A4 1.8t slow build

[Moniek88]

Hi guys.
I'm new here and hopefully will have a chance to share my project with you.
It is a standard b5 1.8t quattro. The condition of the car was not the best when I got it of my mate. It was sitting there for an year before I started to refurbish it last year part by part.
As everything cost and takes time is a very slow process also I'm a single father and working 30h per week.
Last year started to take rear suspension apart as the subframe wasn't looking the best.
I'll add some photos of my work and the rest of work when I get to the PC.
Regards Andrew

 

[Steve b5 quattro]

Great, looking forward to seeing the build.
I'm in the same boat, very slow build
Bought mine 3 years ago now, I've a shed load of parts to go on but time is my biggest challenge.
Done slow but done right

Sent from my SM-G950F using Tapatalk

 

[Moniek88]

Hi, can I add photos larger then 2mb?

 

[Moniek88]

I managed to do it the rest will follow now

 

[Moniek88]

Subframe sandblasted, epoxi primer and black paint, new stiffer bushes

 

[Moniek88]

Tank and the shield done and ready to go

 

[Moniek88]

Ill be here for over a week adding all those photos in

 

[Steve b5 quattro]

Tasty work pal

Sent from my SM-G950F using Tapatalk

 

[Moniek88]

The rear end of the floor prepared for suspention.
Rear brakes out of s4 b7 300mmx22mm, I`ve made the distance for them.

 

[Moniek88]

New bearings, calipers refurbished, valve cover in chrome, diff mount all cleaned up with new bushes, upper wishbone all done

 

[Moniek88]

Most exiting parts so far

 

[Moniek88]

All rear suspension apart of shock mounts ready to go

 

[Steve b5 quattro]

Quality work

Sent from my SM-G950F using Tapatalk

 

[Moniek88]

Quality work

Sent from my SM-G950F using Tapatalk

I have got the time Steve, specially with all of this going on now, I have ordered the rear shock mounts, there is a guy in Poland that manufacturer them from 4mm steal, Ill let you know if is worth the price.

 

[Moniek88]

Sort of up to date now, working currently on differential, new seals and oil, cover will stay aluminum effect and the rest will be black.
Propshaft, all blasted down painted, new bearing.
Driveshafts sanded down, old cv joints for now as they are ok.
Handbrake bracket purple as my mate complained that is all black or gray, it won`t be visible tho.

 

[desertsage]

Wow, good job with your build! I just finished rebuilding my entire rear suspension plus brakes, axles, final drive output flange seals,etc but stopped short of actually removing my rear subframe. With everything out I was able to reach the lower surface, edges and a little of the top with scraping, sanding and paint, but really should have removed it completely as you did for a complete refinish and rustproofing job. Next time!

 

[Moniek88]

Wow, good job with your build! I just finished rebuilding my entire rear suspension plus brakes, axles, final drive output flange seals,etc but stopped short of actually removing my rear subframe. With everything out I was able to reach the lower surface, edges and a little of the top with scraping, sanding and paint, but really should have removed it completely as you did for a complete refinish and rustproofing job. Next time!

It makes sense to do it properly mate, the subframe was the last piece that I paid for blasting, since then I got couple of my one blasters. Now slowly looking to master powder coating.
Done a lot to the differential last night, today it will be all ready to go back on the car, will post some photos when is completed. Regards

 

[Moniek88]

Differential all done, fresh paint, new seals, new drain plugs, stainless bolts.
As soon the rear shock mounts arrive I'll put everything together, make new brake lines, test the rear brakes upgrade. If it all be sound I can then crack on with the front end.

If anyone got calipers brembo 18z I'm looking for a set, can be in a poor condition, I'll refurbish them if needs to be

 

[desertsage]

Ah, your work all looks so great. It's very inspiring!

Oh man, those rear shock mounts! Mine were rusted so badly that it is a wonder that they had held together at all. There were only tiny bits of metal still holding that upper bolt bushing. I wondered if the new ones I'd purchased from Audi would hold up any better over the years than the originals and had considered adding additional coats of paint to them. I ended up installing them as is with the factory powder coating, hoping that the new versions were somehow more rust resistant than the originals.

Looking forward to more photos of your build!

 

[Moniek88]

They have arrived however it is to narrow for the shock bush to go in. I've contacted the manufacturer and they will replace it. This time around I can pick the colour as they not on the lock down anymore.
Unfortunately I'll have to wait another couple of weeks, that will ruin my plans but what can you do...

 

[desertsage]

Oh dang! Sorry about your setback. I only installed Bilstein HDs in mine without a problem but hadn't thought about a conflict there with coil-overs. It's nice that the manufacturer will be able to mod it for you.

 

[PaulJC84]

I saw these mounts on FB and thought they looked interesting. That's annoying they do not fit your KWs. I have the same shocks, they have held up really well other than the springs which are rusty now. But the shock bodies look brand new after cleaning.

 

[Moniek88]

I saw these mounts on FB and thought they looked interesting. That's annoying they do not fit your KWs. I have the same shocks, they have held up really well other than the springs which are rusty now. But the shock bodies look brand new after cleaning.

Those mounts where designed and build for b5 quattro, however something when wrong with welding or they took it off the welding bracket too early. They have left Poland now so any day now. They got a lot of extra strength, made out of 4mm sheets, sounds good but lets wait until they arrive.
Apologies for any spelling errors guys, I`m doing my best, English is my second language.

 

[Moniek88]

I saw these mounts on FB and thought they looked interesting. That's annoying they do not fit your KWs. I have the same shocks, they have held up really well other than the springs which are rusty now. But the shock bodies look brand new after cleaning.

They meant to fit as they made for b5 quattro however something went wrong with welding or they have took it too early of the welding bracket and it polled the material.
They sounds pretty good as they made out of 4mm sheets adding extra strength needed with coilovers,
I`ll let you guys know my opinion about them as soon they arrive.

Apologies for any spelling errors, doing my best, English is my second language

 

[EricTQS7]

They meant to fit as they made for b5 quattro however something went wrong with welding or they have took it too early of the welding bracket and it polled the material.
They sounds pretty good as they made out of 4mm sheets adding extra strength needed with coilovers,
I`ll let you guys know my opinion about them as soon they arrive.

Apologies for any spelling errors, doing my best, English is my second language

Were your mounts not repairable? I installed KW's on my TQS aswell and the mounts were a bit rusty but could still be saved and look brand new now but it is annoying had to wait 2 weeks longer for the coilovers to go on due to the mounts. You will love these KW's tho, mine are only the V1's and they feel great, smooth when u want them to be smooth and hard when you're going past a corner really fast, pretty much no body roll. I replaced all front arms, bushes, bearings, engine mounts etc and running F1 Supersport tires it transformed the handling but i have to do the rear suspension now aswell. Would you be so kind and let me know the part numbers for the bushes for the rear top arms and rear subframe? Did you polybush them? Cheers

Odesláno z mého SM-N960F pomocí Tapatalk

 

[Moniek88]

Were your mounts not repairable? I installed KW's on my TQS aswell and the mounts were a bit rusty but could still be saved and look brand new now but it is annoying had to wait 2 weeks longer for the coilovers to go on due to the mounts. You will love these KW's tho, mine are only the V1's and they feel great, smooth when u want them to be smooth and hard when you're going past a corner really fast, pretty much no body roll. I replaced all front arms, bushes, bearings, engine mounts etc and running F1 Supersport tires it transformed the handling but i have to do the rear suspension now aswell. Would you be so kind and let me know the part numbers for the bushes for the rear top arms and rear subframe? Did you polybush them? Cheers

Odesláno z mého SM-N960F pomocí Tapatalk

I could modify them or the top bush on the strut itself but when you pay the money for something that meant to fit it should fit.
I spoke with the mount guys and I know where they went wrong. Top bush on Audi genuine shock or the kw3 are the same (~57.6 I think) wide, they have made those using KYB shock as a template. KYB bush is narrower by around 1mm. That they story anyway.

The car is in bits anyway but I wanted to put all the rear suspension together in order to turn the car around in my little car port...

For subframe and the top arm I've used Lemforder bushes. I took all the part number from here mate - https://parts.audistratham.com/a/Audi__A4/__6421797/REAR-SUSPENSION/F257150.html

Very useful database there.

The mounts have left poland now so shouldn't be long now.

 

[EricTQS7]

I understand the issue with the mounts, it is very stressful paying for something and then finding out its not been done correctly, especially when its something from another country and u have to wait a lot longer then. Would you mind me asking howmuch did you pay for them mounts? I got mine repaired for £120 and they're like new.

And thanks mate, very usefull site. I used 7zap but now they changed it its hard to find out the exact model i need, even worse for my Cupra R as they now only show Toledo but not a Leon, was such a good database.

Odesláno z mého SM-N960F pomocí Tapatalk

 

[Moniek88]

Those after taking the back plate off and sandblasting it looked like a sieve, that will never be as strong as new so I've found those.
You are looking for 530PLN each what worked out around £100 each.
I think there are worth the money so far but let's wait until there are actually on the car.

 

[EricTQS7]

Those after taking the back plate off and sandblasting it looked like a sieve, that will never be as strong as new so I've found those.
You are looking for 530PLN each what worked out around £100 each.
I think there are worth the money so far but let's wait until there are actually on the car.

Wow those look really bad, would replace them if i was you aswell. Mine didnt look too bad at all but i wanted to repair them so that they dont get worse. £100 each for new is a good price, they're extremely hard to get used and new original cost way too much if u can even get them.

Will definitely keep on following your thread mate, good luck with the build.

Odesláno z mého SM-N960F pomocí Tapatalk

 

[desertsage]

This site has been very helpful for part numbers and reference for ordering and searches. This page is for my '97 B5 so adjust for your own, of course.

https://audi.7zap.com/en/usa/audi+a4+s4+avant+quattro/a4q/1997-157/5/505-505030/

https://audi.7zap.com/en/usa/audi+a4+s4+avant+quattro/a4q/1997-157/

 

[Steve b5 quattro]

Wow, very impressed.

Every detail is looking good.
Are they factory bushes in rear suspension?
I have same problem with my rear suspension that I need to get fixed asso.
Could you let me know where you got the shock mounts too, thanks....

Sent from my SM-G950F using Tapatalk

 

[Moniek88]

Wow, very impressed.

Every detail is looking good.
Are they factory bushes in rear suspension?
I have same problem with my rear suspension that I need to get fixed asso.
Could you let me know where you got the shock mounts too, thanks....

Sent from my SM-G950F using Tapatalk

I got them form Allegro.pl but they not there any longer.
I won`t recommend this company at all, waste of time and money.
They meant to make new set as this first one didn't fit.
What they have done i out of order.

As you can see on the photo what have they done. Guy on the phone said that the car will rust away before this mount when i mentioned lack of paint and the quality of fabrication. I end up keeping both sets and will fabricate the first set on my own.

 

[Moniek88]

As I got the mounts now the rear end is getting together slowly, just need top and bottom shock bolts and some other details.
The s4 b7 calipers and rotors are on now however the brake pipes are only temperately till i get one made to fit.
In order to fit the handbrake cable I have took the cable bracket from the old calipers, the old handbrake cables have the adjustment sized but seams like it will adjust ok. Ill get some new cables and find out. I could only find s4 b7 rear upgrades but using only the rotors, I have install calipers as well.

The front bush for differential came back refurbished. Bit of blasting and it will look good again.

 

[Moniek88]

I have cracked on with the engine service.
New spark plugs, cam belt kit, all the other belts and pulleys etc, water pump. The seals of course as well. I have tried to make a few bit looking fresh.

You can see that the car had developed self lubricating system

New breather pipe went on.

Did a bit of cleaning there, thanks to the oil everywhere the front subframe isn`t looking bad at all.

 

[Moniek88]

Is looking a bit better now, ordered some ss bolts to replace thew rusty ones.

Also the rocker cover been fitted, there was additional vent fitting on the back, oil sump plug fitted fine after tapping the hole

AC will stay until next year, Ill be preparing engine for some power. Till then it will stay.

I have started the floor and middle console underneath, something i dont enjoy at all but got to be done.

4 coats of epoxi primer, Ill seal all the places where sheets are joined before applying fervor paint.
I was thinking of using pick-up truck bedding paint to protect all the underneath, what you guys think of it?

 

[Moniek88]

I'm looking for a couple of days now for a pinout diagram for ECU plug for ajl.
I need to know what pin on the plug is responsible for signal from cam position sensor. Have anyone got any links or diagrams themselves? Cheers

 

[durandal]

Took a pic of what I think you're after, I have the AWM (2001) and this 2000+ diagram has been useful.

#155 in diagram below (near lower left) is the cam position sensor

I have the AWM (170hp) and your AJL (180hp) probably came after?

Edit:
Looks like this is AEB head with the AJL, here is the diagram for pre 2000. Hope this helps.

http://driver.durandal.org/assets/project_a4/pre_2000_a4_18t_wiring.JPG

 

[Moniek88]

Took a pic of what I think you're after, I have the AWM (2001) and this 2000+ diagram has been useful.

#155 in diagram below (near lower left) is the cam position sensor

I have the AWM (170hp) and your AJL (180hp) probably came after?

Edit:
Looks like this is AEB head with the AJL, here is the diagram for pre 2000. Hope this helps.

http://driver.durandal.org/assets/project_a4/pre_2000_a4_18t_wiring.JPG

Thank you. I've found them I autodata software. However I still can't work out the pinout on the plug to ECU.
Basically I got a 00515 fault code, sensor is fine, the car engine runs fine on idle, can't go for a drive as there is no differential at the moment.
So I wanted to check the harness but not sure what pins are related to cam position sensor....

 

[Moniek88]

Also I'm slowly looking to do me3.8 to me7.5 swap. I know all the bits I need for it however I think getting a whole car would make sense, I could have a spare engine etc. at the same time.
What I dont know is what exactly car came with me.7.5 and what mode it will be the best for me?

 

[Moniek88]

So, I did my research.
I think I can use any AWT, APU or ANB.
It could be in a A4 b5, passat b5, a6 c5 or superb mk1.
Correct me if I'm worng please.
Cheers