B3 Audi 80 16V Sport (1.8 Turbo) - loads of pics

[1781cc]

Great project, and full credit to you for ironing out the problems as you go.

I take it you need a smaller oil filter to give you more clearance?

what sort of money did MIJ charge for the exhaust, it looks very neat and well put together?

Keep the updates coming too!

The MIJ system was £395 all in and in my opinion was worth every penny - sounds good, not too obtrustive on day to day but when you run it hard it takes on a distinct edgier tone.

The smaller oilfilter I sourced was off a 1.6 VW Golf - same attachment, thread and internals, just a little smaller on length but runs fine with it. Surprised to learn that the car only takes 3.5L of oil to fill... my S4 V8 took nearly 8L

It appears that I now have some new problems to iron out... the car has taken to starting from cold at about 500rpm, it also does this and stalls sometimes when you come up to a junction and stop. After a while of driving it appears to be fine and idles at the usual 900rpm...

Aidan had it on VCDS briefly and it registered a throttlebody fault, so he cleared that and I guess its come back. Very odd but when I get home on Friday I will pop her on VAG com and see what's showing up.

One step forward and two steps back - sometimes this car just makes me want to sell it or break it, but when she runs well, it changes my mind

[sam80quattro]

what was the reason behind the smaller filter? i may have missed it.. just these engines are common for oil sludging up and causing oil pressure problems. probably just if they never get oil changed. however it might have been twentybenson i got the idea off to use a huge filter that holds a litre of oil on its own if i remember right.

[1781cc]

The stock filter was slamming on the engine mount and punctured, meaning it leaked oil while driving but when parked and under no load the oil sank and it didn't leak on the drive, nearly missed it.

The 1.6 filter is 3cm shorter and thus gives adequate clearance!

[m4xmw]

Persist, because you have adapted this conversion and it will be great when all the gremlins are gone.
PLus you`ll be building in some reliablity once you know which components have failed/need replacing.
Exhaust is good value as it looks like they crafted it properly.
I may use these guys for my 1990 90 2.3 auto as its a rare exhaust to buy.
Look forward to more updates!

[murat]

maybe needs a throttle body adaptation. just clean it and make an adaptation run. quite common in newer vag engines

[bikerjim]

maybe needs a throttle body adaptation. just clean it and make an adaptation run. quite common in newer vag engines

I second this. Clear all codes and adapt the throttle then go for a long drive, the ecu relearns. Mine runs a bit off after first clearing codes and after an adaptation then after a while it settles down.

[1781cc]

thanks guys for the comments about the throttle body alignment - I did some research online via the Passat UK forum and it was pointing in that direction as well.

I knida remember doing something similar in my B6 S4 - not via the computer though, it appeared that you could trick the throttle into learning a new map when you were wide open on the throttle in third gear, but also double tapping the brake pedal at the same time - effectively tricking the car into thinking you are on a track left foot braking and then resetting the throttle adjustments.

Will plug her into VCDS when back and give it a go, but I am thinking of cleaning the throttle body at the moment, but also sourcing another one off ebay, with an inlet manifold as well and working a polish job on it over the winter for better flow.

[Audicted]

Oil Filter: VAG had come up with a larger oil filter to solve the sludging problem in these engines. In order to minimize whatever is causing the sludging problem you may want to investigate the possibility of a remote oil filter kit or relocator in order to take advantage of the bigger filter. Check this out

http://forums.audiworld.com/showthread.php?t=1942453

[1781cc]

engine and interior bits...

Ok peeps, been a while since I updated this with some solid progress, but here goes:

Been having issues with the idle and general running, with continual faults in VCDS flagging up for the throttle body - as some have recommended on here, I tried to run an adaptation but it just hasn't worked... I think the throttle body itself is on its way out, but I have another one coming in the post so should know for definite on friday!

In the meantime, I cleaned the current one and took the battery off overnight to reset everything... the throttle was disgusting!






I've just been outside and done a TBA which appears to have worked, or so VCDS says - I dont trust it, but have to go to Gaydon for work this evening/tomorrow so a good run will flag anything up.

Anyway, the inlet has been bugging me for a while so I gave it some thought and modified the inlet hose to the MAF, shortening the pipe by about 3 inches and jubilee clipping it in place - this has given me more room to reposition the CAI kit and run a feed down into the Kamei front eyelet. I know this solution isn't a long term and I have a silicone replacement ready to go when I swap the turbo over.

That, coupled to the new rocker cover and a few other elements getting reworked has led to a much cleaner and tider engine bay... :ihih:


Now... onto the interior... remember these?



Yup, B5 S4 split fold rear leathers - the ones I tried to fit before and had issues with using the donor vehicle clamps. The main issue being that when using those clamps to retain the split/fold functionality, it makes the seats 1.5cm too wide for the space and the wheel arches force the seats forward - I got round this by discarding the lower seat clamps and modifying some of the existing components...

Step 1: Remove the old seats

Step 2: Cable tie the new seats into the vacated holes from the old seats - they are offset - longer term I will be making some smaller Z brackets to fix this permanently, but for now they are secure.





Step 3: Unbolt and move the petrol tank back to allow access to the firewall and drill safely without perforating it!




Step 4: remove the gravity filter off the rubber holder (harder than it looks)


Step 5: unscrew the feeder pipe retainer, remove the 'O' ring from the rubber seal and push it through into the car



Step 5: line up and drill some holes in the firewall where you want the rear seat central holder to go - measure it right so the top of the seats sit flush with the carpeted parcel shelf - I used cable ties to check it first then switched to bolting it in once it had been tested to work in the right place. At this point I have to admit that I can't remember if I used the holder from the Passat I broke or the S4 - they look quite different, but this one sits lower - if you are thinking of doing this drop me a line and show me what you have, ill cross reference it.




Step 6: Remove the back cover for the ski bag as it bulges out and doesnt sit on the firewall flush


Step 7: The seats should now fold up onto the firewall and rest flush with the top of the
parcel shelf (if you have done Step 5 right )

The bolsters will need the bottom retaining clips cutting off as there is no recess in the wheel arch for them to sit in. I tried to find another way of doing it but to no avail. I also had to fold down the top tabs because the firewall is blocking it from sitting flush. I will look into cutting smaller slits into the firewall when I get my grinder back. These bolters really sit flush and are difficult to move because of the side pressure from the seats into the wheel arches/pillar so if I dont get round to it, no biggie - they certainly wont fall out.



Step 8: drill some small pilot holes through the top of the rear seats and put some washers on them. The rear of the seats is either hard plastic or wood, but certainly not metal - I used metal screws anyway because they were a lot fatter than the wood ones I had and have a tighter thread. Make sure you get someone to push the seats onto the firewall while you do this otherwise they move and you will have secured them in the wrong place :wall:



Step 9: Step back and admire your handiwork!

[sidrick]

Outstanding work. Looks great!

[Greg_S]

Excellent work, looks very OEM too.

[quattrostyle]

Now that looks good, very nice!

[1781cc]

FFS... this is what happens when you are bored at work... my K04 plan just went out the window... :wall:

http://www.ebay.co.uk/itm/1907362744...84.m1497.l2649

[sam80quattro]

you made the right choice
gtir have a slightly bigger exhaust iirc.. i made 274bhp and 310ft/lb with mine on the rolling road last saturday.. still to be mapped

[sam80quattro]

meant bigger exhaust then an s14 200sx(what i use) but cant edit for some reason