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JBD's Project CQ - Starting on the 3B Swap...

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 Post subject: Re: JBD's Project CQ - She Runs Again!
PostPosted: Wed May 22, 2019 5:43 am 
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Had some time to myself last night while the wifey was watching the Bachelorette with her girlfriends. So, I installed the Bravo radio (IND-600BT). Love it so far, especially for only $22. One thing I noticed...the Bravo radio accepts the exact style connectors as the OEM connectors. I would have tried to just "plug n play", but the harness had been hacked on before and totally new wires had been run to some of the speakers and they weren't run through the original connectors.

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 Post subject: Re: JBD's Project CQ - She Runs Again!
PostPosted: Wed May 22, 2019 6:01 am 
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jbrentd wrote:
Finally got around to flushing the cooling system, before adding some g13. 1st one on the left was just water. 2nd one, I ran some Prestone flush product for about 5 hrs of driving time.

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Looks like Colonoscopy prep!

:barf:

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 Post subject: Re: JBD's Project CQ - working that punchlist...
PostPosted: Wed May 22, 2019 11:08 am 
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grillage wrote:
jbrentd wrote:
Finally got around to flushing the cooling system, before adding some g13. 1st one on the left was just water. 2nd one, I ran some Prestone flush product for about 5 hrs of driving time.

Image

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Looks like Colonoscopy prep!

:barf:


Sent from my moto g(6) play using Tapatalk

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 Post subject: Re: JBD's Project CQ - She Runs Again!
PostPosted: Fri May 24, 2019 6:20 am 
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grillage wrote:
jbrentd wrote:
Finally got around to flushing the cooling system, before adding some g13. 1st one on the left was just water. 2nd one, I ran some Prestone flush product for about 5 hrs of driving time.

Image

Image


Looks like Colonoscopy prep!

:barf:


:lol: Luckily, I wouldn't know...yet. :o

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 Post subject: Re: JBD's Project CQ - working that punchlist...
PostPosted: Tue May 28, 2019 6:13 am 
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I spent a little time yesterday messing with the coilovers and the ride height. Back when I bought all of the stuff for the DIY coilovers, I decided to go with 7"/300# and 8"/350# Eibach springs. Can't remember exactly why, but I do remember doing a lot of research and reading. So, I'm hoping/betting I made the right choice. However, the guy I sold the car to was the one to finish the coilover project and I think he put the fronts on the rear and vice versa. Currently, the 7" springs are on the front and the 8" springs are on the rear. With them installed like this, I ran out of adjustment in the rear. And there's another 2+ inches of adjustment on the fronts. So, it looks like I'll be swapping these at some point...probably when I install my stash of AKM bushings.

While I'm at it, I would also like to add some helper springs, because the springs are now losing contact with the upper piece when my suspension droops. Does anyone have suggestions on where to buy them? They seem too expensive for what they are...almost as much as the main springs. I assume there's some sort of piece that goes between the main and helpers springs too?

Front set up...
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Rear set up...
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How it sits currently...
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 Post subject: Re: JBD's Project CQ - working that punchlist...
PostPosted: Mon Jun 24, 2019 5:41 am 
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So, it's getting pretty hot here in my part of the world, and I'd like to charge up the A/C system. But I need to sort out why the system won't direct the air to the main vents. I am only getting air out of the defrost vents, currently.

The flaps were recovered several years back. And the system holds a vacuum when I apply a vacuum at the line on the rear of the intake manifold. Vacuum unit "C" on the picture below was repaired when I had it all apart before, but it might be bad again. However, when I look at the diagram, I think my issue is with vacuum unit "B" (the only one that controls air to the instrument panel vents).

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Before I start to rip the dash out, I'd like to do some less intrusive troubleshooting. Is the vacuum distribution thingy (circled in red) easily accessible? I'm wondering if I can get to it by removing the knee bolster?

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 Post subject: Re: JBD's Project CQ - working that punchlist...
PostPosted: Mon Jun 24, 2019 8:50 am 
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jbrentd wrote:

Before I start to rip the dash out, I'd like to do some less intrusive troubleshooting. Is the vacuum distribution thingy (circled in red) easily accessible? I'm wondering if I can get to it by removing the knee bolster?


yes you can...and between the knee bolster and the instrument cluster you could reach the upper vacuum solenoid if you have to replace it.

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 Post subject: Re: JBD's Project CQ - working that punchlist...
PostPosted: Mon Jun 24, 2019 9:55 am 
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audiPete wrote:
yes you can...and between the knee bolster and the instrument cluster you could reach the upper vacuum solenoid if you have to replace it.


Thanks, I'll give it a shot.

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 Post subject: Re: JBD's Project CQ - working that punchlist...
PostPosted: Mon Jun 24, 2019 10:20 am 
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and if you want to add an early B3/Type 44 vacuum heater valve to the heater core hose, you can add the vacuum line from the distribution block.

There's a vacuum distribution block under the dash on the driver's side, right against the airbox. There is a white vacuum line entering the block from the Climate Control vacuum controller, and it has a plug on the opposite side.

Remove the plug, then run the vacuum line from there through the firewall grommet of your choice to the engine side of the firewall.You may have to cut a bit of the heater hose on the engine side to make room for the type 44 heater valve. Connect the heater valve vacuum nipple to the vacuum hose you installed, connect the electrical lead to the temp sensor in the heater valve and you should be good to go.

I used some scrap green rigid vacuum hose from the locking system and a short section of rubber vacuum line to connect the heater nipple to
the rigid vacuum line.

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 Post subject: Re: JBD's Project CQ - working that punchlist...
PostPosted: Sat Dec 28, 2019 4:46 pm 
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It’s been a while, but round 2 of the engine swap has begun. At least the car is running this time around, while I work of cleaning up the replacement.

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 Post subject: Re: JBD's Project CQ - working that punchlist...
PostPosted: Wed Jan 01, 2020 6:45 pm 
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Well, with 7 out of 16 exhaust studs broken, a few stripped Allen head bolts and an unknown number of future broken bolts, I figured it was time to buy one of those fancy bolt extractors. Now to learn how to use it.

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 Post subject: Re: JBD's Project CQ - Starting on the 3B Swap...
PostPosted: Mon Jan 06, 2020 7:13 am 
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Tear-down continues...

Couple questions. 1) Is the oil deflector absolutely necessary? I found about 6 pieces of it in various spots. Neither of my 7As had one. 2) There's a piece blocking the nut that secures the distributor collar. How does that come off?

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Part of the oil deflector
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 Post subject: Re: JBD's Project CQ - Starting on the 3B Swap...
PostPosted: Mon Jan 06, 2020 8:07 pm 
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#2....seems like I center punched it and drilled it on mine Brent. I know it’s so people didn’t tamper with the timing and if I remember right it just goes into the hold down piece.

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 Post subject: Re: JBD's Project CQ - Starting on the 3B Swap...
PostPosted: Mon Jan 06, 2020 8:36 pm 
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czd3my wrote:
#2....seems like I center punched it and drilled it on mine Brent. I know it’s so people didn’t tamper with the timing and if I remember right it just goes into the hold down piece.


Thanks Chuck. Hope your 200 project is going well!

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 Post subject: Re: JBD's Project CQ - Starting on the 3B Swap...
PostPosted: Fri Jan 10, 2020 4:55 pm 
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Dropped off the head with a local reputable machine shop, today, to get it cleaned up, decked and new valve seals. Hopefully, it’ll be crack free and good to go for a long time. It’ll get 7A cams upon re-assembly.

I’ve read about different valve angles that can improve performance, but I have no idea what I would tell the guy, other than the factory specs. Any advice?

I am starting to collect parts...in mass. Upper and lower gasket/seal sets, new brake pads/rotors, caliper rebuild kits, ball joints, engine/tranny/diff mounts, etc, etc. I already have all the AKMS poly bushings waiting on the workbench.

Also looking at what is needed for relocating the batter to the rear. And I need to find a 3B S2 oil filter housing so I can keep the AC compressor in the stock 7A location. If anyone has a lead on one of those, please let me know. I see several on eBay.de, but not sure what the going rate for them are.

My wallet is hurting.

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 Post subject: Re: JBD's Project CQ - Starting on the 3B Swap...
PostPosted: Sat Jan 18, 2020 12:41 pm 
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Didn’t have much time to work in the garage today, so I just did some inventory, cleaning and inspection of the puzzle pieces.

I guess there are two types of 7A AC brackets. Mine is flat on the back and should also serve as a block off plate for the turbo oil port at the block.
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Throttle body boot is a little dry. Debating getting a new one.
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The TIP and Michelin man hose both look good. Ignore the 200’s coolant hose. Just wanted to get a picture of it for comparison to the S2 coolant hose that I still need to find.
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Just notice this oil cooler line. Looks kind of pinched to me. Anyone else agree?
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 Post subject: Re: JBD's Project CQ - Starting on the 3B Swap...
PostPosted: Sat Jan 25, 2020 8:25 pm 
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Picked up the head from the shop yesterday and spent some time in the garage today. Got it torqued down per the ARP instructions. Anyone know if I’ll have to retorque after some heat cycles?

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Had to use my mad welding skills on another rounded off Allen head bolt.

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 Post subject: Re: JBD's Project CQ - Starting on the 3B Swap...
PostPosted: Sat Jan 25, 2020 9:07 pm 
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I remember that tab on the dizzy stopping it from being removed.

Had to use a long screwdriver down from above with a hammer to remove it on my first s2 3b, I sheered the dizzy drive cog when I was on my way home from work resulting in coasting to a stop outside a police station. Funny story is I did the exact same thing with my 20v quattro sport saloon except that coasted further and ended up in the garage on the other side of the police station.

Check the dizzy gear cog, if its plastic which it may be its worth getting hold of the metal replacement one to stop it breaking in the future. Only other issue i've ever seen happening with 3b dizzy/cam is the cog on the end of the cam actually falling off


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 Post subject: Re: JBD's Project CQ - Starting on the 3B Swap...
PostPosted: Sat Jan 25, 2020 11:15 pm 
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jbrentd wrote:
Picked up the head from the shop yesterday and spent some time in the garage today. Got it torqued down per the ARP instructions. Anyone know if I’ll have to retorque after some heat cycles?

Image

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Had to use my mad welding skills on another rounded off Allen head bolt.

Image
Lookin good. When I did the head gasket on my s4 I used arp undercut studs and I have not re torqued them. That was about 20k ago. I think you need to if its not the undercut ones and its probably best practice generally to retorque after the first heat cycling with head studs regardless.

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 Post subject: Re: JBD's Project CQ - Starting on the 3B Swap...
PostPosted: Wed Jan 29, 2020 5:30 pm 
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Speedyurs4 wrote:
Lookin good. When I did the head gasket on my s4 I used arp undercut studs and I have not re torqued them. That was about 20k ago. I think you need to if its not the undercut ones and its probably best practice generally to retorque after the first heat cycling with head studs regardless.

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Thanks. I’ll plan to re-torque.

Spent some time prepping the block for a treatment of POR15 engine paint.

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 Post subject: Re: JBD's Project CQ - Starting on the 3B Swap...
PostPosted: Fri Jan 31, 2020 7:25 am 
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Got a coat of primer in the other night. Finish color will be silver, like I did on the 7A. The POR15 kit I bought last time has enough of some of the products to do 3 or 4 engines. Other products, only enough to do 2.

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 Post subject: Re: JBD's Project CQ - Starting on the 3B Swap...
PostPosted: Fri Jan 31, 2020 10:33 am 
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Definitely re-torque if they are head studs vs bolts. When I re-torqued the ARP studs on my URQ I got a decent turn on them.

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 Post subject: Re: JBD's Project CQ - Starting on the 3B Swap...
PostPosted: Sun Feb 02, 2020 2:45 pm 
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Two coats of silver on the block and the EM is on. I think we’re getting close to yanking the 7A.

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 Post subject: Re: JBD's Project CQ - Starting on the 3B Swap...
PostPosted: Fri Feb 14, 2020 11:21 pm 
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Kind of stuck until I can find time to head to a buddy’s shop to use his sand blast cabinet. I suppose I could put the car on jack stands and start disassembling it.

Managed to get a few small things done.

Serviced the injectors
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Received a couple 3B S2 hoses
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And I feel like I’ve spent a small fortune on new hardware. Got a bunch of Norma hose clamps and this is my second batch of fasteners.
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 Post subject: JBD's Project CQ - Starting on the 3B Swap...
PostPosted: Fri Feb 21, 2020 4:13 pm 
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Sand blasting done on these and a box of misc engine parts. Need to go buy some paint , but they came out looking so nice, I kind of want to leave them raw.

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Last edited by jbrentd on Fri Feb 21, 2020 7:28 pm, edited 1 time in total.

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