MC1 10VT into my 4KSQ

[Ben Swann]

Chris,

Although I have done a little documentation on the wiring, I have not done the HTMLized writup  for this conversion yet.  The best advice I can give at this point is get as much info prior to doing anything regarding the conversion.  I installed an MC-1 into an '83 CGT and it literally took over 6 months full-time.  OK - this included, exhaust, brakes, Quaife differential install, intercooler and plumbing fab, AC/Altermtator refitment/relocation, battery relocation - a ton of custom fabrication, sourcing parts from at least three different vehicles - CGT, UrQ, and 5kt.  I figure I might have cut this time in half had I known what i know now.  The brief info. i give below will save you 2 months if you follow out the details prior to doing the work and fit check things prior to final installation.

There are some other writups on similar conversions that I referred to.   Although helpful, take things with a grain of salt, as I found some of the information tended to be misleading.

In the swap I did, although the engine that went into the car is an '87 5000 turbo quattro, the layout most resembles an UrQuattro and it was necessary to source parts from both 5kt and Urq.  An UrQuattro would be your best model for the swap.  

Couple of things/caveats:

Dropping engine and trans as a complete assembly after removing subframe is the preferred method.  Otherwise, you can cut the cross-member and pull the engine out front without removing trans.

Battery needs to be relocated - I installed a custom box under the seat, almost identical to the UrQuattro one.  This alone took me an entire week.  I located a battery positive standoff using rubber insulators on the firewall where the original battery Positive was.  The ground from firewall to engine bell-housing tied directly into the firewall mounted coil/ground tying together all grounds from the ECU systems.

ECU harness routing should precede engine installation once original engine is pulled.

I ran a separate ECU circuit from the fusebox, replicating the wiring diagram for the '87 5000 turbo quattro.  The current track 15 for ignition was taken from the oil-buzzer relay or similar to trigger a relay to control the ECU and susbsytems.

Fuel-pump relay necessitates re-wiring at the fuse-box and I had to swap the earlier fuse box out for the 5kt one although at first glance they appeared Identical.  ref. my wiring info. for details: http://www.homestead.com/ben_swann/MCWiring.html.  I added a second fuel pump relay to carry the pump load directly from battery positive to the pump and used the existing positive lead to control the relay.

Air conditioning greatly adds to the complexity of the swap, but in my case was a requirement.  5000 AC/bracketry will not fit and inerferes with the radiator.  Need to source UrQ setup or make a custom bracket.  A special hose was fabbed to interface the evaporator line with the line in the car, otherwise obtain the UrQ evap/line.  

Alternator from 5kt is good if doing the AC/alt. swap in order to install AirCondioning.

The 5kt oilpan can be used, but needs to be modded (BFH wise) so the radiator can fit.  Oil cooler lines will have to be custom fabbed.

UrQuattro fuel distributor, airbox, intake igloo are used with 5kt injector lines.. parts from CIS from 5kt, CGT, and Urq used to make the system complete. .the time needed to cobble the parts together and their added cost may justify going with an EFI solution, as I will for any future swaps like this if ever again.

Use 5000 TQ/MC flywheel, pressure plate and clutch setup works fine.  I Advise to swap slave cyl. and release bearing while you're in there.

Make sure the flywheel sensor mounting hole exists in your transmission, and if not make the cutout whle the engine is out of the car.

You might need the special bent tie-rod which can be sourced through 2-Bennett or maybe fabbed.

Intake temp. sensor can be located on the 5kt manifold by carefully fabbing the holes on the boss just after the throttle body.

Intercooler - no easy way.  I used a SAAB 9000 IC and mounted below front bumper - had to cut a long notch from the aluminum bumper mount and custom weld bracket to hang behind the bumper but in front of front cross-member.  Others have just cut the front cross portion out and remade to fit the IC of choice.  Running the plumbing is very tricky due to limited space.

A bypass valve is very useful toward keeping your custom hoses from blowing apart.

Electrical integration can be fun - make sure harness is marked identifying comonents for MC-1/MAC-11 system to avoid confusion when things are being put together.  Improper/missing labels through me for a very bad troubleshooting ordeall that I never should  have dealt with.

There are so many details, I doubt I'll ever recall them all and  above are just the major issues I recall right away.

I hope I can get around to doing this writup soon, but I need to catch up on a lot of other work that didn't happen while I did this conversion.  http://www.homestead.com/ben_swann/GTCTurbo.html  will be the page where I document this conversion, but I have not even finished documenting the NG transplant into 4kq "Project GTQ" - finished at about the same time, and continue onto the next projects.  So I will likely use the information in this email as a starting point.

Good-luck.

Ben
p.s.  the NG transplant is a piece of cake compare to the turbo swap and AFAIK you will not be stuck in a class that may make you less competative due to the turbo engine.  I have the NG engine in my 4kq and there is plenty of power for autocrossing.


[Date: Thu, 17 Feb 2005 18:27:29 -0500
From: "Denis" <sparkplugvw at hotmail.com>
Subject: Re: MC1 10VT into my 4KSQ
To: "Chris M" <elchulachaser69 at yahoo.com>, <quattro at audifans.com>
Message-ID: <BAY103-DAV4D8E35FAA77A09CE51F5EBB6D0 at phx.gbl>
Content-Type: text/plain; charset="iso-8859-1"

  Yep.
  You need to go there.

  http://www.homestead.com/ben_swann/myaudi.html

  Ðenis]

[From: Chris M <elchulachaser69 at yahoo.com>
Subject: MC1 10VT into my 4KSQ
To: quattro at audifans.com
Message-ID: <20050217204800.68574.qmail at web51110.mail.yahoo.com>
Content-Type: text/plain; charset=us-ascii

Hello all,
 
Here is my newbie question, I have finally made up my mind and decided to go turbo charged in my 4KSQ. Now this is the thing. I know there are alot of shops out there who would like to do this conversion for me for an astronomical price but I was thinking of tackling the conversion myself. I've done many conversions via VR6's into alot of the older VW chassis but I do know that the Audi chassis and wiring is a bit more involved. Ofcourse arms with the trusty Bentleys for the models, I would like to know what would I actually need from the doner car. My car in question is an 84' 4KSQ that I autocross and the doner is a prisinte running 86 5KTQ Avant. 
 
Ok, o.k Now I know I would need the engine, Transmission, manifilds, wastegate, and piping aswell as the ECU but what else would I actually need from the engine bay? Wiring I know for one but what and what actually??? Is there anyone here who can point me in the right direction??
 
Thanks All,
CK]be