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5 minute(s) of a 30 minute read
9-7-2010
I was able to get the engine compartment cleaned up a bit more this weekend. Pulled the A/C lines out that were already cut and just hanging in the compartment. Pulled the booster and booster brackets. Brackets will go off to be powder coated, and the booster is going to get painted satin black.
Also, I thought I would mention a bit of a hassle I ran into when I first got the motor, and the way that I was able to resolve it. When I first looked at the swap, I didn't notice anything out of the ordinary with the mounting of the K04, I made sure it had the factory manifold, and figured that was good enough. Well, when I got the car home, and looked closer, I found myself looking at this (is this OEM? Obviously not).
Assuming the worst, I pulled one of the huge bolts out... I actually thought someone had drilled and tapped out the turbo to these huge bolts. I even thought they might have been SAE instead of metric. So, instead of doing the smart thing and checking to see the size of the bolts, I started looking for a new K04, as I figured this hoaky setup would easily result in the turbo loosening over time, etc. (especially with those soft brass spacers that you can see under the bolts.
So, long story short, after searching high and low, I came across this thread. Basically, the K04-022 has threaded inserts that can come out when the turbo is pulled. The guy that I got this swap from, had the inserts pull out, and they got jacked when pulled, so he just put 14x1.5 bolts in the place, with the hoaky spacers you see. In the end I can't be too tough on him, as Audi makes no mention of these, and they cannot be purchased anywhere, unless a machine shop makes them (like the guy did in the thread linked above).
Here is a pic of the inserts that I bought:
The studs, washers and nuts to get this back to an OEM setup is like $100 retail (YIKES), so I am working on some better pricing and hoping to have all of that hardware by the end of this week.
I'm also trying to un-Jerry-rig the turbo coolant hose setup that was on the motor. I know it worked, but he basically took a factory K04-022 hard coolant line, and un-bent/re-bent/contorted it to make it work. So, it basically looks like a garden hose with a bunch of golf balls stuck inside of it.
I contacted Pro-Imports, company that used to sell the K04-022 install kits for the mk4 chassis, and even though they don't sell the kits anymore, they still had the fittings and hi-temp hose for the coolant lines. Hopefully that will be here this week as well.
Back to preparing the engine compartment.... I pulled the clutch cable and throttle cable, and compared the Eurovan clutch cable with the factory clutch cable, and its going to work perfectly. I also compared the 034 throttle cable with the factory cable, and as you see below, the end of the 034 throttle cable has a ball instead of the dog leg (which matches the 034 gas pedal that came in the drive by cable kit I got with the 034 engine management setup). I'll get some pics of the drive by cable setup, and how it mounts in another week or so.
I was hoping to do a test fit of the engine/trans and all mounts this week, but it looks like I won't get my trans back from the LSD install, or the mounts back from WRD until next week (bummer).
Going to put the wheels back on and pull the car out to get pressure washed this week. Hopefully it will clean up nicely. Here is what it looks like now:
Finally, here is a pic of the attrocious front valence. This will get fixed at the body shop in the coming weeks (along with the holes in the rear area below the tail lights), and some other small stuff.
