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1991 90 AAN Swap and more

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 Post subject: 1991 90 AAN Swap and more
PostPosted: Wed Apr 28, 2021 9:57 am 
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Finally, after 3 years of on/off searching, I've scored a car! It is in pretty darn good shape mechanically, with an AAN swap, some moderately upgraded brakes, fresh suspension, and a really crummy paint job. It's got a lot of work that it needs (wheels aren't aligned, RS2 bumper is rubbing on bumps, some windows don't work, needs new seats, etc), but it's a relatively put together project. I'm going to look to upgrade to Euro H4 headlights, possibly some 034 parts like the injector kit, but I am open to suggestions for other things we can do.

Attaching some prelim photos and will try to keep track of it here. Thanks to anyone and everyone who's answered questions and helped along the way.


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on trailer.jpg
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Current Car:
'91 90 Quattro (AAN Swap)
Past Cars:
'90 Audi 80 Quattro
'92 Audi 80 Quattro
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 Post subject: Re: 1991 90 AAN Swap and more
PostPosted: Wed Apr 28, 2021 10:38 am 
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Another potential project is getting an AC compressor in there. Has anyone fit one into a B3 Sedan/Coupe? It seems like there's room on the passenger side under the turbo, but my mechanic hasn't done one before.

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Current Car:
'91 90 Quattro (AAN Swap)
Past Cars:
'90 Audi 80 Quattro
'92 Audi 80 Quattro


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 Post subject: Re: 1991 90 AAN Swap and more
PostPosted: Wed Apr 28, 2021 10:59 am 
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When I dropped the 3B into my CQ I kept the AC compressor in the original location. So it will physically fit. Turbo Oil Drain will need to be plumbed to the oil pan extension wing. I have no idea about making it work with the other accessories, especially if you are still using the serpentine drive.

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90 CQ (3B, K26/K27 hybrid, VEMS)
07 S8 (Stock)


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 Post subject: Re: 1991 90 AAN Swap and more
PostPosted: Wed Apr 28, 2021 11:55 am 
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Car looks good! Heads up the 034 injector kit is for 7A, the AAN/3B injectors generally aren't as problematic.

I'm working on A/C in my AAN swapped 80 putting the compressor in the stock 80/90/coupe location on the passenger side. As Jonas noted you'll need to move the turbo drain to the pan extension like an S2. I want to keep the serp belt so I'm going to try swapping the AAN clutch/pulley onto the stock 90 compressor and then I'll need to build a custom bracket to get belt alignment right and then likely have to have a custom line or three built because of where I don't think I have room to put the accumulator back in the stock spot.

There's also the condenser to fit, but it looks like that should clear your intake manifold without issue.

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-Shawn C.
2002 B6 A4 3.0l->1.8t+Southbend+VEMS+Rods+HX35=happy daily
1987 5ktq most reliable $500 I've ever spent
1989 200tq Avant- Gone but not forgotten
1986 GTI- longterm project
And one brindle pup in the back


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 Post subject: Re: 1991 90 AAN Swap and more
PostPosted: Wed Apr 28, 2021 2:13 pm 
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Okay awesome. We might have to meet up in Burlington to try to figure out how to fit AC on these things haha.

I just see almost everyone and their mother who swaps an AAN in has the new valve covers and coil packs and whatnot. The stock AAN feels good but it's definitely not much different feeling than a stock 7A. I'd like to see the turbo have a little more affect down low. Sounds like the 034 AAN injector kits + the coil upgrades would be a solid boost to consistency.

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Current Car:
'91 90 Quattro (AAN Swap)
Past Cars:
'90 Audi 80 Quattro
'92 Audi 80 Quattro


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 Post subject: Re: 1991 90 AAN Swap and more
PostPosted: Wed Apr 28, 2021 6:26 pm 
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Wow I'm dumb. The "new valve cover" is just the 20v turbo piece removed and the coil packs directly on top haha. I've got a lot to learn.

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'91 90 Quattro (AAN Swap)
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'90 Audi 80 Quattro
'92 Audi 80 Quattro


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 Post subject: Re: 1991 90 AAN Swap and more
PostPosted: Thu Apr 29, 2021 4:46 am 
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Car looks great, gonna be super fun for sure.

If your AAN feels like a 7A something might be off. The 7A is a fun motor, no doubt, but no comparison to having some boost. Make sure you don't have a boost leak somewhere. Do you have a gauge to tell you how much boost you're making? An AAN that isn't making any boost will feel pretty much exactly like a 7A.

For stock level boost I think the factory ignition coils are fine. They are just expensive to replace, and the TFSI coil packs are super cheap, so that is part of the reason. Also red is cool.

Lastly, for the 034 injector kit, are you talking about upgraded injectors/chip sets or the 7A Injector kit?

You don't need the 7A kit because the AAN/3B fuel rail already works with Bosch-style injectors.
Upgrading injectors won't do anything if you don't have the boost and fuel delivery map to match, so probably not the first thing I'd do.

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90 CQ (3B, K26/K27 hybrid, VEMS)
07 S8 (Stock)


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 Post subject: Re: 1991 90 AAN Swap and more
PostPosted: Thu Apr 29, 2021 5:17 am 
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jonas-k wrote:
Car looks great, gonna be super fun for sure.

If your AAN feels like a 7A something might be off. The 7A is a fun motor, no doubt, but no comparison to having some boost. Make sure you don't have a boost leak somewhere. Do you have a gauge to tell you how much boost you're making? An AAN that isn't making any boost will feel pretty much exactly like a 7A.

For stock level boost I think the factory ignition coils are fine. They are just expensive to replace, and the TFSI coil packs are super cheap, so that is part of the reason. Also red is cool.

Lastly, for the 034 injector kit, are you talking about upgraded injectors/chip sets or the 7A Injector kit?

You don't need the 7A kit because the AAN/3B fuel rail already works with Bosch-style injectors.
Upgrading injectors won't do anything if you don't have the boost and fuel delivery map to match, so probably not the first thing I'd do.


I think it's just been a long time since I was in a 7A haha. So it maybe just doesn't feel too quick. It is definitely boosting, although I don't have a boost gauge. I'm getting all the pleasant turbo whirls and definitely boosting. The pieces I was considering from 034 were here:
https://store.034motorsport.com/chip-tu ... e-164.html
https://store.034motorsport.com/034moto ... coils.html

Not sure if I'd need to add actual coils, but as you said, the stock AAN ones might be fine? https://store.034motorsport.com/coil-2- ... -715f.html

It's (seemingly) very much an OEM AAN motor, so I figured a chip and the updated coil harness would be a good place to start.

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Current Car:
'91 90 Quattro (AAN Swap)
Past Cars:
'90 Audi 80 Quattro
'92 Audi 80 Quattro


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 Post subject: Re: 1991 90 AAN Swap and more
PostPosted: Thu Apr 29, 2021 7:47 am 
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Ah, I see.

Those would both be fine. Should make for a screamer. Lots of good info here about limits of the k24 turbo, factory EM, etc and how far you can go before those need to be upgraded.

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90 CQ (3B, K26/K27 hybrid, VEMS)
07 S8 (Stock)


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 Post subject: Re: 1991 90 AAN Swap and more
PostPosted: Thu Apr 29, 2021 8:10 am 
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jonas-k wrote:
Ah, I see.

Those would both be fine. Should make for a screamer. Lots of good info here about limits of the k24 turbo, factory EM, etc and how far you can go before those need to be upgraded.


Yea that is what I was figuring. If I really wanted to boost up power, I'd have to get a VEMS and a bigger turbo and all that jazz. Not looking to do any of that yet. Probably not ever for this car. I plan on it being my daily and using it in the winter, so I don't want it 300+ hp. It's still on the 01A transmission too, so not looking to wreck that thing. I figure some tasteful fueling and ignition upgrades for the stock setup is a good starting point. Makes for more controlled throttle steering in the snow rather than just spinning tires like nuts. Hoping it gives more usable torque and a little more oomph, but nothing crazy.

Now to find a clean, not destroyed shift boot leather.. haha

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Current Car:
'91 90 Quattro (AAN Swap)
Past Cars:
'90 Audi 80 Quattro
'92 Audi 80 Quattro


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