B4Q 80-AEB TD04HL-15T; Pump it up

Document and share your build!

Re: B4Q 80-AEB; Fuel Pump relayed! Finally...

Postby ringbearer » Wed Feb 14, 2018 12:49 pm

Powerflex?
User avatar
ringbearer
 
Posts: 1226
Joined: Feb 27, 2013
Location: Nor-Cal

Re: B4Q 80-AEB; Fuel Pump relayed! Finally...

Postby ChrisAudi80 » Thu Feb 15, 2018 5:11 am

alxdgr8 wrote:What did those poly bushings for the inner tie rod come from? Want to replace mine but it doesn't look like anyone makes any.

Oh, they were some PU parts locally made laying around my mechanic's shop. They were close, but had to be machined to be made to fit.

Not Powerflex.

I'm not 100% satisfied with them because the sleeve is not the same diameter as stock, but works for now.
It would be better to use the old steel sleeves and pour PU around them.
96 S6 auto
95 80Q AEB VEMS
ChrisAudi80
 
Posts: 795
Joined: Mar 2, 2013
Location: Bangkok, Thailand

Re: B4Q 80-AEB; Fuel Pump relayed! Finally...

Postby ChrisAudi80 » Wed Sep 19, 2018 6:40 am

Been a long time since updates and plenty of things have happened.

In June, spent a bunch on new EBC rotors and EBC Red Stuff pads all around. Sure makes a difference, but not major. Unless working the brakes hard. They bite harder when warmed up. Got the stock calipers painted red.

Also got some more bushings from AK MS. Front and rear ARB and snub mount.

The fuel tank has been redone. It's actually bolted to the chassis now and has a rollover valve on the vent! Redid the pump set up in the tank and relay wiring. Still not totally happy with it.

All rubber lines have been replaced with AN-6 PTFE hoses and I got a great deal on a Fuelab regulator and billet fuel rail from speedingG60.
All installed now with a 100psi fuel pressure sensor. I have also installed a post-turbo pressure sensor and put the EGT sensor in the same place to use as post-turbo temp sensor. Works great. In full boost, outlet temps can hit up to 180c, IM IAT shows 52c or so.

The stock PCV system has been completely eliminated and got the block breather adapter from IE that connects to an AN-10 push-on going to the catch can.

Coming up is the turbo swap. Bought a SAAB TD04HL-15T, no shaft play. Got a cast EM with T25 flange. Should be good for 300 crank. It'll run out of injector at 3 bar base pressure, but might squeeze by if going to 4 bar which corresponds to 727cc.

Learning more about tuning. The tune is getting better, IMO. No idea where I am on the Dunning-Kruger curve.

However, the clutch now slips. It has 50,000kms of abuse on it so I guess that is OK life span. Will get it redone when the turbo swap is being done.
Attachments
IMG_20180713_172116.jpg
IMG_20180713_172116.jpg (2.92 MiB) Viewed 3692 times
IMG_20180711_164948.jpg
IMG_20180711_164948.jpg (2.44 MiB) Viewed 3692 times
IMG_20180701_180154.jpg
IMG_20180701_180154.jpg (2.42 MiB) Viewed 3692 times
IMG_20180701_175759.jpg
IMG_20180701_175759.jpg (1.56 MiB) Viewed 3692 times
96 S6 auto
95 80Q AEB VEMS
ChrisAudi80
 
Posts: 795
Joined: Mar 2, 2013
Location: Bangkok, Thailand

Re: B4Q 80-AEB; Updates with pics, still ghetto AF

Postby ChrisAudi80 » Sat Oct 06, 2018 7:23 am

Clutch swap and turbo swap in progress. Did a bunch of work this past week.

The rebuilt clutch and pressure plate assembly arrived Friday late, so don't have any pictures of that now, but I do have some of the old clutch plate. As you can see, it was done and left a bunch of shit inside the bellhousing.

The TD04HL-15T is fitted on the EM. The stock oil feed line bolts up, but the hardline had to be shortened 70mm and rotated about 45 degrees.
Coolant feed was relatively easy too. Used a banjo fitting I had laying around for that. Connects right up to the stock hose. Oil and water return is up next week.
One of the AC lines to the dryer was in the way of the oil drain and way too close to the turbine and down pipe. That has been modded too.
You can see what it was like.

Replaced the valve cover gasket as it was leaking.

Pics
Attachments
43246205_336295423608563_2034071454546395136_n.jpg
43246205_336295423608563_2034071454546395136_n.jpg (259.96 KiB) Viewed 3583 times
43146445_953083481563771_5789853332210188288_n.jpg
43146445_953083481563771_5789853332210188288_n.jpg (203.43 KiB) Viewed 3583 times
43307250_175667616696110_8814746945642823680_n.jpg
43307250_175667616696110_8814746945642823680_n.jpg (207.22 KiB) Viewed 3583 times
43178787_2103098879722233_4543505856439779328_n.jpg
43178787_2103098879722233_4543505856439779328_n.jpg (132.64 KiB) Viewed 3583 times
43065484_1917959988281439_6493227649396113408_n.jpg
43065484_1917959988281439_6493227649396113408_n.jpg (194.8 KiB) Viewed 3583 times
96 S6 auto
95 80Q AEB VEMS
ChrisAudi80
 
Posts: 795
Joined: Mar 2, 2013
Location: Bangkok, Thailand

Re: B4Q 80-AEB; Turbo swap time!

Postby ChrisAudi80 » Fri Oct 12, 2018 9:31 am

Today was a big day.

Had the car towed to the exhaust shop. Down pipe was modded to the new turbo and wrapped it. Have a 2.5" V-bad at the bottom now.
Also had them make the compressor to IC pipe and the intake pipe. Plenty of pie cuts.
I will put some kind of air box around it. Eventually.

The shop is a bit rough and not all the welds are pretty, but it works.

Also, pictures.
Attachments
43750752_680773625639153_8883570540976013312_n.jpg
43750752_680773625639153_8883570540976013312_n.jpg (262.82 KiB) Viewed 3494 times
43739006_243121156558392_7164062787541401600_n.jpg
43739006_243121156558392_7164062787541401600_n.jpg (222.86 KiB) Viewed 3494 times
43728818_237743356894230_6839884518669680640_n.jpg
43728818_237743356894230_6839884518669680640_n.jpg (230.53 KiB) Viewed 3494 times
43708924_1924308037664209_7219233124222238720_n.jpg
43708924_1924308037664209_7219233124222238720_n.jpg (247.11 KiB) Viewed 3494 times
43708911_1539944686152009_6647769394569019392_n.jpg
43708911_1539944686152009_6647769394569019392_n.jpg (242.49 KiB) Viewed 3494 times
96 S6 auto
95 80Q AEB VEMS
ChrisAudi80
 
Posts: 795
Joined: Mar 2, 2013
Location: Bangkok, Thailand

Re: B4Q 80-AEB; Turbo swap time!

Postby ringbearer » Fri Oct 12, 2018 12:53 pm

Sweet! Love the pics, no OSHA out your way ;)
User avatar
ringbearer
 
Posts: 1226
Joined: Feb 27, 2013
Location: Nor-Cal

Re: B4Q 80-AEB; Turbo swap time!

Postby pilihp2 » Fri Oct 12, 2018 4:08 pm

Welding barefoot with no gloves. ho man. that's hilarious.
-Phil
87 5ktq - 20vt
91 v8 5spd - I guess I'm a masochist
05 S4 - "Daily"
16 KTM 690 Duke - 2 wheeled hooliganism

-Terrible at responding to PM's
User avatar
pilihp2
 
Posts: 1073
Joined: Mar 1, 2013
Location: Reno, Nv

Re: B4Q 80-AEB; Turbo swap time!

Postby DE80q » Fri Oct 12, 2018 5:21 pm

pilihp2 wrote:Welding barefoot with no gloves. ho man. that's hilarious.

Hey wait... He has flip flops on! :rofl:
"If you can't find one, make one"

Dallastown, PA
1991 Audi 80 quattro (10vt project)
2007 Mitsubishi Raider(Dakota in disguise)
2014 Chevy traverse (It's what she wanted)
DE80q
 
Posts: 2219
Joined: Mar 4, 2013
Location: York PA 17403

Re: B4Q 80-AEB; Turbo swap time!

Postby ChrisAudi80 » Sat Oct 13, 2018 4:27 am

You wouldn't believe some of the other shit I see in this country. Dudes welding with just sunglasses on.

Anyway, the clutch needs needed a lot more bleeding. It is still hard to get it into gear. The AC system needs a charge.
Really looking forward to driving and tuning this.

If I got this right, the turbo should be good for 300 crank.
96 S6 auto
95 80Q AEB VEMS
ChrisAudi80
 
Posts: 795
Joined: Mar 2, 2013
Location: Bangkok, Thailand

Re: B4Q 80-AEB; TD04HL-15T much wow

Postby ChrisAudi80 » Thu Oct 18, 2018 11:50 am

Went for a long drive today. About 300km or so.

This thing is LOUD! First thought the stock 710n was done, but then went for a boost leak test. Should have done that sooner.
Found three leaks. Fixed that.

The stock DV was fine, but still lots of whooshy sound. Very noise, much wow. An open pod filter is quite noisy.

Will see if I can make a decent vid to post up. The tune is coming along nicely. Only have it up to 170kpa at this time.
It does need more throttle input now to make boost, but it is quite controllable with throttle.

Smiles for miles :D
96 S6 auto
95 80Q AEB VEMS
ChrisAudi80
 
Posts: 795
Joined: Mar 2, 2013
Location: Bangkok, Thailand

Re: B4Q 80-AEB; TD04HL-15T much wow

Postby ChrisAudi80 » Sun Oct 21, 2018 3:09 am

Tuning boost control.

Target 180kpa, spikes a little to 192kpa. Sure is a different car now... :drive:

Anyone have advise for working with the circled part? I have read the boost control guide many times.
I think I get it, but need a few pointers.
Attachments
Boost control.jpg
Boost control.jpg (290.53 KiB) Viewed 3247 times
96 S6 auto
95 80Q AEB VEMS
ChrisAudi80
 
Posts: 795
Joined: Mar 2, 2013
Location: Bangkok, Thailand

Re: B4Q 80-AEB; TD04HL-15T much wow

Postby ChrisAudi80 » Tue Oct 23, 2018 3:34 am

A little test run...

https://youtu.be/loehvMo0miE
96 S6 auto
95 80Q AEB VEMS
ChrisAudi80
 
Posts: 795
Joined: Mar 2, 2013
Location: Bangkok, Thailand

Re: B4Q 80-AEB; TD04HL-15T-> Test run video

Postby PRY4SNO » Wed Oct 24, 2018 1:18 pm

Seems pretty responsive for freeway driving, bet it feels nice.

Is that compressor stall on the lift off, or your BOV?
Find me on Instagram @pry4sno

|| 2010 Golf Sportwagen TDI /// Farmenwagen
|| 1992 80 quattro 20v /// Eventual AAN'd Winter Sled
|| 1990 Coupe quattro /// Because Racecar

|| Spare parts for sale
User avatar
PRY4SNO
 
Posts: 2111
Joined: Mar 3, 2013
Location: Edmonton, AB

Re: B4Q 80-AEB; TD04HL-15T-> Test run video

Postby ChrisAudi80 » Fri Oct 26, 2018 4:40 am

PRY4SNO wrote:Seems pretty responsive for freeway driving, bet it feels nice.

Is that compressor stall on the lift off, or your BOV?


You mean surge? No, I think that is induction noise and the STOCK DV blowing off.
This car has no MAF and an open pod filter.

I have a post-turbo MAP sensor hooked. It shows slight boost. Say IM MAP is around 86kpa, the post turbo shows 122kpa. Because of that,the DV opens slightly.
96 S6 auto
95 80Q AEB VEMS
ChrisAudi80
 
Posts: 795
Joined: Mar 2, 2013
Location: Bangkok, Thailand

Re: B4Q 80-AEB; TD04HL-15T-> Test run video

Postby mrdeye » Sat Oct 27, 2018 4:01 pm

ChrisAudi80 wrote:You wouldn't believe some of the other shit I see in this country. Dudes welding with just sunglasses on.


Yes!!! MTGA! Deregulate! Dude working like he’s building a model at the kitchen table. Cool project!
:thumbsup: :flag: :beer:
Matt
Daily driver: '01 Toyota 4Runner
Project car: '84 Audi Coupe GT
Previous cars:
'95 S6 Avant, '87 5K TQ, '95 VW Golf, '84 VW Jetta turbo diesel, '84 VW GTI
mrdeye
 
Posts: 69
Joined: Nov 13, 2016
Location: Colorado

Re: B4Q 80-AEB; TD04HL-15T-> Test run video

Postby ChrisAudi80 » Sun Oct 28, 2018 7:57 am

mrdeye wrote:
ChrisAudi80 wrote:You wouldn't believe some of the other shit I see in this country. Dudes welding with just sunglasses on.


Cool project!
:thumbsup: :flag: :beer:


:ty:
96 S6 auto
95 80Q AEB VEMS
ChrisAudi80
 
Posts: 795
Joined: Mar 2, 2013
Location: Bangkok, Thailand

Re: B4Q 80-AEB; TD04HL-15T-> Test run video

Postby ChrisAudi80 » Tue Nov 06, 2018 9:26 am

Still just running 180kpa. Starting to get the boost control dialed in, I think.
The turbo still needs about 0.8sec to hit boost target. Full spool at 3400, but can get 180kpa already at 2800 if I load it right, but it becomes like a dog then.

Have played with the timing a little bit. Managed to reduce load at 120kmh cruise from 83-85kpa to 72-75kpa. TPS did not really change. Maybe from 23 to 21%
More response and torque in most places.

Did a little compression test today.
cyl 1: 152+
cyl 2: 170
cyl 3: 160 something
cyl 4: 175

But that was cold and the pressure blew the tester off. I didn't use the screw in adapter.
Still need to check hot.
96 S6 auto
95 80Q AEB VEMS
ChrisAudi80
 
Posts: 795
Joined: Mar 2, 2013
Location: Bangkok, Thailand

Re: B4Q 80-AEB; TD04HL-15T-> Test run video

Postby ChrisAudi80 » Tue Nov 13, 2018 10:30 am

Been working on boost control. So far, with the settings in the picture, I get the results seen in the other two.

This is a log from Sunday when I tried to keep up with a new Panamera. Yeah, right...

In unrelated news, the left front shock is bad again.

And found out the AK MS ball joint strut mounts had dislocated the ball joint out of the housing. There is a groove for retaining C clips, but there are none. Looked at the picture from when I got them. No C clips.
Odd. However, the ball joints pressed right back in. I bought and installed 034 Track Density strut mount bushings because I thought the ball joints were worn out. Nope.
Attachments
Boost control updated.jpg
Boost control updated.jpg (285.89 KiB) Viewed 2324 times
Screen cap log.jpg
Screen cap log.jpg (278.86 KiB) Viewed 2324 times
Screen cap log2.jpg
Screen cap log2.jpg (286.29 KiB) Viewed 2324 times
46160153_945589288969231_4328411102527356928_n.jpg
46160153_945589288969231_4328411102527356928_n.jpg (114.81 KiB) Viewed 2324 times
46193028_749482578733835_9111900228021125120_n.jpg
46193028_749482578733835_9111900228021125120_n.jpg (270.42 KiB) Viewed 2324 times
96 S6 auto
95 80Q AEB VEMS
ChrisAudi80
 
Posts: 795
Joined: Mar 2, 2013
Location: Bangkok, Thailand

Re: B4Q 80-AEB TD04HL-15T; Suspension trouble & pics

Postby ChrisAudi80 » Fri Nov 16, 2018 4:44 am

So, turns out I had to buy two new shocks. Great. Luckily not expensive.
Will see how the 034 track density strut mounts work out compared to the ball joints.
96 S6 auto
95 80Q AEB VEMS
ChrisAudi80
 
Posts: 795
Joined: Mar 2, 2013
Location: Bangkok, Thailand

Re: B4Q 80-AEB TD04HL-15T; Suspension trouble & pics

Postby ChrisAudi80 » Tue Dec 04, 2018 12:03 am

Running out of injector... :roll:

Hitting 21ms PW and 89% max. I could increase the FP to 4.0bar, but then would have to run quite rich in the very low load areas.
Already sitting at 1.7ms @ 1000 rpm and 52kpa idle. I can see EGO struggling to keep lambda at 0.95.
96 S6 auto
95 80Q AEB VEMS
ChrisAudi80
 
Posts: 795
Joined: Mar 2, 2013
Location: Bangkok, Thailand

Re: B4Q 80-AEB TD04HL-15T; Pump it up

Postby ChrisAudi80 » Wed Dec 05, 2018 3:49 am

For a long time, the fuel tank gets quite hot in the afternoon. The pump was not so large that it should not heat the fuel so much.
Decided to have a closer look at the pump and wiring. Yeah... Not good. As you can see in the picture, the 12v supply wire was a disaster waiting to happen.
This pump and plug with wires is about 5-6 years old and had 60,000km on it.

Swapped out the old AEM 320lph pump to a Walbro 342 255lph and made new wiring (2.5mm wires). Forgot to take a picture of that of course. The in-tank plumbing is all AN-6 with PTFE hose now. The AN-6 5/16" ID hose fits perfect on the pump.

Before this, I changed some small things in the trunk. Added a check valve on the fuel feed line so I don't have E85 spraying everywhere when I need to open the tank for the umpteenth time. Also added a ball valve so I can take pressure off the line if needed or to take a sample. That flex sensor is doing FA right now. Quite sure it is a fake, but will try to send the signal through a frequency to voltage converter I am slowly making.

In the engine bay, redid the crank case breather hose with AN-10 hose and fittings. Already had the IE block adapter.
The old hose was sweating oil because it was for coolant only.

Hopefully will be able to make a new VEMS to Motronic adapter harness and subharness for the fuel pressure sensor, coolant pressure sensor, wideband and EGT during Christmas.
Attachments
47379767_2238625679685579_4643769273804652544_n.jpg
47379767_2238625679685579_4643769273804652544_n.jpg (273.71 KiB) Viewed 940 times
47235511_894667170741102_5704415235713007616_n.jpg
47235511_894667170741102_5704415235713007616_n.jpg (310.34 KiB) Viewed 940 times
47572456_732211707139496_1037206560142524416_n.jpg
47572456_732211707139496_1037206560142524416_n.jpg (294.14 KiB) Viewed 942 times
96 S6 auto
95 80Q AEB VEMS
ChrisAudi80
 
Posts: 795
Joined: Mar 2, 2013
Location: Bangkok, Thailand

Re: B4Q 80-AEB TD04HL-15T; Pump it up

Postby ChrisAudi80 » Mon Dec 10, 2018 3:49 am

Have had a few educational days.

Changing the in-tank hose from pump to bulkhead to PTFE from nitrided rubber and using PTFE line from IM to FPR was a bad idea with the Walbro.
For some reason, it created a resonance at 2750-2900rpm. It suddenly wanted 10% more fuel in that small band, but only in vacuum.
WTF. My VE table was suddenly all wrong. Everywhere.

So, last night, changed it back to rubber hose and silicone hose from original nipple to FPR. It is much longer than the AN-3 PTFE line, but it fixed the issue.
The light came on after watching this VERY educational video(s) from Injector Dynamics seminar at PRI2012.

https://youtu.be/4QF5BmQtXZA

This dude knows his stuff and can explain it very clearly.

BTW, why do I have over 80k views but few comments?
96 S6 auto
95 80Q AEB VEMS
ChrisAudi80
 
Posts: 795
Joined: Mar 2, 2013
Location: Bangkok, Thailand

Re: B4Q 80-AEB TD04HL-15T; Pump it up

Postby audifreakjim » Mon Dec 10, 2018 1:29 pm

I'm a lurker :) Paul Yaw is awesome, follow him on FB too. He has some pretty epic rants from time to time. He helped me diagnose my hot start problem that I swore was fuel related, but turned out being heat soak of the ignition coils.
User avatar
audifreakjim
 
Posts: 2047
Joined: Mar 3, 2013

Re: B4Q 80-AEB TD04HL-15T; Pump it up

Postby PRY4SNO » Mon Dec 10, 2018 6:30 pm

Glad to see you found a solution.

I follow along, but try to only post when I have something to add so as to not clutter up your thread. Usually I'm stumped, or learning something new!
Find me on Instagram @pry4sno

|| 2010 Golf Sportwagen TDI /// Farmenwagen
|| 1992 80 quattro 20v /// Eventual AAN'd Winter Sled
|| 1990 Coupe quattro /// Because Racecar

|| Spare parts for sale
User avatar
PRY4SNO
 
Posts: 2111
Joined: Mar 3, 2013
Location: Edmonton, AB

Re: B4Q 80-AEB TD04HL-15T; Pump it up

Postby ChrisAudi80 » Mon Dec 10, 2018 9:51 pm

audifreakjim wrote:I'm a lurker :) Paul Yaw is awesome, follow him on FB too. He has some pretty epic rants from time to time. He helped me diagnose my hot start problem that I swore was fuel related, but turned out being heat soak of the ignition coils.


Lurking is life. I get it.

Yeah, Paul is quite passionate. Hehe.
Cool that you got him to help you. Hope your Comet is still running well. Haven't seen any updates for a while.
Or maybe I missed them.
96 S6 auto
95 80Q AEB VEMS
ChrisAudi80
 
Posts: 795
Joined: Mar 2, 2013
Location: Bangkok, Thailand

PreviousNext

Return to Projects

Who is online

Users browsing this forum: No registered users and 11 guests