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Drove the 4000q to work, ECU is running fantasticly. But didn't stop it from shredding the alternator belt for some unknown reason. Thankfully got to an Autoparts store and got it sorted.
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Mar 23, 2023 20:11
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The John Deere is already pulling its weight, used it to tow the 4000 Quattro Turbo to the back for an engine swap: It pulled the car with zero hesitation, up a minor slope, without even having to really throttle up more than half way
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Mar 27, 2023 00:12
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I think I'm finally at the point where I can say most of the operational issues are sorted with the 4000 Quattro 20v Turbo. And man....does it move. This car is too much fun for a 37 year old hunk of metal.    Most of the remaining issues are cosmetic and structural (replace rusted metal, weld in some new metal on the floor pan, etc.) But man does it sprint like a beast.
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Mar 30, 2023 20:30
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CommieGIR posted:I think I'm finally at the point where I can say most of the operational issues are sorted with the 4000 Quattro 20v Turbo. It's cool as gently caress
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Apr 4, 2023 13:53
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biglads posted:It's cool as gently caress Thank you. Its been a long time to get this far, but I'm really happy with how its come out.
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Apr 4, 2023 14:47
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The 20v engine is incredibly good, it just really sucks they’re so rare.
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Apr 8, 2023 02:18
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Frank Dillinger posted:The 20v engine is incredibly good, it just really sucks they’re so rare. It was honestly Audis best motor, and when they brought it back for the RS3 and TTRS it continued to deliver. But yeah I keep a lot of spare parts for my 20v.
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Apr 8, 2023 02:26
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So, we had an oil pressure loss incident, an oil cooler host burst. We have a rod knock under load now. So engine change it is. I had a fresh AAN/3B on the stand for the 90 Quattro, it'll now go into this one, and I'll overhaul the other AAN for the 90 Quattro and then overhaul the 3B that comes out. It was still running okay other than the knock at load, with all 5 cylinders firing. So hopefully a spa day at the machine shop and new bearings/piston rings will bring it back.  Disconnect the wiring loom and pulling intake hoses, radiator, etc.  Almost ready for engine out  Old 3B out.  New and old engine, gotta swap cams to get the distributor gear cam.  Cam journals are in good shape, so hopefully we only lost some bearings on the bottom end.  There's gold in them there engine oil.  A sloppy paint job for the AAN/3B frankenmotor before it goes in.  A fresh coat of paint for the timing belt rear cover too Waiting on some parts like the pilot bearing and stronger oil cooler hoses. CommieGIR fucked around with this message at 15:32 on May 21, 2023 |
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May 21, 2023 15:29
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Sucks about the oil cooler hose. Via the cam journals it looks pretty saveable though. Made quick work of it all too
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May 21, 2023 17:22
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cursedshitbox posted:Sucks about the oil cooler hose. Via the cam journals it looks pretty saveable though. Made quick work of it all too Important to remember that the original 3B had 100,000+ miles on it when I got my hands on it, and has been driven a lot since then. I'm hoping that the likely already worn bearings just finally threw in the towel when starved. Because yeah, the cams look about as good as a couple spare 'new' sets I have, and the engine came home under its own power, only knocking when under load.
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May 21, 2023 17:47
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Reassembled the new engine after the paint dried and installed new NGK spark plugs  Exhaust manifold and wastegate are installed  Fresh knock sensors. Waiting on the Pilot Bearing still but after that we're ready for install.
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May 21, 2023 23:29
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Oof. Classic old car bullshit. Sucks but looks like a minor bump in the road for you.
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May 22, 2023 11:57
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Welp, the old engine is on the stand for its overhaul: New engine is ready to go in:   Pilot bearing, flywheel, and clutch installed  and she's seated.  Install is reverse of removal  Had an issue of the timing belt walking into the engine, turns out the idler pulley mount was slightly damaged, had to create a shim to get it aligned correctly.  And she's mostly done, final crank bolt torque and then leak check and drive. She runs like a sewing machine. https://i.imgur.com/tP1TDYF.mp4 (has audio)
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Jun 1, 2023 02:29
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IT LIVES, IT DIES, IT LIVES AGAIN. Hell yes awesome work. That was quick turnaround. Is the shim gonna bee fine long term? that's kind of a spicy place for a point of failure.
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Jun 1, 2023 02:35
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cursedshitbox posted:IT LIVES, IT DIES, IT LIVES AGAIN. It should be fine, yes, it wasn't so much that the idler didn't stay in place, but that it was slightly offset. It holds the idler fine, just needed to be ever so slightly angled on one side by ~2mm Eventually I'll replace the oil pump housing to fix the issue, but I gotta drop the oil pan to do that. CommieGIR fucked around with this message at 02:46 on Jun 1, 2023 |
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Jun 1, 2023 02:43
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....and it sheared the TDC timing pin off the flywheel. Don't know why but engine will have to come back out.
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Jun 4, 2023 20:56
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FFS. Check the harmonic balancer when it's easier to access it. I'm curious to see what you find.
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Jun 4, 2023 21:03
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cursedshitbox posted:FFS. Check the harmonic balancer when it's easier to access it. I'm curious to see what you find. Harmonic balancer is in good shape. Unsure why the pin sheared
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Jun 4, 2023 21:20
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Drilled out the old pin and hammered in a new one. Car runs again. Turned the motor over by hand and there's nothing audibly or visibly hitting the pin on borescope, it's a mystery.
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Jun 5, 2023 01:04
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Now that the fun is over with the other 4000 Quattro, back to the 10vT one: Engine out!  Time to prep the new engine to go in after I powerwash the engine bay!
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Jun 11, 2023 01:49
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So while the 20vT Audi 4000 woes are done, I didn't feel comfortable with the pin just being hammer set, so I TIG'ed it into place  Took it out, gave it the beans, it seems happy. Still adjusting the wastegate pressure a bit. I still have not found a root cause for the loss of the first pin, but I borescoped the back of the flywheel and engine while turning it over by hand. Nada. Only conclusion I can come up with is some debris were present or got into the bellhousing through the two water drain holes on the bottom.
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Jun 22, 2023 19:19
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So added a Turbo blanket and wrapped the downpipe to help control heat in the engine bay:  It made a significant difference in under hood temperatures, doesn't feel like an oven anymore CommieGIR fucked around with this message at 21:36 on Jun 25, 2023 |
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Jun 25, 2023 21:32
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We've completed the first 500 miles of breakin for the new engine's rings, oil remains clean, catch can shows very little in the way of excess blowby oil, and it's driving well after repairing the timing pin. Now it needs tires and an alignment. The turbo blanket and exhaust wrap significantly decreased engine bay temperatures so I'm super happy. Will likely repeat on the 10v build
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Aug 16, 2023 21:59
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Anything special with the exhaust wrap other than take your time and that it sucks? The 7 engine bay and transmission tunnel get very hot and I'd like to decrease how much my feet get cooked.
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Aug 17, 2023 14:21
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NitroSpazzz posted:Anything special with the exhaust wrap other than take your time and that it sucks? The 7 engine bay and transmission tunnel get very hot and I'd like to decrease how much my feet get cooked. Take your time, get good overlap with each layer (I wrapped mine with 1/2 of the wrap covering the previous layer) and for god's sake wear gloves, the stuffs essentially fiberglass so it'll make your hands itch like the devil. I wrapped from the end of the turbo/wastegate to the coupling for the exhaust underneath the CV shaft heatshield and that seems to be enough to keep temps down overall. Ideally I want to eventually also add vent slits over the turbo to help draft cool air into the bay and pull the heat out even more. CommieGIR fucked around with this message at 18:19 on Aug 17, 2023 |
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Aug 17, 2023 18:14
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Its been awhile. I did a (terrible) job welding in new sheet metal into the floor, because no shop wanted the job. Future, I'll rip out the entire pan and spot weld an entire new pan in, but for now, it's `an floor`.  TIG was the best balance of 'penetrate' and 'not eat up the thin 22 guage sheet metal', sadly I ran out of TIG gas and had to wirefeed MIG the rest.  Treated with rust converter and sealed with undercoating sealer and seam sealer both above and below the car. And no, I didn't bother to grind down the beads, since it was such a lovely job and realistically it'll be living under a floor mat, so I don't care. It's better than a gigantic gently caress off rust hole, and should slow any rust for a while  As a bonus - electric sunroof is greased and working again. Also - checked and topped off the transmission and rear diff fluids. Not too low considering its a 37 year old car. CommieGIR fucked around with this message at 00:51 on Oct 25, 2023 |
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Oct 25, 2023 00:38
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Nothing worse than loving around with ancient sunroofs and guides, good job on that.
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Oct 25, 2023 01:39
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wallaka posted:Nothing worse than loving around with ancient sunroofs and guides, good job on that. I previously thought the motor had burned out, but after some chain lube on the rails, its sliding and running like clockwork.
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Oct 25, 2023 13:32
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Tell us more about the gauges at the bottom of the center stack
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Oct 25, 2023 17:22
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cursedshitbox posted:Tell us more about the gauges at the bottom of the center stack Ah, that'll be your Voltage, Oil Temperature, and Diff Locker vacuum switch  I only have the rear diff lock anymore, as my transmission is upgraded to the Torsen center diff rather than the locker, but you really cannot use the diff locks above 35 miles an hour. CommieGIR fucked around with this message at 17:56 on Oct 25, 2023 |
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Oct 25, 2023 17:24
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 Had a friend at the local German car show. First time in forever an 80s Audi showed up besides me.
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Oct 30, 2023 02:36
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Tore down the bottom end on the oil-starved 3B: Ouch  It'll need some polishing, but I suspect I can save the crank.
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Dec 15, 2023 20:15
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Crank out time! New bearings time!    Pistons are back in with new rings and connecting rod bearings  Time for paint - partner chose neon green for this one   And reinstall the engine components   Meanwhile, diagnosing some clutch noises on the Rally Audi and doing a output shaft seal that's leaking:  The clutch itself looked fine, springs rattled a little, I swapped in an older style 200 clutch to see if that would help  Flywheel still looking good  Nasty rear end output shaft seal, ugh. New one did stop the leak at least.  Throwout bearing is worn but serviceable, not the source of our noise  Back together!  Unfortunately, while the older style clutch helped the noise, it cannot take the Stage 1 tune, so gonna have to swap a new clutch in. Ugh. CommieGIR fucked around with this message at 21:35 on Dec 31, 2023 |
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Dec 31, 2023 21:29
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Pulled the AAN out of the scrap S6, gotta tear it down and do piston rings:
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Jan 2, 2024 00:46
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Now me and the mad scientist gotta rip apart the block and replace the piston rings you fried.
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Jan 2, 2024 12:39
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Suburban Dad posted:Now me and the mad scientist gotta rip apart the block and replace the piston rings you fried. Don't threaten me with a good time! The engine does run, but I suspect sitting for 10 years caused the rings to sieze. We'll find out soon enough!
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Jan 2, 2024 12:58
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Prototyped some brackets to adapt an RS2/AAN Fuel Rail to a 3B intake:  Came out okay, gonna make the final versions ARP headstuds arrived for the in progress motor:  Cleaned up the surface of the head and the deck:  Reinstalled head and torqued down to 80 ft/lbs: 
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Jan 5, 2024 00:05
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Got the RS2 Fuel Rail installed, other than being a pain to put in with the distributor in place, it works! Its much much easier to get the Fuel Pressure Regulators for these rails than the standalone ones the 3B uses, so this futureproofs it a bit. Anyways, back to something somewhat different - The 2.4l TDI Frankenstein Motor I used the mill and cut the oil squirter passage into the ALH pistons that will be going into the AAB:   Piston weights are as closely matched as I can manage, so should be okay. We'll find out. Waiting on one more connecting rod to install.  Test fit of the AEL 2.5l TDI head on the 2.4l AAB. It fits like a charm and everything lines up.
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Jan 10, 2024 01:30
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More work done on the 3B rebuild, its basically ready to put in the car:   Prepped the AAB Diesel block for painting and and installed the first 4 pistons and rods, waiting on the matched rod for #5  
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Jan 16, 2024 18:16
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Plum purple is a nice engine color, right?
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Jan 17, 2024 02:22
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