Tom's urS4 motor swap "mini-project"

[saltinot]

Had a little more time to polish things up over the last couple of days. I removed the coil packs from their aluminum cover on the kitchen table. My wife was obviously not home at the time.



After a session of being pelted with glass beads the "20V turbo" lettering on the valve cover had lost their machined look so I wrapped some 1200 grit sandpaper around a flat piece of plastic and began to sand the tops of the lettering. After just a few minutes the letters started to look as they did before. See below.



After I sanded the letters I took some alu polish on the end of a pencil eraser to add just a bit more shine.



Polished up the heat shield.



Coil packs reunited with the cover and mounted. Fuel rail and injectors installed with new o-rings





Once I've finished stripping the donor car and get it off my lift I will be able to pull my car in and get busy removing the old motor.

[saltinot]

Last night I finished stripping the S4 parts car. I've been pulling wiring for the last two nights. Tonight I dropped the fuel tank, removed the rear seat belts, rear Bose speakers, parcel shelf, and a few other bits before I dropped her onto my newly built "car cart". Once on the cart I alone was able to push the S4 carcass out of my garage. It was dark then so I couldn't take pictures until this afternoon.

Kind of sad that I started out with......



.....and ended up with this and a garage FULL of spares. IF anyone needs anything let me know. You might be able to talk me out of a few things.





I have been scrubbing the garage down all night in preparations for driving my S4 in tomorrow and start pulling the old engine. FINALLY!

[yodasfro]

Hey Tom how much you want for the fuchs? Is the RS2 gonna be ready for Carlisle?
http://forums.audiworld.com/4000/msgs/177523.phtml
http://www.theaudiclub.com

[Nace20]

do i see right, that this car had a 3rd brake light?

[saltinot]

Hey Tom how much you want for the fuchs? Is the RS2 gonna be ready for Carlisle?

Hi Austin, I'm using the Fuchs on my avant. Sorry.

Maybe Carlisle next year.

[saltinot]

do i see right, that this car had a 3rd brake light?

Yessir, it does....errr did.

[s2 on the way]

wow tom, you can sure make an engine look perty

do you have an extra throttle body from one of those motors?
I just need the housing without the tps and the throttle door.

last night I was trying to pull out these little dents in mine that got there from overtightening my hoseclamp onto it and the darnded thing decided rather than bending just to break a chunk off
a very dumb mistake, that cast doesn't like to bend ...

thanks....

[Nace20]

Yessir, it does....errr did.

is it for sale perhaps :mischeif:

[Acidburn]

Looking good and I like how clean the engines come up

Whats the spec of the saloon that can be seen in the background of the above picture?

[saltinot]

is it for sale perhaps :mischeif:

Of course. I sent you a PM.

[saltinot]

Looking good and I like how clean the engines come up

Thanks!

What's the spec of the saloon that can be seen in the background of the above picture?

You must be referring to Petie, my 90q? Petie is currently running a urq WX motor with a ECU upgrade, stiffer wastegate spring, K26/K27 hybrid turbo. I'm also using the urq downpipe and exhaust with a factory cat bypass pipe up to the rear axle. From there I have built two choices. One is a straight pipe for the track, which sounds like a biplane , and the other has a Magnaflow muffler for getting around local roads. The front suspension is same as the S2 with cast control arms two piece struts with coil overs damped by Koni adjustables. The rear suspension is from a 91 90q 20v sedan which includes the rear subframe running a coupe GT 22m front sway bar turned around backasswards . Front brakes are G60s and the rears are standard. Wheels are 15 inchers from a B4 Cabrio with a set of slicks.

Petie also has a Hella steering wheel, Original Treser smoked taillights, H1/H4 lights, European market front bumper complete with fog lights/orange repeaters with a Votex front spoiler. That pretty much sums up Petie.

A pic.


I bought Petie as a daily driver, but that plan didn't last long.

[Acidburn]

Thanks for the specs of that car, Looks like a lovely "daily driver" I've owned loads of coupe's/coupe quattros and actually just got yet another coupe gt to break but I have never had a saloon, think I might have to have a look into one as my mates having a clear out of cars at present so they are all going seriously cheap.

[saltinot]

A few pics from this weekend's activities.

The bad motor.


labeled, disconnected, and pulled the harness back to the firewall


Removed the viscous fan and boost hoses. I left the hydraulic pump hoses attached and just moved it to the side.


Normally I would wait until the motor was out before removing the exhaust manifold, but I was getting antsy. I had soaked all the nuts down with penetrating oil for a couple of days before which made loosening them easy. The turbo and downpipe were obviously removed also at this time.


my parts catchall box

[saltinot]

Once I had disconnected everything I hooked up the hoist and started pulling out the old motor. Do you think that chain could be a little longer?


Up, up....


....and away!

[saltinot]

Anybody home!!! I wiped a few things down while I had the opportunity.


Bolted on the exhaust manifold with a new gasket, studs, and nuts. Before bolting the turbo onto the manifold I removed the compressor housing and hit it with some glass bead. I thoroughly cleaned it and put it back where I found it.


A gratuitous pic of her bottom. A result of a few hours of hand polishing while the baby is sleeping.


With the cooling system empty I thought it a good time to replace the original coolant reservoir with a new one. I also replaced the problematic plastic coolant flange on the back of the head with a new one.


Puttin' the new motor in. For ease of installation I remove the motor mount bracket on the turbo side and the front stub bracket. I find the engine lines up better with the gearbox without having to fight that bracket.


Resting now on both side mounts, I replaced the rubber mount on the stub bracket in front and centered it in the bracket on the front cross member. By this time it was getting late so I connected a few hoses and turned the lights off.