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1986 4000 Turbo Project(s)

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 Post subject: 1986 4000 Turbo Project(s)
PostPosted: Mon Aug 29, 2016 7:13 am 
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Been searching for a long time for a clean, straight, alpine white 4000. Well as luck would have it I found not only one, but two. Within a week of each other. One was clean body and a california car that was well maintained but didnt run right, the second was beat up and rusty but had the AAN, 01E, and supporting mods.

The first one is significant because it is all original, totally straight, no rust california car. 156,000 miles approx and everything works and the interior is in really nice shape. Its the Commemorative edition with the red leather and black carpet.

Details:
1986 4000 CS Quattro Commemorative Edition
White/Red leather
156,000 Miles

Edit: 1/28/17 Current build details

Engine:

AAN (stock internals)
440CC Injectors
034 Fuel rail
Aeromotive FP Regulator
stock 3B intake
URQ intercooler
RS2 Exhaust manifold
3" Stainless TIG exhaust, Magnaflow muffler
Factory AAN Harness
Bosch Wideband 02
VEMS Plug and play ECU
Upgraded oil cooler, custom lines

Drivetrain:
RS2 replica mounts (unknown brand)
01E "Wide first" 5-Speed
URS interior parts to retain reverse lockout
034 Short shift kit
Ground Control adjustable coilovers
Koni Struts
16 ATS Type-10 wheels

Maintenance:
Relocated battery to trunk 9/2016
New battery 9/2016
Fuel Filter 9/2016
New Tires 9/2016
New front Ball joints 12/2016
New rear Ball joints 12/2016
New front tie rod ends 12/2016
New front wheel bearings 1/2017
New alternator brushes 1/2017
Oil pan gasket 1/2017
Brake fluid flush 1/2017
Trans Mounts replaced 1/2017








The CE:
Some better pics to follow. This is exactly as I picked it up just after unloading it.
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The Turbo Donor:
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Current condition pics:
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Engine bay
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Current:
1983 Ur Quattro, White/Mocha. http://www.motorgeek.com/viewtopic.php?f=6&t=78665
1985 & 1986 4000 http://www.motorgeek.com/viewtopic.php?f=6&t=142634


Last edited by Afterthought on Sat Jan 28, 2017 11:08 pm, edited 3 times in total.

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 Post subject: Re: 1986 4000 Turbo Project(s)
PostPosted: Mon Aug 29, 2016 7:30 am 
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following. let me know if you have any questions as i am currently performing a turbo swap on my alpine white 87 4KQ as well. because of your post I might even update my build thread.

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 Post subject: Re: 1986 4000 Turbo Project(s)
PostPosted: Mon Aug 29, 2016 7:57 am 
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701509 wrote:
following. let me know if you have any questions as i am currently performing a turbo swap on my alpine white 87 4KQ as well. because of your post I might even update my build thread.

I have a 10vt that i pulled from my UR Quattro. I may consider putting that in the "rusty" car because I want to end up with the 20vt in the commemorative.
Ill post up a couple pics of the engine bay. The front mount rad is really sweet for a B2 car. Not sure which direction you're going with the radiator and intake, ETC. I really like the way the PO did it because I have screwed around quite a bit trying to jam the radiator in the side on my 1990.
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Current:
1983 Ur Quattro, White/Mocha. http://www.motorgeek.com/viewtopic.php?f=6&t=78665
1985 & 1986 4000 http://www.motorgeek.com/viewtopic.php?f=6&t=142634


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 Post subject: Re: 1986 4000 Turbo Project(s)
PostPosted: Mon Aug 29, 2016 1:28 pm 
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Nice! Looks like a fun project! I'd be willing to "help with funding" if you'd be willing to sell me the carpet out of one of these. :)


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 Post subject: Re: 1986 4000 Turbo Project(s)
PostPosted: Mon Aug 29, 2016 2:05 pm 
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Hey I'm glad Alex tagged you in that post i made on the FB page. Glad you scored it!!

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'95 S6 Avant '04 A4 Avant '95 90 quattro


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 Post subject: Re: 1986 4000 Turbo Project(s)
PostPosted: Mon Aug 29, 2016 3:50 pm 
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jclayne wrote:
Nice! Looks like a fun project! I'd be willing to "help with funding" if you'd be willing to sell me the carpet out of one of these. :)

If I end up deciding to part one out I will keep you in mind.

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Current:
1983 Ur Quattro, White/Mocha. http://www.motorgeek.com/viewtopic.php?f=6&t=78665
1985 & 1986 4000 http://www.motorgeek.com/viewtopic.php?f=6&t=142634


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 Post subject: Re: 1986 4000 Turbo Project(s)
PostPosted: Mon Aug 29, 2016 3:53 pm 
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Afterthought wrote:
jclayne wrote:
Nice! Looks like a fun project! I'd be willing to "help with funding" if you'd be willing to sell me the carpet out of one of these. :)

If I end up deciding to part one out I will keep you in mind.


Awesome. Thanks! If not, that's ok too!


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 Post subject: Re: 1986 4000 Turbo Project(s)
PostPosted: Mon Aug 29, 2016 3:53 pm 
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I sprinkle rubber on my Cherios

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I got the comemorative edition for pretty cheap because I had to trailer it home.
It runs OK until it reaches full operating temp and then just dies. will start and sputter a bit but will only run again once it is cooled.
The first thing I tried is to check the coolant temp sender and found nothing there. Still looking through vacuum lines and grounds.
Also may need to test fuel pressure. But to me it seems like a CIS sensor issue.
I'm really tempted to just swap over the whole drive train from the turbo car into the clean body, but I know it isn't that easy.

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Current:
1983 Ur Quattro, White/Mocha. http://www.motorgeek.com/viewtopic.php?f=6&t=78665
1985 & 1986 4000 http://www.motorgeek.com/viewtopic.php?f=6&t=142634


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 Post subject: Re: 1986 4000 Turbo Project(s)
PostPosted: Thu Sep 01, 2016 5:35 pm 
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I sprinkle rubber on my Cherios

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Well had some time this morning so I started prepping the clean 86 for a 20vt.
Image
[img]
http://i1180.photobucket.com/albums/x41 ... scarfk.jpg[/img]

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Current:
1983 Ur Quattro, White/Mocha. http://www.motorgeek.com/viewtopic.php?f=6&t=78665
1985 & 1986 4000 http://www.motorgeek.com/viewtopic.php?f=6&t=142634


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 Post subject: Re: 1986 4000 Turbo Project(s)
PostPosted: Fri Sep 02, 2016 7:27 am 
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I sprinkle rubber on my Cherios

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Getting the battery tray out
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Need to smooth over what's left and get it painted.
Then I will be getting rid of the unneeded wiring, and getting the engine bay clean.

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Current:
1983 Ur Quattro, White/Mocha. http://www.motorgeek.com/viewtopic.php?f=6&t=78665
1985 & 1986 4000 http://www.motorgeek.com/viewtopic.php?f=6&t=142634


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 Post subject: Re: 1986 4000 Turbo Project(s)
PostPosted: Sat Sep 03, 2016 6:41 am 
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I sprinkle rubber on my Cherios

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stock 4K engine out.
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Time to work on the "donor"
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Old Exhaust out. With the Magnaflow muffler this sounded reallllly good. I think I am going to save it. Everything else will get redone with stainless and V-bands. I am not looking forward to doing the over-the-axle portion.
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One thing that is sweet about this 4000 is that all the mounts are done on the subframe front and rear.
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Really surprised with a car from Canada, I didn't have the use the torch barely at all. Had a few bolts stuck on the driveline and had to be really careful there. One broke, but other than that everything is coming apart real easy.
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The challenge on dropping this engine out of the bottom is going to be the turbo. I got the downpipe off but getting the 4 bolts to remove the turbo is going to be really tough. Everything has been soaking in Kroil all night. Only other way i can picture it happening is if I can lift the car of the top and have the engine also move toward the drivers side, just enough for the turbo to clear the engine mount. Not sure if there's room.

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Current:
1983 Ur Quattro, White/Mocha. http://www.motorgeek.com/viewtopic.php?f=6&t=78665
1985 & 1986 4000 http://www.motorgeek.com/viewtopic.php?f=6&t=142634


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 Post subject: Re: 1986 4000 Turbo Project(s)
PostPosted: Sun Sep 04, 2016 8:30 am 
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I sprinkle rubber on my Cherios

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Well I did get the engine out the bottom. Turbo did have to come off but it wasn't too hard to get once I removed the oil and coolant lines to it so I could get a wrench in there. Not too bad really. Everything came apart
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Got the rear diff, suspension and subframe out too.
http://i1180.photobucket.com/albums/x41 ... gw5zhz.jpg

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Current:
1983 Ur Quattro, White/Mocha. http://www.motorgeek.com/viewtopic.php?f=6&t=78665
1985 & 1986 4000 http://www.motorgeek.com/viewtopic.php?f=6&t=142634


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 Post subject: Re: 1986 4000 Turbo Project(s)
PostPosted: Sun Sep 04, 2016 8:36 am 
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I sprinkle rubber on my Cherios

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The next thing I need to figure out is my linkage issue. When I purchased the swapped 4000 with the 01E the linkage was hitting the trans tunnel. Very hard to see here. So I need to compare the stock to the 01E, do some reading and see what needs to happen.
time to look through the 01E swap thread - this is for B3/b4 but some applies i'm sureImage
Hard to see here but the picture shows where the linkage hits
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Current:
1983 Ur Quattro, White/Mocha. http://www.motorgeek.com/viewtopic.php?f=6&t=78665
1985 & 1986 4000 http://www.motorgeek.com/viewtopic.php?f=6&t=142634


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 Post subject: Re: 1986 4000 Turbo Project(s)
PostPosted: Sun Sep 04, 2016 8:36 am 
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Nice

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81 CGT
83 CGT
87 4KQ -10VT pending
2010 VW Golf TDI -215k mi VW buyback
00 F250 -198K sold
94 Ranger -210K sold
93 Bronco
2016 VW Golf 1.8T Gen3
2002 Ford F250 7.3L Powerstroke


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 Post subject: Re: 1986 4000 Turbo Project(s)
PostPosted: Mon Sep 05, 2016 7:28 pm 
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I sprinkle rubber on my Cherios

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I am at the point now where i am ready to transfer over the AAN/01E into the "clean 4000" commemorative edition body.
I have one thing left to sort out, the donor car already had the 01E swapped in- From driving it I could tell it had an issue with the shift linkage, turns out it was hitting the tunnel and rubbing against the back of the trans. I have read through some threads about how to swap in the

I need a little help deciphering what exactly I can do to remedy this issue but the problem is that I'm a little unsure of what parts were used to do the swap in the first place. Although they are rusty now the brackets look professionally made but I can't tell where they are from.

The easiest way I can think of to remedy the issue is to find a way to drop the back of the trans a little. I could use something smaller in place of the 30mm spacer under the drivers side bracket but that will effectively rotate the trans as well and that's not what I want to do I don't think.

Here is the trans. It is installed using no spacers for the axle and these "mystery" brackets as shown.
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Clearance shot in the car:
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brackets
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Selector lever, 4A0 711 185 B (stock UrS car it looks like)
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Afterthought

Current:
1983 Ur Quattro, White/Mocha. http://www.motorgeek.com/viewtopic.php?f=6&t=78665
1985 & 1986 4000 http://www.motorgeek.com/viewtopic.php?f=6&t=142634


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 Post subject: Re: 1986 4000 Turbo Project(s)
PostPosted: Mon Sep 05, 2016 7:56 pm 
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Keep em comin. Massage the tunnel to ensure it doesn't rub. Should be good to go.

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81 CGT
83 CGT
87 4KQ -10VT pending
2010 VW Golf TDI -215k mi VW buyback
00 F250 -198K sold
94 Ranger -210K sold
93 Bronco
2016 VW Golf 1.8T Gen3
2002 Ford F250 7.3L Powerstroke


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 Post subject: Re: 1986 4000 Turbo Project(s)
PostPosted: Tue Sep 06, 2016 8:00 pm 
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Got the engine/trans/subframe set in place and bolted up.

These are the engine mounts. Energy suspension 1044 which I think is for a ford mustang 5-speed transmission.

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Engine sitting in place. The AAN intake manifold will have to come off for a 3B.
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Throwing some wheel studs in while I'm at it.
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Got my brakes compressed and new pads in but not without some drama. Thanks harbor freight for another tool that literally didnt even last one use.
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This is odd and doesn't make sense to me but the trans linkage seems to have more clearance in this car in the neutral position but I'll have to revisit this tomorrow and actually take a look at how it would shift.
Image

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Current:
1983 Ur Quattro, White/Mocha. http://www.motorgeek.com/viewtopic.php?f=6&t=78665
1985 & 1986 4000 http://www.motorgeek.com/viewtopic.php?f=6&t=142634


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 Post subject: Re: 1986 4000 Turbo Project(s)
PostPosted: Wed Sep 07, 2016 7:35 pm 
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I sprinkle rubber on my Cherios

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Posts: 337
Getting some work done on the exhaust today. Ran the muffler, tailpipe and over the axle piece. It was a real bitch to get that done and i did it in at least twice as many welds as a fab shop would because I don't have a bender so everything is cut and fit up from mandrel bends.
The only piece I reused was the muffler because it was a nice 3" Magnaflow straight through unit and sounded good.
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Also started swapping the real coilovers in. I am eventually going to swap the whole subframe. I ordered new bushings and mounts for it. But want to get the other one cleaned up and painted first, then do new bushings, solid mounts, new ball joints and need to find a solution for rear tie rods without dropping $260.

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Its too bad the strut housings have so much rust but I may sandblast and repaint them. Problem I have found is even with sandblasting and using acid etch primer, no spray paint will stick very well.

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Current:
1983 Ur Quattro, White/Mocha. http://www.motorgeek.com/viewtopic.php?f=6&t=78665
1985 & 1986 4000 http://www.motorgeek.com/viewtopic.php?f=6&t=142634


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 Post subject: Re: 1986 4000 Turbo Project(s)
PostPosted: Wed Sep 07, 2016 8:02 pm 
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Wowzer. Good progress

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81 CGT
83 CGT
87 4KQ -10VT pending
2010 VW Golf TDI -215k mi VW buyback
00 F250 -198K sold
94 Ranger -210K sold
93 Bronco
2016 VW Golf 1.8T Gen3
2002 Ford F250 7.3L Powerstroke


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 Post subject: Re: 1986 4000 Turbo Project(s)
PostPosted: Thu Sep 08, 2016 7:44 pm 
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Went out to the shop and decided to finish the suspension. Started by replacing the ball joints. Immediately first 20 minutes of being in the shop I snapped off a bolt doing something stupid.
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So first I tried to take it out with a screwdriver...
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Not that lucky... So I had to figure out how to weld on a bolt.
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Finally got the car on the ground so thats nice to be done with one piece of the project.
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Decided to take off the intake manifold so I can get the 3B manifold on, but realized with the damn AAN Manifold I need a super long allen.
I see that Snap on makes one, so I am going to get one of those. But in the meantime I got something to work.
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Intake manifold off
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Water Manifold off
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So that's where she sits for the night. For those looking to do anything on the intake manifold , Snap on tool # T10197

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Afterthought

Current:
1983 Ur Quattro, White/Mocha. http://www.motorgeek.com/viewtopic.php?f=6&t=78665
1985 & 1986 4000 http://www.motorgeek.com/viewtopic.php?f=6&t=142634


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 Post subject: Re: 1986 4000 Turbo Project(s)
PostPosted: Sat Sep 10, 2016 8:23 pm 
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I sprinkle rubber on my Cherios

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Spent a while entire day yesterday cleaning and organizing the shop. it needed to be done. No more time wasted looking for tools.
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Today stopped by the store and got the things I needed to relocate the battery
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Need to get the old battery connections organized and tie them into this block.


Also removed the AC , Made a little cover plate
Image

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Current:
1983 Ur Quattro, White/Mocha. http://www.motorgeek.com/viewtopic.php?f=6&t=78665
1985 & 1986 4000 http://www.motorgeek.com/viewtopic.php?f=6&t=142634


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 Post subject: Re: 1986 4000 Turbo Project(s)
PostPosted: Sun Sep 11, 2016 12:00 pm 
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I sprinkle rubber on my Cherios

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Posts: 337
Did a little more today, realized I never did put in the proper tie rod when I had the engine out so I got that taken care of.
This is how everything has come apart on this car. Its been real nice that the PO used never seize everywhere but still most of the stuff has required a little but or coaxing to get out.
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Finally. New tie rod end.
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Also took of the P/S pump from it's location which wont work with the radiator.
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The bracket for picking the head, that also holds the CPS , those bolts I can already tell aren't going to come out. So I don't know if I'll have to weld a nut to them or what.

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Afterthought

Current:
1983 Ur Quattro, White/Mocha. http://www.motorgeek.com/viewtopic.php?f=6&t=78665
1985 & 1986 4000 http://www.motorgeek.com/viewtopic.php?f=6&t=142634


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 Post subject: Re: 1986 4000 Turbo Project(s)
PostPosted: Sun Sep 11, 2016 12:13 pm 
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Keep em coming! I've got shop envy lol

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81 CGT
83 CGT
87 4KQ -10VT pending
2010 VW Golf TDI -215k mi VW buyback
00 F250 -198K sold
94 Ranger -210K sold
93 Bronco
2016 VW Golf 1.8T Gen3
2002 Ford F250 7.3L Powerstroke


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 Post subject: Re: 1986 4000 Turbo Project(s)
PostPosted: Mon Sep 12, 2016 6:46 pm 
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I sprinkle rubber on my Cherios

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Posts: 337
Wrestled with the car for a bit today, goal was to get this bracket off head, bolts were about to strip and couldn't find any reasonable way to get them out. I wasn't pretty. only had an hour and a half or so, unfortunately most of my time went into that
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Anyway got that out. Ate up most of my time. This little piece I got from Hank is probably going to be the best looking part of this engine until it gets rebuilt with rods. I will be doing that eventually but I don't have time to give this car the same attention my coupe is getting if I ever want to finish the coupe.
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3B water manifold on
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3B intake manifold. I think I have to run the 7A or 3B cover for fitment with the throttle body.
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on another note... What is the green stuff, just anodizing on the factory bolts? or some kind of coating that PO put on ?
Image

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Current:
1983 Ur Quattro, White/Mocha. http://www.motorgeek.com/viewtopic.php?f=6&t=78665
1985 & 1986 4000 http://www.motorgeek.com/viewtopic.php?f=6&t=142634


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 Post subject: Re: 1986 4000 Turbo Project(s)
PostPosted: Mon Sep 12, 2016 7:00 pm 
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Chirping second
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Newer vw's have the same treatment on their bolts as well. Idk could be factory loc tite or something. What year is your coupe

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_________________
81 CGT
83 CGT
87 4KQ -10VT pending
2010 VW Golf TDI -215k mi VW buyback
00 F250 -198K sold
94 Ranger -210K sold
93 Bronco
2016 VW Golf 1.8T Gen3
2002 Ford F250 7.3L Powerstroke


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