T-minus 21 days (Long)

[Ameer Antar]

---Original Message---
>
>Date: Sun, 07 Sep 2003 22:19:39 -0400
>From: Eric <eric_audi.ql at mindspring.com>
>To: quattro at audifans.com
>Subject: T-minus 21 days   (Long)
>
>Well it is 21 days until the due date of our first child and our family
>car is still on jack stands.  I have been spending almost all of my
>waking hours (when I don't have to be at work) on the car.  I am getting
>very close, but I have a number of questions.  I am hoping that with
>some help from you guys I can drive it this week.
>
>The swap is a '85 KH engine into a '85 4kq - more detail on my site.
>
>
>Current big headache -- Vacuum lines
>
>I am at a bit of a disadvantage since I have never seen under the hood
>of a 5k.  I have both Bentley manuals.  I am considering ignoring the
>emissions system for now.  I don't fully understand how it works and
>thought leaving it off might be best for now.  Any thoughts?  Should I
>just get caps and plug off the lines where they come through the fender
>wall?  I would like the car to comply with emissions eventually (it has
>a cat), but it is not tested in my area so there is no urgency.

I would take a close look at the Bentley diagrams for both the 5ktq and 4kq and I bet a lot of things will match up. I'm pretty sure you can get away w/ disconnecting lot's of stuff for now, like the fuel evap. canister, but there are a few things that need to get vaccum, like the wastegate, ECU, etc.

>As an extension to the vacuum problem I have a question about this
>vacuum switch on the side of the head at number 5 cylinder.  Is it
>supposed to have two hose barbs on it?  I have two of these and they
>both have just one barb and one hole, but it looks like a second barb
>was broken off?  It seems to be something to do with cold enrichment.
>Does anyone know how this subsystem works or can they point me to a part
>of the Bentley that describes it?

Yep, this is called the thermo-pneumatic valve, aka. thermo-vacuum valve. It was only put on the '85 turbos, and I think on many NA engines. Basically, it provides for additional full-throttle enrichement when the engine is cold. My engine had both barbs broken off, so I bought a new one from somebody on eBay. There's also a related pressure gradient switch. All the info is in the Bentley in sec. 26.35.

>Another question... The Bentley does not show a check valve between the
>engine and the differential lock system.  Should there be one?
>
>On the crankcase ventilation system one of the ports connected to the
>valve cover appears to have a check valve.  Where is this connected to?
>The Bentley is not clear on this.

I'm pretty sure the valve is actually inside that weird vacuum connector on top pf the valve cover.

>The blue wire...
>
>I have been unable so far to figure out what the blue wire does.  There
>is a blue wire that connects the left side engine harness with the right
>side harness (near the CIS fuel distributor).  It is connected by a red
>single blade waterproof connector.  I have not broken out the multimeter
>yet as I thought someone might know off the top of their head.  The only
>thing I have found so far in the wiring diagrams that has a blue wire is
>the field for the alternator.  The reason I ask is I have rerouted my
>harnesses somewhat and they are about 1.5" too short to plug into each
>other.  If I still need it with the KH I will lengthen the wire.  Any
>thoughts?

don't know, but if it looks like a non-VW/Audi connector, someone may have spliced this wire or who knows. I think Audi never really used those cheap crimp-on blade type connectors. Almost all of the wiring in my car looks like it has special connectors, so I would try and see if this is not part of the po's car alarm wiring or who knows...

>Coolant afterrun system
>
>I am using the JT heater pipe on the side of the block.  I am also using
>the KH heater outlet on the back of the motor (I could not get it out).
>I am planning to use the one 1/2" pipe off the back originally for the
>automatic tranny cooler as one of the points for the afterun pump.  I am
>going to use a splice into either the upper or lower radiator hose for
>the other.  My brain is rather fried by this project so I am unable to
>figure out which would be better?  Any thoughts?

I would look at the pictures of the coolant system for the turbo engines. The one in the Bentley sucks; the one in the family album is much better. I think you should be able to implant this system in most cars just by buying the hoses for a water-cooled 5kt/tq. One thing about the drawing in the album is that they now only use one hose to connect the upper radiator hose to the after-run pump. It looks like a Y. Also you'll need to figure out how to moun the pump b/c the 5kt has a special mount welded to the body.

>Misc
>
>Does anyone know if the afterrun coolant pump and the injector fan
>thermo-switches are set at the same temperature?  Has anyone run into
>problems with not running the injector fan?
>
>
>Thanks for the help!  I am sure I will have more questions as the week
>goes on.
>
>
>--
>Eric Sanborn
>'85 4kq - 225k+ (work in progress)
>'8X VW Race Rabbit - EFI
>'89 Honda CRX Si - 175k (Wife's car)
>'88 Chevy Suburban - 190k (Tow vehicle)
>
>http://www.mindspring.com/~robinsanborn/4000/
>
>
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