B4 Avant - 2.0E to 2.2T

[NiTeC]

silly photobucket....thinks it can slow me down

started mocking stuff up in wait for the head....


tried to figure out what bumper to use...I gotta hang a pretty big IC (Greddy 28r off my old Mk4) and was thinking it has to fit the rad as well...the V6 rebar seems to work (without the dampers)...I`ll have to drill some holes...


here's the front done...


interior is ready for some cables:


hey look what I found at the local junk yard...


all of my problems are solved lovin the price list too: rad 40$, alu head with cams - 40$...gotta put apart a whole lot of it to get to the passenger side engine mount though - pain in my a**...

oh wait - I was wrong...the rad won't work



sigh....

[bikerjim]

Nice work I love this project. Photobucket is playing silly ******s on your pics through the other pages of this thread tho?!

[NiTeC]

yeah I`m waiting for it to reset but i`m starting to consider upgrading to their pro version or whatever...it's not like i`ll stop posting pics any time soon...

[andy10v]

Some folk have got the rad to work by tilting and angling, and using a slimline fan. Or using an alloy honda rad. Have a search for aan intake manifold and you should get some pictures/solutions.

Good score on the head.

[NiTeC]

yey pics are back up...holy **** - I ran out of 10GB of picture bandwidth...at 200k a picture that's a LOT of viewing...

here's some more

drivetrain is complete - everything is installed...had a little problem with the front diff supports - the shop welded the plates with the thought of using nuts on top - super hard when the gas tank is in to get nuts on top of the diff nose....might have been better if I had the gas tank in place when they were doing the brackets...



also got the passenger side engine mount on - needed a little trimming to the mount but get everything nice and tight at the end...had to figure out the rad and the intercooler today so I mocked it all up...installed the TB to see how things will line up with the side rad...




yeah...that's not gonna work...so let's see what else can be done here...



I`m liking this - OEM rad from this car...it will need to be moved a little forward to clear the accessory belt...I haven't decided whether I`m using the UrS4 setup or the 7A stuff yet...i`m doing the brakes tomorrow and the rad and IC will be done right after...the dash and electrical are next...if all goes well everything will be done by the time the head comes back....

[NiTeC]

all right...spent another couple of hours measuring and scratching my head to find the best solution for the cooling...

a few of the options are:

1. 7A rad - tilted sideways to clear the AAN intake and TB
2. 7A rad tilted in a combination with a short front mount rad to improve cooling
3. V6 rad with V6 rebar
4. 4cyl rad with 4cyl rebar
5. AAN rad with custom rebar

some limitations:

- AAN intake and TB position
- clearance on front
- Front bumper design
- Intercooler mounting
- AAN vs. 7A accessory belt setup

and this is what I came up with:

1. too much work to install, insufficient air flow, no space for stock fan, ugly as sh*t
2. still too much work, a little better air flow, looks like poop, must find a skinny rad, no space for fan behind front rad due to accessory belt
3. fits perfectly (sort of)...spaced the rebar 1.5" forward to clear the accessory belt - plenty of room behind the bumper BUT still no space for a rear fan...the V6 rad is slightly taller than the AEG rad so the rebar dips down...if it was on it's own it would be perfect - unfortunately that goes smack in the middle of the front bumper opening, which of course is reserved for the intercooler...it would look like poop and doesn't leave me with much space for the IC itself unless I use a sidemount which would be too much work and wouldn't be very efficient
4. Ok - now we're cooking....you can already see this solution in my post above...there's def difference in the cooling area of the 4cyl and the V6 rads but not enough for me to scrap the idea...the rebar hides right behind the bumper and if I tuck the IC inside of it (will need some cutting) it will line up with the bumper perfectly....the rebar still needs to be spaced out about 1.5" (or cut out to clear the accessory belts - decided against that because there wouldn't be much structure left to an already weak bar) but with that there's lots of room for the belt behind...still no space for a 'sucker' fan, however I can easily mount a pusher on the front provided it's skinny enough...my dad drives a Mercedes Sprinter and showed me the AC fan they use which is no more than about an inch wide and mounts to the front of the AC rad...I`m lovin it and I'm sure there's other aftermarket solutions to that as well...
5. way too big, too much work, no space for intercooler, no space for fans

so - there you have it folks - the decision's been made...I will try to finish all of the work today and take pictures of all the options discussed above (forgot my camera yesterday)...of course this will need to be tested - no question about it...I will be bringing an extra rad or two with me just in case we need to modify the system....I`m also planning on returning the 7A and get that skinny Echo rad and fan - they might make a good secondary rad for this setup and should have no problem fitting on the side...

while I was working on the rad setup I also finalized the accessory belt situation - I was going to try and use the 7A dual V belt idea, however looking at the brackets and the main pulley - everything gets pushed way too forward....the AAN pulley uses one big belt to drive everything (similar to my B5 actually) and keeps things tucked away....I wanted to eliminate the fan pulley bracket but I`m running out of time to make my own supports so it will have to stay for now...so I will be using the 120A alternator and the AAN hydraulic pump...i`ll have to look into the pressure differences between the B4 and the S4 pumps but I thought people said everything should be fine...

the car is scheduled for exhaust and IC piping next week...Sam@034 hopes to send the head back to me by the end of this week, which means it should all come together next weekend...I`ve also started working on the wiring - I split up the engine and chassis harness yesterday - the next step is to install the engine harness, install the B4 chassis harness and mate the two together...this should all be finished by sunday but can't test it until the head's back...

[NiTeC]

made some measurements yesterday:

in/out:

MAF: 3"/3"
Turbo: 2"/2"
IC: 2.5"/2.5"
TB: 3"/NA

so I think the system will look as follows:

3" filter -> MAF -> 3" to 2" coupler -> turbo -> 2" coupler -> 2" pipe -> 2" to 2.5" coupler -> IC -> 2.5" coupler -> 2.5" pipe -> 2.5" to 3" coupler -> TB

thoughts?

also installed the rad and IC - the ABK rad is 12" x ~23"...and I have about 2.5" of depth to play with to mount fans on the front...

this will allow me to run something like this:



12" Universal Electric Cooling Fan
Amps: 7.0
CFM: 1200
Dimensions:
A: 12.250"
B: 12.750"
C: 2.500"
D: 1.250"



can't seem to find a dual fan setup with those specs and can't put 2 side by side either...

[NiTeC]

wow...haven't posted in a while...

bled the brakes and the clutch although the clutch took a little while....it looks to me like the clutch has discovered the secret to anti-gravity...the liquid was NOT flowing down that's for sure...the most exciting part of the brakes:



the rad and intercooler were finalized and I cleaned and painted the rebar...the pictures are a little dark but I`m happy with the result...



it ain't easy bein cheesy let me tell ya certainly did wonders for boostin my enthusiasm



busted out a box of goodies that I've been itching to get my hands on for over 5 months...




got everything mounted up and came up with 2 acc. belt setups
1. tightened using the alternator and a custom bracket i`m about to fab up

2. conventional belt tensioner


about an inch difference between the two....notice I`m not using the fan pulley

this is where I`m going to put the bracket for the alternator if I go that route....


hydraulic pump issue solved - V6 pump swapped over..you can see the differences here - the AAN pump has an 'add-on' that is basically that third port...


the ABK pump is actually the same but uses different mounting so can't use it...


actually so is the Eurovan one anyways...the alternator is in a rough condition - been sitting around for a while but the damn thing is 200$...it's the same as the V6 one but my V6 alternator is completely seized...


the Eurovan one is different...I can probably make it work but won't try until I've made sure I can't find a V6 one...


belt's done...46" using the conventional tensioner and no fan pulley...it's pretty solid...


ready for battle


well...not exactly but def ready for exhaust and IC piping...


proper wheel gap...and it will only get bigger with the Kumho tires


hmm...I noticed today the bumper is a little short with the IC installed...i`ll have to come up with a creative bumper extension...

mmmm clean....




straight 2.5" pipe, used the Urs4 downpipe but modified to fit the B4 chassis + added an extra 02 bung for the wideband sensor...3" hi-flow cat, no muffler or resonator...this will be LOUD!


stainless steel piping for the IC - next time it will be done with thinner walled alu but for now this will do...the MAF is mounted just before the TB - I was going to put the whole thing together but couldn't get those damn silicone couplers over the MAF....any ideas how to 'soften' them up a little?

[Nuno Cristiano]

Very good project!

I see that you bought injectors kit from 034MotorSport 7A.

You know specs of injectors? At 4bar what CC?

[NiTeC]

hmmm not exactly sure actually...I thought they're supposed to be RS2 replicas...I`m sure 034 would be happy to answer any specific questions...

[NiTeC]

picked up some goodies...



that helmet is BADASS!!!! gotta take some better pics of it on my heat...the intercom is also Stilo WRC and it's amazing...

also managed to get the couplers loosened up - used a bottle of Baileys and a heat gun - worked like a charm...so here's the finished setup...







swapped on my R615s so I can bring the rims over to get the Kumhos mounted....205/50/15 - this is what the actual wheel gap will be...I`m wondering why the front wheels are seeing a bigger gap than the back - I would have expected the opposite...




overnight from Japan - Mishimoto low profile fan....nice and snug..




and this is where I`m going to mount the battery...it would be good to get something a little thinner so it fits in the floorpan better...

[Ruffiano]

Any updates?

[NiTeC]

plenty...

read at: http://motorgeek.com/viewtopic.php?f...=unread#unread

[Ruffiano]

wow...








sensor flush:

sensor aligned:

sensor from the side:

[V6quattro]