Sky InsuranceEM Tuning
Results 1 to 26 of 26
  1. #1
    "Stick a V8 in it!"

    Status
    Offline
    Join Date
    Jan 2008
    Location
    Glenrothes, Fife, Scotland
    Posts
    15,287

    The A4 gets a new heart.

    Well thanks to the assistance provided by Mark (Byzan_A4) we finally managed to get the engine swapped in the A4.

    Pauls old 1.8T went in, along with marks old turbo, a new timing belt and water pump, and a frankenclutch of my making involving a single mass flywheel from an Audi 80 and a clutch from an early A4 TDi. A sprinkling of new gaskets and seals finished it off nicely.

    Took us two days, taking it easy and there were only minor issues. I seem to have damaged the PAS pump trying to beat the pulley off it with a hammer (it now makes a nice rattly noise), and the radiator looks distinctly knackered, so they'll be needing changed at some point soon.

    Didnt take enough pics tbh, but i have the obligatory "engine on the crane" shot:


    As well as a pic of my frankenclutch:


    And for comical effect, a video of just how much play there was in the old DMF:
    http://friesian.lr90.org/gallery2/d/116-1/MOV00402.MP4

    Hopefully this will give the car many more thousands of miles of driving, and shows us a reasonably cheap Single Mass Flywheel setup for a 1.8T that seems to work just fine.

    Enjoy.
    Last edited by aragorn; 1st February 2010 at 14:37.

    2000 A4 1.8T Sport Quattro Avant, Berry Pearl
    2000 A4 1.8T Sport Quattro Saloon, Black-ish
    1997 S4 - PPC £999 Challenge Track Car Build
    TD5 Land Rover Defender build


  2. # ADS
    ADS
    Join Date
    Always
    Location
    Global
    Posts
    Many
     
  3. #2
    Geeman's Avatar
    Low Life

    Status
    Offline
    Join Date
    Mar 2009
    Location
    Grimsby
    Posts
    1,318
    Did you have fun splitting the gearbox from the engine, or was it pretty straight forward?

    I'm assuming there should be no play with the DMF then? What were the symptoms it was displaying?
    NEW 6 cylinder 40mm front springs - £40

    PM me for more info

  4. #3
    Lee Goodall's Avatar
    ..got my head together!

    Status
    Offline
    Join Date
    Oct 2007
    Location
    UK - Midlands
    Posts
    2,223
    Nice one! Loving the hybrid clutch. Should see you to 1000000 miles now with a bit of TLC
    Bit surprised it's not got an extra 4 cylinders firing diagonally though lol.

  5. #4
    "Stick a V8 in it!"

    Status
    Offline
    Join Date
    Jan 2008
    Location
    Glenrothes, Fife, Scotland
    Posts
    15,287
    DMF was showing no symptoms actaully. About 2 months ago it started juddering really badly. Especially when reversing, felt like there were boulders under the wheels it was that bad, then one day it stopped and drove normally again. No idea how much play there should be, but it seemed like waaay too much to us!

    The old clutch was gubbed, and i didnt fancy putting a new clutch into a knackered flywheel, or spending 300 on a new DMF, so i got the TDi unit for 35 from ebay and pored over the parts books until i found a matching clutch, which is from a 95-96 A4 TDI. Some time in 96 they converted the TDi's to dual mass as well, so it needs to be the early one. You could use the clutch from the 80 TDi, but i suspect the A4 one is a little stronger, as the pressure plate is a different part number, and given the 80 engine only makes 75hp, i figured the A4 one was a better choice.

    Splitting the box was easy (once we found that one last bolt), getting it back together took a bit of jiggling wedging levering and shaking though.

    2000 A4 1.8T Sport Quattro Avant, Berry Pearl
    2000 A4 1.8T Sport Quattro Saloon, Black-ish
    1997 S4 - PPC £999 Challenge Track Car Build
    TD5 Land Rover Defender build


  6. #5
    jcb
    6th Gear

    Status
    Offline
    Join Date
    Sep 2005
    Location
    uk
    Posts
    4,077
    nice one. have all this fun to come!
    that flywheel is comedy. Its meant to move about 3/4" when moved by hand!!

  7. #6
    "Stick a V8 in it!"

    Status
    Offline
    Join Date
    Jan 2008
    Location
    Glenrothes, Fife, Scotland
    Posts
    15,287
    I suspect when it started juddering a few months ago something has jammed, and its finally unjammed by breaking/bending whatever is inside. I'm just amazed it drove normally!

    When i get a chance i'll try and get the DMF off the old engine and see if its obvious whats wrong with it.

    Lee: The V8 is sat in the garage, infact mark was using it as a toolbox stand, but while tempting this car needs to stay sensible! I'm having to fight the urge to find some nice wheels and lower it a little. Anything i spend on the A4 is taking funds away from making progress on the land rover. Theres enough little bits and pieces required on the car as it is. Rad, PAS pump and rear wiper motor all need fixed, its needing some tyres soon too.

    2000 A4 1.8T Sport Quattro Avant, Berry Pearl
    2000 A4 1.8T Sport Quattro Saloon, Black-ish
    1997 S4 - PPC £999 Challenge Track Car Build
    TD5 Land Rover Defender build


  8. #7
    Geeman's Avatar
    Low Life

    Status
    Offline
    Join Date
    Mar 2009
    Location
    Grimsby
    Posts
    1,318
    Quote Originally Posted by aragorn View Post
    I'm having to fight the urge to find some nice wheels and lower it a little.
    You, lowering it? Nooooo...!

    Quote Originally Posted by aragorn View Post
    ...its needing some tyres soon too.
    I'm assuming Tractor tyres... right?

    NEW 6 cylinder 40mm front springs - £40

    PM me for more info

  9. #8
    "Stick a V8 in it!"

    Status
    Offline
    Join Date
    Jan 2008
    Location
    Glenrothes, Fife, Scotland
    Posts
    15,287
    Yep! I dont mind a little drop.

    http://www.lr90.org/gallery2/main.ph...serialNumber=4

    That for example is perfectly fine. Nice even arch gap all the way round.

    And yes nice 205/55R16 tractor tyres. Unless i fall over some Boleros for 25p.


    2000 A4 1.8T Sport Quattro Avant, Berry Pearl
    2000 A4 1.8T Sport Quattro Saloon, Black-ish
    1997 S4 - PPC £999 Challenge Track Car Build
    TD5 Land Rover Defender build


  10. #9
    Lee Goodall's Avatar
    ..got my head together!

    Status
    Offline
    Join Date
    Oct 2007
    Location
    UK - Midlands
    Posts
    2,223
    Quote Originally Posted by aragorn View Post
    Lee: The V8 is sat in the garage, infact mark was using it as a toolbox stand, but while tempting this car needs to stay sensible! I'm having to fight the urge to find some nice wheels and lower it a little. Anything i spend on the A4 is taking funds away from making progress on the land rover. Theres enough little bits and pieces required on the car as it is. Rad, PAS pump and rear wiper motor all need fixed, its needing some tyres soon too.
    Sell the Land Rover and make a beast of an A4.. simple! lol

    Only joking.. glad to see you've got the engine and turbo sorted on the old girl though

  11. #10
    rasA4's Avatar
    Four Rings Mafia Specialist

    Status
    Offline
    Join Date
    Apr 2003
    Location
    Deep
    Posts
    3,096
    well done guys!

    Bee Five | A4 2.4 V6 30V Tip SE | OEM S4 Alloys | S4 Bumper | S4 Leathers | HIDs| Billy's & Bachs | I Aint new to this | Hit the THANKS Button if my post is any use |Thanks!

  12. #11
    andybnwc's Avatar
    4th Gear

    Status
    Offline
    Join Date
    Jun 2007
    Location
    lancashire
    Posts
    744
    have you got your own crane or did you rent it?
    99 Nogaro S4 now black bonnet and roof,blackdiamond discs and pads,Hybrid K04 with uprated actuators ,Rs4 clutch custom lightweight flywheel, esp lightweight pulley set ,Rs4 intake pipes ,rs4 mounts ,full samco hose set,F-hose delete ,BMC carbon induction, full stainless exhaust with de cat pipes, custom chip,18"ultra lights,LED rear clusters,6000k xenons ,LED sides,KW coilovers,powerflex bushes ,Boost guage in pillar pod,isotta steering wheel and gearknob,B&M short shifter

  13. #12
    Broken Byzan's Avatar
    Photographic Moderator

    Status
    Offline
    Join Date
    Apr 2004
    Location
    Cardiff, United Kingdom
    Posts
    12,500

    My Social Networking

    Follow Broken Byzan On Twitter Add Broken Byzan on Facebook Add Broken Byzan on Google+ Visit Broken Byzan's Youtube Channel
    He bought it, as he will need it for putting the V8 in the landy amoungst other things

  14. #13
    Broken Byzan's Avatar
    Photographic Moderator

    Status
    Offline
    Join Date
    Apr 2004
    Location
    Cardiff, United Kingdom
    Posts
    12,500

    My Social Networking

    Follow Broken Byzan On Twitter Add Broken Byzan on Facebook Add Broken Byzan on Google+ Visit Broken Byzan's Youtube Channel
    I was impressed by the franken clutch, works well and is soooooo progresive and light. It's a shame about that noisey PS pump, its ruining a perfectly good swap/upgrade.

    It was also good to drive the car with some boost as the WG penny had fallen off the original K03 as suspected,what was suprising was the condition and location of the penny. We expected to find it in the CAT,not inside the turbine housing blocking the exhaust outlet.

    I did however find a use for the V8.......

  15. #14
    "Stick a V8 in it!"

    Status
    Offline
    Join Date
    Jan 2008
    Location
    Glenrothes, Fife, Scotland
    Posts
    15,287
    haha excellent, didnt realise you'd snapped that one!

    2000 A4 1.8T Sport Quattro Avant, Berry Pearl
    2000 A4 1.8T Sport Quattro Saloon, Black-ish
    1997 S4 - PPC £999 Challenge Track Car Build
    TD5 Land Rover Defender build


  16. #15
    Broken Byzan's Avatar
    Photographic Moderator

    Status
    Offline
    Join Date
    Apr 2004
    Location
    Cardiff, United Kingdom
    Posts
    12,500

    My Social Networking

    Follow Broken Byzan On Twitter Add Broken Byzan on Facebook Add Broken Byzan on Google+ Visit Broken Byzan's Youtube Channel
    You need to get that WG penny pic up.

  17. #16
    LPG Abuser & have VAGCOM

    Status
    Offline
    Join Date
    Aug 2005
    Location
    Essex
    Posts
    171
    I wish I had the time to check for parts, I went for the quickest and most painful way...dmf...500 DMF and clutch kit

    I was told that you will expect alot of judder if you use a new cluch plate on an old DMF. BTW I hope you used new flywheel bolts!

    Mine lasted for 150,000 miles and was pretty sha**ed, down tothe rivets...

    I have kept items for posterity or if someone wants to measure them.....

    Michael

  18. #17
    jcb
    6th Gear

    Status
    Offline
    Join Date
    Sep 2005
    Location
    uk
    Posts
    4,077
    Ha. I laugh in the face of sound advice!

    running a second hand stage 3 south bend clutch on my original Dual Mass (over 110k so far) and original flywheel bolts reused! it was a stop gap and needed to be done sharpish.

    that said, doesn't judding and there was way less float on my DMF compared to the video above.!

  19. #18
    "Stick a V8 in it!"

    Status
    Offline
    Join Date
    Jan 2008
    Location
    Glenrothes, Fife, Scotland
    Posts
    15,287
    Rallyman: TBH i didnt have 500 spare. I baught a clutch from Siena with the engine which turned out to be fubar, so that was 100 wasted, and the 400 the local factors quoted for a single mass conversion was out of my budget so i started looking at other options. This cost me 130+vat for the Sachs clutch kit and 35 for the flywheel, so pretty reasonable i recon.

    I reused the TDI bolts with a dab of locktite. They're shorter than the DMF ones and luckily they came with the flywheel.

    This is on 193k, so it'll be interesting to see the condition of the clutch plate itself. I'll get it out later in the week when i have some time.

    2000 A4 1.8T Sport Quattro Avant, Berry Pearl
    2000 A4 1.8T Sport Quattro Saloon, Black-ish
    1997 S4 - PPC £999 Challenge Track Car Build
    TD5 Land Rover Defender build


  20. #19
    2000 a4 1.8tqs-yellow

    Status
    Offline
    Join Date
    May 2008
    Location
    perth
    Posts
    1,197
    When i did my clutch at about 175k i just stuck a clutch kit on the old flywheel and used the old bolts etc. Would have like to get a single mass one but couldnt afford it at the time.

  21. #20
    LPG Abuser & have VAGCOM

    Status
    Offline
    Join Date
    Aug 2005
    Location
    Essex
    Posts
    171
    It was cheque book repairs, and not much time to replace it, I went from a job where I didnt use my car to a job that I drive 40 miles, so I needed it to be done with the least agro as possible! I was also changing the box as well (I had buggered 4th gear). I would have liked to fit a SMF but all the factors / shops I rang said that there wasnt a kit for the QTS! Doh.... I wish this thread with parts had been written ages ago! LOL Would be interesting to see if the plates are the same size
    Im glad I diY'd it the garages would have charged me a fortune removing all the mud from the spline bolts!
    The only reason I bought new FW bolts is that I have seen a FW come loose on a rally car..... not a nice sight...

  22. #21
    2000 a4 1.8tqs-yellow

    Status
    Offline
    Join Date
    May 2008
    Location
    perth
    Posts
    1,197
    That clutch you made up is it the early a4 tdi cover on it and what dia disk is it?

  23. #22
    "Stick a V8 in it!"

    Status
    Offline
    Join Date
    Jan 2008
    Location
    Glenrothes, Fife, Scotland
    Posts
    15,287
    Its a complete early TDI clutch kit, i can get you the sachs number if you want? i ordered it from AllGermanParts.

    228mm plate just the same as the 1.8T, cept because its not dual mass the plate has springs in it.

    2000 A4 1.8T Sport Quattro Avant, Berry Pearl
    2000 A4 1.8T Sport Quattro Saloon, Black-ish
    1997 S4 - PPC £999 Challenge Track Car Build
    TD5 Land Rover Defender build


  24. #23
    2000 a4 1.8tqs-yellow

    Status
    Offline
    Join Date
    May 2008
    Location
    perth
    Posts
    1,197
    Pitty it wasnt 240mm so you could use the s4 clutch.

  25. #24
    "Stick a V8 in it!"

    Status
    Offline
    Join Date
    Jan 2008
    Location
    Glenrothes, Fife, Scotland
    Posts
    15,287
    yeh, there arent any OE 4cyl 240mm flywheels unfortunately.

    Some of the 5cyl motors are 240mm single mass, but they have a different bolt pattern for whatever reason.

    2000 A4 1.8T Sport Quattro Avant, Berry Pearl
    2000 A4 1.8T Sport Quattro Saloon, Black-ish
    1997 S4 - PPC £999 Challenge Track Car Build
    TD5 Land Rover Defender build


  26. #25
    docurley's Avatar
    Moderator

    Status
    Offline
    Join Date
    Dec 2003
    Location
    UK, London, SE
    Posts
    3,841
    Quote Originally Posted by jcb View Post
    Ha. I laugh in the face of sound advice!

    running a second hand stage 3 south bend clutch on my original Dual Mass (over 110k so far) and original flywheel bolts reused! it was a stop gap and needed to be done sharpish.

    that said, doesn't judding and there was way less float on my DMF compared to the video above.!

    That would be 3rd hand as I bought it used from the US and had it in my car for all of 3 weeks, I have to say it felt real good and very OEM.

    Arragon thanks for the sunday night help
    Last edited by docurley; 3rd February 2010 at 08:36.
    Black Audi RS4 2006 Exclusive edition, Black optic option (stock for now)

  27. #26
    jcb
    6th Gear

    Status
    Offline
    Join Date
    Sep 2005
    Location
    uk
    Posts
    4,077
    ah yes, forgot you had it in yours!
    still going strong and abused daily!

 

 

Posting Permissions

  • You may not post new threads
  • You may not post replies
  • You may not post attachments
  • You may not edit your posts
  •  
Single Sign On provided by vBSSO

Garage Plus, Vendor Tools vBulletin Plugins by Drive Thru Online, Inc.

Content Relevant URLs by vBSEO