I will be joining the 20v ranks by finally being able to build something I have wanted for almost 20 years now - a wonderfully running, beautiful turbo'd 4000 Quattro. I'll spare the story and give the highlights: found my third-time-a-charm 4000 last month in NH ('87 Quattro, Alpine White, script interior, potential 'special build', 79k on odo [not believed] but solid and very clean) and then a less-than-stellar '91 200 20v donor the same week. Pictures are attached.
As I finish my project plan, I am starting the build thread with two things: 1) project intent; and 2) the current build sheet, open for opinions. Overall, I am building this as if Audi built a UrQ sedan, if you will. Here is what I'm after:
Project Intent
With that in mind, below is my current build sheet. The notes within ( ) is the planned source while anything with '?' are items I am still researching or debating. I have not completed my review of all the MG or Project Pad threads on similar builds yet, so, any of you been-there-done-that experts, please chime in. I will be updating this post as we move along, hoping it will become a solid reference for any others following this path. This will not be a fast build, as I want it done well.
Block / head / cooling / accessories
Turbo / intake / exhaust
Stay with stock k24 turbo (initially)
- Replace any hoses?
- Replace/upgrade turbo oil lines? (034)
- w/ feed & drain line gaskets
Do anything to wastegate?
- Replace wastegate diaphragm (034)
- w/gasket
Exhaust manifold - Rs2 evo (EFI)
- w/ replaced shorter exhaust studs (034)
Full 3" exhaust back (custom)
- Or dual?
Stock 3b intake, should handle hp
- w/ new filter
Stock UrQ intercooler as core for APIKOL UrQ upgraded
- sits low and will require minor trimming
Upgrade MAF?
EFI / ECU / fuel management
Convert to AAN coils (EFI)
- New plugs
AAN or 3b ECU?
- Potentially go VEMS plug n play/standalone down the road
What injectors?
- Clean and balance any used
Bosch 044 fuel pump
- How to wire?
- How to connect fuel lines?
Adjustable FPR (034)
Replace fuel filters
Changes to fuel rail or lines?
- All new fuel lines?
Run hall sender or cam position sensor?
- Machine head if factory CPS w/bracket
Tranny
Stick with 016 trans
- Locked center & rear setup (initially)
- Maybe go to torsen rear later
- Maybe 01e down the road
Replace trans mounts (034)
Replace throw out bearing (034)
Rebuild shifter linkage
Rebuild syncro while out?
Southbend? 3b clutch
Replace shifter bushings
Replace brake rack while motor is out?
Suspension / brakes
Replace front coils due to added weight of 3b?
Subframe bushings (034)
Rear diff mount (034)
Replace Struts?
- w/ strut mounts (034)
Front sway bar bushings, all (034)
Front sway bar (4 cylinder, fwd 4k bar?)
Rear sway bar (2b or front 4kq)
Shock tower brace (wiechers-sport.de)
As I finish my project plan, I am starting the build thread with two things: 1) project intent; and 2) the current build sheet, open for opinions. Overall, I am building this as if Audi built a UrQ sedan, if you will. Here is what I'm after:
Project Intent
- - Reliable and durable w/ near OEM quality and look
- All functionally retained, except a/c (initially)
- Smooth, early power delivery - city driven, will never be tracked
- Targeting high-200hp with ability for high-300s upon turbo and ECU upgrades
- Built so motor is only pulled again if needing to be rebuilt
With that in mind, below is my current build sheet. The notes within ( ) is the planned source while anything with '?' are items I am still researching or debating. I have not completed my review of all the MG or Project Pad threads on similar builds yet, so, any of you been-there-done-that experts, please chime in. I will be updating this post as we move along, hoping it will become a solid reference for any others following this path. This will not be a fast build, as I want it done well.
Block / head / cooling / accessories
- Have block checked for warpage (Area Auto Machine)
- Have it dipped cleaned?
- Replace freeze plugs?
Have cylinders checked for out-of-round and taper
Replace/upgrade rods (EFI or 034)
- w/ rod bearings
Reuse pistons if good
- OEM replace if needed
Polish and balance crank
- w/ main bearings
- w/ new seal
- w/ new crank bolt?
Replace oil pump
Hot tank oil pan?
Balance 3b flywheel (local)
Rebuild head (Area Auto Machine)
- ARP bolts
- New MLS gasket (034)
- Only replace valve hardware if needed
- Port/polish?
7a exhaust cam (used)
Stock 3b intake cam or AAN intake cam if going AAN CPS (used)
Replace timing belt
- w/ hardened timing belt gear (EFI)
Replace 4k motor mounts (034)
- w/ new snub mount (034)
Refresh radiator (or replace w/ 2b?)
Replace thermostat w/ full coolant flush
Replace/upgrade coolant hoses
- w/ shorter coolant flange (EFI)
Use 4000 stock accessories
- Need power steering adapter brackets to use the 4k pump
- replace water pump
Stock 3b oil cooler?
Turbo / intake / exhaust
Stay with stock k24 turbo (initially)
- Replace any hoses?
- Replace/upgrade turbo oil lines? (034)
- w/ feed & drain line gaskets
Do anything to wastegate?
- Replace wastegate diaphragm (034)
- w/gasket
Exhaust manifold - Rs2 evo (EFI)
- w/ replaced shorter exhaust studs (034)
Full 3" exhaust back (custom)
- Or dual?
Stock 3b intake, should handle hp
- w/ new filter
Stock UrQ intercooler as core for APIKOL UrQ upgraded
- sits low and will require minor trimming
Upgrade MAF?
EFI / ECU / fuel management
Convert to AAN coils (EFI)
- New plugs
AAN or 3b ECU?
- Potentially go VEMS plug n play/standalone down the road
What injectors?
- Clean and balance any used
Bosch 044 fuel pump
- How to wire?
- How to connect fuel lines?
Adjustable FPR (034)
Replace fuel filters
Changes to fuel rail or lines?
- All new fuel lines?
Run hall sender or cam position sensor?
- Machine head if factory CPS w/bracket
Tranny
Stick with 016 trans
- Locked center & rear setup (initially)
- Maybe go to torsen rear later
- Maybe 01e down the road
Replace trans mounts (034)
Replace throw out bearing (034)
Rebuild shifter linkage
Rebuild syncro while out?
Southbend? 3b clutch
Replace shifter bushings
Replace brake rack while motor is out?
Suspension / brakes
Replace front coils due to added weight of 3b?
Subframe bushings (034)
Rear diff mount (034)
Replace Struts?
- w/ strut mounts (034)
Front sway bar bushings, all (034)
Front sway bar (4 cylinder, fwd 4k bar?)
Rear sway bar (2b or front 4kq)
Shock tower brace (wiechers-sport.de)