B4 Avant - 2.0E to 2.2T

[NiTeC]

well....this was a busy day got lots done and lots more to go...

as promised this weekend was devoted to the quattro swap so here we go...

8am...."ahhhhh ****...the shock mounts are different..."




well this project ended up quite quickly...

wait...what's this?



looks like Audi in their infinite wisdom decided to put the holes just in case so I have a 'universal' bolt pattern meaning I can put in the FWD rear shocks or the quattro rear shocks...


k...the shocks are out...clearly different even though they looked pretty close while installed on the cars...


what's next...well let's drop it all down...


you can kind of see where the front diff mounts align with...


it's the right hole here:


these holes are already there...the back I thought was going to be a little different, however I tried the screwdriver trick again and guess what - the holes are there




all right - let's sum this up....the shocks mount 100%...the two front diff mounts bolt directly to the body...the two back diff mount holes are there but there's no thread...it looks like the floor is right above that which means we'll need to cut the floor up a little bit to get access to the top of the holes...I'm thinking of simply welding a nut there or something...

here are the two floors:
Quattro:

FWD:


here are the two tanks:
Quattro:

FWD:


some minor differences:
Quattro:

FWD:


Quattro:

FWD:


and mandatory quattro shots:



still to do:
1. fab up mounts for the front diff support - not existent on the FWD floor plan
2. fab up mounts for the drive axle bearing
3. swap the transmission
4. enjoy quattro

I`ll have to source out the tank supports for the quattro - the ones from the sedan were completely rusted through...also I've have to refresh everything up at the back...perhaps a sway bar that's thicker than a pencil...

so there you have it folks...quattro swaps - no big deal...

[andy10v]

That is amazing, good work! Thanks for sharing the pictures/info and documenting.

tdi 80q anybody?

[Audicted]

Nice progress. And quick too. High five's all around

[macspring]

Congratulations, nice work, thanks for sharing, looking forward to further updates as and when.

Kind regards.

[NiTeC]

some engine work...




I`ll try to finish most of it by the end of the week...still stuck with the head issue...waiting for a call from the shop today...got the call that the turbo was refinished at GPopShop - picking it up on tuesday...

[Jeffer]

That fwd to quattro opens new oportunities
Great project you got here!

[Ryan80]

Theres a part of me wishes i hadnt read this thread! At least its nice knowing the option for quattro might happen, i pictured having to swap bits of floorpan about, so had dismissed it as too much hassle. But from your pictures it looks like it might be do-able! Means when im looking for a 2.5tdi a6 donor car for the dagdag project, i can consider a quattro one!

[NiTeC]

hmmm...the A6 will be different though? we took the rear end off of a URS4 and that's not gonna match for sure...the engine and tranny should be fine but the rear end won't swap over...

basically B3 to B4 doesn't work...B3 to B5 doesn't work...B4 to B4 works, B5 to B4 works (B4 and B5 are identical rear ends - transmissions are different)....might be a few more combinations but that's what I have access to...

I want to see if B5 quattro to B5 FWD would work - perhaps even think about swapping over an audi rear end to a passat...I have access to both so I`ll try to research this as well...

[NiTeC]

mmmm spare parts




do you think my mom will flip when she sees the driveway?


and thumbs way up for the work Jim and Gary at GPopShop did...






let me remind you how it left my house:

[NiTeC]

the shop asked me to get the tranny to them so they can make sure everything is aligned properly...so I took it out



let's play a game I like to call 'what did this tranny come from'





some more work:

waiting on a gasket or two to finish the bottom end completely...



meanwhile got the wastegate off the manifold and managed to clean everything up...

everything was insanely rusted...I wonder if I can still use this diaphragm...


some parts ready to go - just need the head now...




I`ll try to get the gaskets tomorrow...as soon as I mount them up, I`ll get the clutch on and mount the tranny...then I`ll have to wait for the welding to finish for the quattro and then everything is going in...my hope is to have everything finished by the end of June except the head...waiting on a quote from Sam@034 for a complete rebuild and 7A->AAN conversion...I`m done playing around with this - not much time left - I still need to test this car out before we head to Targa...

[NiTeC]

here's today's progress:

took the 7A pan off and cleaned it up as much as I could...


added the AAN baffle...



mounted on the engine:

block->gasket->baffle->gasket->pan (a little bit of a weird design IMO)


worked on the 01A from the A4...took the shifter off, swapped the plastic clutch slave cylinder with the metal one off the V6, got the new bearing in there....




got working on the engine side of things:



had to stop because I needed some help with aligning the tranny and stuff...so I decided to take apart the extra bits I got off the V6...

oh look at this - brakes are 2 piston vs. my tiny 2.0E brakes...nice!


the calipers haven't been used in a while so it will take a little bit of elbow grease but I think it will be a nice upgrade to what's on the car right now...also took the shocks off to start rebuilding with the Billsteins but decided to wait for the car and see which ones are in better shape...

shipped the head out to 034....hopefully it will be back by mid July....I should have done this a long time ago...who would have thought nobody would want to do this locally...60.9lbs shipping weight - should be even higher when they ship it back to me...

hmmm...just realized Dave suggested using the 7A oil pickup tube - I have already closed everything up with the AAN tube - what's the problem? everything lined up fine...

[NiTeC]

all right...let's see...




noticed something rather 'odd'...mounted the B4 tranny mounts to the A4 01A - they are offset a bit weird...the holes align fine but if you tighten one of the bolts the rest of them are off by about 2-3mm...you can see it here...



nothing to be worried about - a few spacers will fix this up but I wonder why that is...should I get a set of A4 mounts? will they line up with the subframe? we`ll have to wait and see

oh and the calipers cleaned up nice...the holders are fubered up but they look identical to the ones on the car - again we`ll have to wait and see....

[bikerjim]

I like this project, good work

[NiTeC]

I'm getting dangerously efficient at destroying cars



a shot of the ABS...


notice - no prop valve as this is FWD and the prop valve is mounted to the rear sub frame...


the fan...I`ll try to use the same rad-fan setup if possible...


the ABK - pretty sure the engine's been swapped at some point...the odo reads 400+ km...




weird (different) driver side tranny mount...


results in the following difference in subframes...



dirty:


clean:


ABS completely out...didn't cut a single wire - very proud of myself


wiring mess in:


wiring mess out:


I wonder if the 01A will have issues with this extra bit?


mandatory quattro shots:




the quattro work the shop had to do was fairly straight forward...nothing crazy...i`ll drop it down tomorrow to get better shots....

and got the heater out:



tomorrow is a short day but I still hope to drop the rear end, clean it, clean the interior, put apart the heater and remove all AC ****, figure out the clearance issues with the 01A and mount everything up...sounds like something I can do by lunch right?

all of this was performed at 30+ degree sunshine....I need beer...bad!!!

[NiTeC]

short but insanely hot day today...

dropped the rear diff to take some shots of the mounts...

rear subframe bolt mounts:


front diff mounts:



central bearing mounts:


and yeah...mounted the engine...WTF!!!!



I sat there staring at it for a few minutes freaking out...luckily I had the 7A mount to try...


phew...I`ll source out the passenger side as well...looks like the UrS4 mounts aren't a good fit...I should have expected that...

somebody teach me 'rear diff'....maintenance? necessary service? lock actuation? give me anything and everything....