupe]

So, great start to the long weekend. Trans mounts are tacked together and everything is supporting itself. I haven't gotten my shift linkage yet so i am not going to finalize trans mounts till i know i don't need more room between the box and the tunnel.

Mk4 rad and condenser also arrived today instead of next week. Looks like i will get everything i want to fit. Except i am 99% certain i will have to lose the hood release and go to pins. Oh well, can't win'em all...

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[ottawa coupe]

So, great start to the long weekend. Trans mounts are tacked together and everything is supporting itself. I haven't gotten my shift linkage yet so i am not going to finalize trans mounts till i know i don't need more room between the box and the tunnel.

Mk4 rad and condenser also arrived today instead of next week. Looks like i will get everything i want to fit. Except i am 99% certain i will have to lose the hood release and go to pins. Oh well, can't win'em all...

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[david1980]

What linkage are you using?

[ottawa coupe]

B5 s4

[ottawa coupe]

Well, i never said i was a GOOD fabricator....

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In my defense, the engine crane was always in the way when i was looking.

At any rate, i've sorted the offending engine mount and it's now all straight. trans mounts need a quick tweak and i'll be back to where i was last night.

[ottawa coupe]

More betterer....

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[ottawa coupe]

Right, coupla more hours of messin around and it is in it's proper place. Thanks to my stumbling across a b5 rear diff for the 3.89 gears, i also have the 100mm output flanges for the 01e. Popped those in as well and so i put the front axles in too. I still need to get my mill working again and when i do, i'll cut them down the 3mm to match the 108mm flange length and it'll be that much less of a hassle to install the axles. After much searching, and a few cheap purchases on amazon, i have the couplers for the mk4 rad that will work. The lower port points to alternator. Had to find a 90⁰ coupler that works. 3C0122291 is an upper rad connection for a mk5 with auto trans. I got an aluminum one. I'll need to have the small port welded up. I also had to cut the alignment tabs off the port on the radiator to get it pointing the right way.

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[ottawa coupe]

Been busy and waiting for a new visco clutch for the fan but i had a moment last night to look at things and i thought to myself: "maybe i should double check the master cylinder fitment.

Holy hell that was close! Touching the engine because no fasteners but there's maybe only 10mm of clearance.... yikes.

And the plumbing at tbe back of the head gets even tighter.... i am wondering if hard lines will be a better solution for compactness....

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[ottawa coupe]

Baby steps...

The rad support is supporting the rad. It's all a bit flimsy still but that just means there's not a lot for me to cut in order to adjust it lol. Visco clutch should be waiting for me when i get home tonight, if i get an hour or 2 over the weekend, the rad may be placed for good. Will then be working on the lower cross member for clearance and strengthening. At that point, i am cautiously optimistic that the big structural mods are done. Feelin a bit ripped off on the motor though. Seller delivered it to me without the maf and intake, a few sensors and the engine covers. Seemed like a decent dude and it felt like an honest mistake. Says he'll ship them up. In the meantime, i realized i needed shift linkage. He has some so i say add it to the box. Obviously a cost for the new parts. Got the box yesterday, linkage yes, maf yes, but nothing else. And it's been how many weeks....

i mean, i guess it'll RUN now but still....

Frustrating. At the time i did the deal for the engine, an entire lower mileage a6 v8 showed up on marketplace a couple hours away for a few hundred more. I probably should have jumped on that instead. Oh well.

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[ottawa coupe]

Rad is now attached at 4 points that are tacked into the supports. I think i may be forced to trim a few mm off the front of the visco fan blades just to be safe but otherwise i think i have messed around enough for everything to fit up front. The last mystery in that area now is radiator hoses. I think i have what i need save for a few couplers but we shall see. Then on to the rear mounted crossover pipe....

I am also happy to say that the v8 maf will fit in the v6 airbox, subject to significant trimming.

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[ottawa coupe]

A dig around various boxes produced rad hoses that were completed by a trip to good ol home depot motorsports for some couplers for a whopping $1.50 each so that's sorted. Got the pipe that goes from the back of the head to tbe upper rad hose trimmed such that it at least clears the steering arm. Will deal with the rest of it when the engine is out. Squeezed the maf into the v6 airbox. Given that the maf itself is removable, i may glue the housing to the airbox for ultimate strength. I need to figure out how to attach the maf to the throttle as the run is now much shorter. Amazon sells some 3.75" diameter couplers which i think will be the solution. Will give that a whirl and then i believe the engine comes out again and i weld all the things to full strength.

The third motor mount is....somewhere en route.... i am certain it will get in the way of everything upon arrival lol

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[ottawa coupe]

Many cans of brake cleaner later, i felt it was safe to open it for inspection without introducing too much dirt. Needn't have bothered.... yikes.... guess i am getting a borescope next to look at the bores..... pray for me.

Methinks it's goin to a shop for proper cleaning....

I shluld say tho it seems sludgy and carbony, not metallic at least.... 20250913_151418.jpg 20250913_152541.jpg 20250913_153147.jpg 20250913_151423.jpg 20250913_153145.jpg 20250913_152545.jpg

[ottawa coupe]

lol, guys in 4.2 group on FB say this is actually in GOOD condition...i guess the bar is different for these engines?!?! borescope should be here today...

[ottawa coupe]

Whew. Borescope makes the bores seem like they were machined this morning.

Now on to the fun thing with audi v8s, friggin intake flappers. One was seized and i managed to free it up. The free one had to be removed to separate the manifold (which i now realize wasn't needed) and of course this happened.

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There are no part numbers listed for these that i can find. So i am looking at buying a whole figgin manifold??? Gonna see if any of my friends have a lathe yet lol.

last check before i put a list together is the rod and main bearings. It's a chore to get to them. And because they can, there are 2 rod bolts listed, one is 10x the cost of the other. Not sure if interchangeable. And i can't find part numbers for main bolts....