Pat's 1990 CQ - AAN / GT3071R / VEMS

[Afterthought]

Hey guys figured I would start a thread here.
Ive owned plenty of Audis since I was ~17 and one of my favorites was the coupe, I've always wanted a CQ with a 20VT in it.
I was able to get one off of a friend. Really good deal since I know the history of the car (Washington car, he's had it since high school). Body work and paint work free, all panels are original. And while some sports in the clearcoat are a little faded, this is important to me because i know what I have here.
He had already started the swap so the car was completely gutted when I got it, no interior, ABS & brake booster are gone, battery tray is gone.

Trying to keep this list current of how she stands now:

Suspension/Brakes
-Added Koni/GC coilovers and 5 lug hub conversion.
-Koni/Ground control coils (350/380# I think)

-Front 5 Lug swap:
-Urs4 rotors/hubs front
-New A8 323x30 rotors, X-drilled
-Porsche "black" calipers
-RS2 Carrier brackets (milled down to fit with UrS hub offset)
-Braided stainless lines

- Rear 5 lug swap:
-UrS hubs
-New B5 A4 rotors, x-drilled

Wheels:
-B5 S4 Avus
-235/35/17 Michelin Pilot Super Sport (new 7/15)

UPDATE: Engine Rebuild done in MAY-JUNE 2015 :
-All bottom end gaskets and seals replaced, lower end rebuild kit (new from EFI Express- 4/2015)
-All top end gaskets and seals, top end rebuild kit (new from EFI Express- 4/2015)
-Head: Leakdown test, Valve grind, new valve stem seals (Reed Auto Machine- 5/2015)
-Block was well within factory clearance, but had it cleaned and Honed (Reed Auto Machine- 5/2015)
-7A cams from original 180k coupe engine
-New MLS head gasket (New 6/2015)
-New Goetze piston ring set (new from EFI Express- 4/2015)
-New DM Forged I-Beam connecting rods (new from EFI Express- 4/2015)
-Used Crankshaft from INA engineering, polished, balanced (new from EFI Express- 4/2015)
-New Calico dry film coated main and rod bearings (new from EFI Express- 4/2015)
-Sent out the Rods, Crank, clutch, flywheel, crank pulley, pistons, and rings- everything 0 balanced. (Perpetual Balance 6/2015)
-New OE crank pulley bolt (new from EFI Express- 4/2015)
-New timing belt kit, water pump, thermostat, tensioner roller. (new from EFI Express- 4/2015)
-7A valve cover, powder coated "fire engine" red (Mt Baker Powdercoating)
-034 Tubular header - Cerakoted in "black velvet" (Mt Baker Powdercoating)
-034 3" Downpipe - Cerakoted in "black velvet" (Mt Baker Powdercoating)
-Tig'd stainless 3" exhaust running one Magnaflow 3" single in/dual out muffler (New 5/2014)
-Garrett GT3071 0.63 A/R, 4" Anti-surge inlet 3" V-band outlet - new from 034 MS (New 3/2014 034 MS)
-034 coolant and oil supply and return lines (New 3/2014 034 MS)
-034 Aluminum flywheel (New 3/2014 034 MS)
-Spec 3+ Feramic clutch - (New 3/2014 034 MS)
-034 Fuel rail - (New 3/2014 034 MS)
-Aeromotive FPR (New 3/2014 034 MS)
-RS2 replica injectors - sourced from motorgeek
-Bosch 044 fuel pump - (New 3/2014 034 MS)
-GSP v taper FMIC - (new from ebay)
-Mishimoto X'line 3 row aluminum radiator (New, Summit)
-Perma-cool 1,200 CFM fan, wired to a switch under the dash (New, Summit)
-New upgraded oil cooler, custom made high pressure oil hoses from Industrial Supply Co. (New cooler and lines 7/2015)
-OEM AAN Alternator and tensioner (6/2015 Roger Jobs Audi)
-1995 Audi 90 PS pump to facilitate Hydro Brake boost and ABS delete - Sourced from parts stash
-Audi 4000 brake booster to facilitate Hydro boost/ABS delete - Sourced from parts stash
-New interstate MTP-91 , relocated to trunk (6/2015 Roger Jobs Audi)
-VEMS PnP software using AAN harness, integrated into CQ (New from EFIExpress)
-Bosch Wideband 02 sensor (New from EFIExpress)
-VEMS "display only" round gauge (New from EFIExpress)
-034 High output coil kit - (Sourced from motorgeek)
-Brand new oil pressure gauge and sender, from the AUX gauge location in the engine block (New, 6/2015 SUMMIT)

Exterior/body
-Fiber images carbon fiber B4 hood (was damaged and then repaired at one point)
-Rieger RS2 front bumper skin. (New from RPI Equipped 5/2014)
-Rs2 ellipsoid headlights
-HID kit installed in RS2's utilizing a seperate VLEDs Relayed harness to avoid power issues and clean up the garbage that was there
-Euro rear license plate section
-Stubby antenna
-Rear wiper delete

Condition of car taking delivery:

[Afterthought]

Found the S2 hubs and suspension for sale locally in bellingham so I sprung for it and picked all this stuff up on the way to work one day


Eibach coils, Bilstein HD's, and Porsche 996 Blacks with stainless lines. I Was told this was S2 hubs S2 caliper carriers, later found out that the Hubs arent all S2 (fronts are URS4/URS6) and the RS2 carriers had been milled down some to fit. So this caused alot of issues until I realized what was going on.
Got everything swapped over, welded on new perches on the strut tubes that were in better shape and transferred everything over,
sandblasted and painted the carriers since those were a bit corroded as well.



Rear with new 5 lug brake rotors from an A4 avant quattro. Stock rear calipers for now.


So the final result is:
Porsche 996 calipers
-Stock front coupe Hub carriers
- 5x112 front Hubs 441-501-853 B.
-323X30 A8 rotor, Audi Part # 4D0-615-301A
-RS2 caliper carriers
-A4 Avant rear rotor

[Afterthought]

Got started cleaning the block and put some coats of black engine paint on there after getting it stripped/masked.


blasted cover and intake manifold.



Small progress but got the block cleaned up and head studs in, head put on. Extracted the broken studs from exhaust manifold (what a B!tch) and put that on with new studs.
Got the 7A oil pan installed with the 7A pickup tube and AAN windage tray.



Manifold and wastegate on

[Afterthought]

-Re-assembled most of the interior
-Installed Bosch 044 Fuel pump
-Worked on the ABS delete, well it was already gone but I needed to figure out what I was going to do to have brakes. Sourced a few different vacuum boosters, ended up using a 4000Q booster since the URS6 and 90Q boosters are larger diameter and would've been hard to fit in the space. Even the 4K booster is a tough fit!


Testing fitment of downpipe/turbo

[chaloux]

I was gonna tell you to come over here after you posted that pic on qw! Nice work, getting close!

[PRY4SNO]

Nice to see a black on black coupe getting rescued and properly rehabilitated. Keep the updates coming!

[scubadave]

very nice work. reminds me of a car I know.

By the way, I would not use the master and (prop valve is a total POS) from the 4k. the coupe parts are much better.

[Afterthought]

very nice work. reminds me of a car I know.

By the way, I would not use the master and (prop valve is a total POS) from the 4k. the coupe parts are much better.

Ok, that's good advice. I wasn't able to find much info on abs deletes, unfortunately. So I figure with the ABS gone , I need a master cylinder out of a non-ABS car. Am I correct on this? Or can I just run the stock coupe MC?
I'm not opposed to just ordering a new one as long as I know the right one to get.
I am running the porsche black calipers so I want to make sure I have adequate braking for sure !

[scubadave]

Nah, the stock master cyl and prop valve will work fine. There is no difference between abs and non. I just said something since I saw you were using that leaky pos prop valve from the 4k. when I converted my 4kqt, I got a proper valve from a newer car and threw that junk away. Honestly I cant believe some suppliers still selll it.

The stock MC will handle the Porsche calipers fine.

[scubadave]

what are your plans for a radiator? I see you kept the AAN intake. were you going to delete the A/C and just tilt the rad?

[Afterthought]

Dave, I wasn't sure about the MC yet. I just have that booster bolted in there for a test fit but nothing's been done yet. Maybe I'll tackle that next .
As far as the radiator I am probably going to run a modified stock intake manifold like Hank makes. After seeing how far Id have to tilt the radiator I don't think I like that option, but I guess it's an option.
If the Wagner IM from 034 didn't have an extra 400 tacked on to the price over what Wagner sells them for is just get one of those.
Also the AC is going to be deleted but not power steering.

[chaloux]

You can get it direct from Wagner, why bother with 034?

[scubadave]

Dave, I wasn't sure about the MC yet. I just have that booster bolted in there for a test fit but nothing's been done yet. Maybe I'll tackle that next .
As far as the radiator I am probably going to run a modified stock intake manifold like Hank makes. After seeing how far Id have to tilt the radiator I don't think I like that option, but I guess it's an option.
If the Wagner IM from 034 didn't have an extra 400 tacked on to the price over what Wagner sells them for is just get one of those.
Also the AC is going to be deleted but not power steering.

Well, if you can weld alum, then modify. If you can indeed get the Wagner directly from Wagner at 400 less, then cool.

I used a B4 90 booster and just used original MC and prop valve on my coupe. bolted right in with no mods and all I had to do was use a hose to hose straight barb for the return line on the p/s and removed the high pressure pistons in the pump. Drilled a hole and tapped for a 90* hose barb on the intake and it was done. be sure to put a check valve on the booster.

you should browse my thread for some ideas. I've had a lot of good ones, and a few harder ones to deploy. It may help in your build. I had it ported over from MG so the first 6-7 pages may be a better read over there. many of the pictures did not show up.

I too have had may Audi's since I first got my licence, and my favorite is also my coupe. however, I did not sell mine off. I've had it since 95, and have had many adventures in it over the years.

[Afterthought]

I can't weld aluminum very well but my dad can handle that, so for now that will be my plan, modify my stock IM and should be able to have that come out looking clean.
This is the Wagner manifold I was looking at ---> http://www.wagner-tuning.com/AUDI-S2-RS2-5-CYL-20-V-TURBO-Intake-manifold_p_14.html
This looks like it would work but I'm not sure which throttle body I would need with it, but unless I am missing something that seems like a good price. However, it's still alot of money and I don't need that for what my plans are with the car. So sticking to the original plan for now
I will browse your thread ... I'm always in need of ideas ! Half of the stuff I have ahead of me I don't know how I'm going to do yet...
Pat

[Afterthought]

Couple hundred hours of overtime this year and I havent done anything on the car but finally got back to it.
Started the exhaust the other day but got to a stopping point when I realized I needed to order another V-band clamp for the rear section. Its going to be really tough to get 3" in and with enough clearance not to rub over the subframe with the thermal growth of stainless.





Also cut and relocated the throttle body portion of the intake manifold. My measurements didnt reflect this but it's still going to be very difficult to get the radiator in there. I dont know if anyone has any pictures of a completed setup like this but I wasn't able to find any.

[Afterthought]

I am almost kicking myself in the ass for getting the " 4 inch anti-surge compressor inlet on the turbo" as it's going to make things really difficult when I try and figure out an intake. I wasn't planning on EFI but I may have to now. The easiest, cleanest, and best looking route would be just a 4" mushroom filter on the end of the turbo. However, if I ditch the MAF it's a whole different ball game.
Any suggestions?

[Dave]

Cobra head inlet. That is what i used. simple solution

http://intakehoses.com/Merchant2/mercha ... _Code=CHEW

[Afterthought]

Thanks Dave, that's a great idea. I have never seen one of those before.

[Afterthought]

Got the exhaust finished today. 3" stainless TIG welded, Borla 3" straight through stainless muffler, no resonator .
Running 3" over the rear axle is an absolute pain in the ass, but I don't think it's going to hit anywhere. Ran out of metal for the hangers so I'll have to beef those up a bit.
Was planning on dual 3" polished stainless out but I ran out of bends and the extra stainless required to make a 3" Y is going to be about $60, so for now I used my last two trimmings that were left to make a single 3" out. It comes out at an angle but I kind of like it that way.
I really like the way this exhaust turned out cant wait to get the car started and hear it... so time to work toward that.

[Afterthought]

Night off tonight so I finally went to work on the intake. Tried the "cobra head 90" as a turbo inlet but it wont clear my headlight and actually gives me less room than this 9-ply silicone 4" to 3" 90 I found on ebay. Clears the headlights and fits nicely under the RS2 Bumper. I'll need a solution for rainy weather driving though...

[PRY4SNO]

Nice work. Looks like a belly pan would do the trick keeping water out, and increase engine bay cooling as well. I've cross referenced part numbers, and it appears the B5 used the same belly pan.

One other thing, and this is tough to tell from behind a keyboard... but are you sure your muffler is adequately supported? Exhaust looks nice, otherwise.

[Afterthought]

Nice work. Looks like a belly pan would do the trick keeping water out, and increase engine bay cooling as well. I've cross referenced part numbers, and it appears the B5 used the same belly pan.

One other thing, and this is tough to tell from behind a keyboard... but are you sure your muffler is adequately supported? Exhaust looks nice, otherwise.

You are totally correct, the exhaust needs a couple more hangers in the rear, or at least that one hanger to be beefed up.
I had the car at a friends shop on the lift to make that exhaust, but ran out of metal (both hangers and mandrel bends) and I wanted to get it out of his way as soon as possible. Now that I have it at home i will be able to pick up some metal and weld on more support soon.

[Afterthought]

More progress on the car last night.
got the brakes hooked up in what I believe is the correct order...
Now running:
-4000Q Vacuum Brake booster
-Coupe Q (stock) Master cylinder
-No ABS
switching from the ABS to non ABS leaves one less port out of the master cylinder. I believe the way I have it hooked up I will have one line for the fronts and one for the rears, running a splitter for the fronts as there is only one line out.


Without the lines needed for the hydralic "bomb" I basically tied the supply and return together. Hoping this will work for now until I can locate a different power steering rack. /


Got the intake manifold all tightened up. I forgot with the Hank style modification of moving the TB forward it's an absolute PITA (near impossible) to tighten the bottom bolts on the intake manifold as you can no longer go through it with a long allen. Whoops.
Radiator fitment with modified intake:




Also the coolant line to the block is way too long, unless I have something crossed up. It would be stupid to get these lines wrong, but again I didnt take it apart and dont have one to look at so I dont know what stock looks like. This line that looks right and has the proper end on it is way too long:



The main issue I need to sort out right now is power steering pump mounting. I dont seem to have the power steering bracket that mounts to the block anywhere, in fact since I didn't take the car apart I don't even have a clue what it looks like. . If anyone has this part PM me!
Pictured below is the bracket I do have which I believe is for the 7A engine

[Afterthought]

Still working on how to get power steering set up.
The goal for now will be to locate an AAN power steering bracket, but I'll need to locate and try one to see how it fits.
Never found a definitive answer on this but it looks like If my research is correct I should be able to use the stock AAN PS bracket, 12V V6 PS pump, AAN intake manifold, AAN water manifold.
Current setup is modified intake manifold with throttle body moved forward to clear tilted radiator, and an AAN water manifold.
I have the 3B water manifold and can modify this and use it if I need to in orfer to gain space for the power steering.
Then it looks like I will have to swap on the 7A crank pulley so I can run V-Belts.
Hopefully this all works out, then I can get to making some real progress.

Looks like my Ebay intercooler will fit perfectly within the RS2 replica bumper.


Will have to trim some space out of here for the intercooler:

[PRY4SNO]

Interesting radiator solution when using an AAN intake in a typ89 coupe in this build:
http://www.s2forum.com/forum/showthread ... 38&page=36

Maybe shoot him a PM and ask what he came up with for the PS pump as a solution?

HTH,

Dustin.