RE: Calling all 4kq turbo conversions

["PAT MARTIN" <MARDKINS@classic.msn.com>]

You are forgetting a major component here.  The whole wiring harness needs to 
change to get the computer and all the other electronics to work.  This also 
entails removing the dash and interior.  And in the 4kq the intercooler will 
NOT fit in the front without major modifications.  Intake is really the most 
difficult thing overall but getting the coupe quattro intake would make that a 
lot easier.  There are many other little things that come up as well and I 
will be posting a complete list when I am done.  This is at least a month long 
project in a 4kq and more likely 2 months.  Even the Bennet Bros. who do this 
for a living take 6 weeks and only work on 1 car at a time. 
Pat Martin
864000csq  2 1/2 cat back, H&R-Boge,advanced and loving it.  Drilled and 
stopping it.  Koenig Cobra 16x7 with AVS Intermediates, conversion in 
progress, K&N.
95 subaru legacy 
Bothell, Wa

Hi there.
I've done the swap on my front wheel drive Coupe, but I think the 
procedure is the same.

> relocating the battery

I stuffed it into the pass side well in the trunk.

>, the right tie rod

Modified an Ur-q a used tie-rod (thanks to Mike Hopton) to accept 4000 end 

>, air conditioning

Threw it out long time ago.  For the swap you will have to 
relocated it to the other side of the engine like in the Ur-q (if you 
really have to have it).

>, radiators,

Since I am using an oil cooled turbo I took a chance and run it with a 
stock re-cored radiator and it works very well even on the hottesd days.

> intercoolers, etc, etc.

I used a 1988 5kt intercooler and hoses and stuck it in the grill.
Didn't even loose the high beam light (four light system) but I did 
have to use hood pins and had to do some cutting to the grill itself 
and the metal around it.  All uoy can see hwever from the front is 
the intercooler a' la Mitsubishi Lancer rally car.

> 
> In other words, what problems they ran into and how they went around
> them like if the 5kt clutch/flywheel would bolt up to the 4kq
> transmission,

Without a problem.  You just replace the pilot bearing in the 
crankshaft if your engine came out of an automatic tranny car.

> or if the intake manifold fit under the hood without modifications

Same intake as on the Ur-q so there is no problems.  You have to get 
the 5ktq throtle cable.  I used the stock Coupe cable but that's 
streching it.  now the gas pedal is very high and uncomfortable for 
heal and toe driving.

> or the hydraulic system.  

I use the intake vacuum to operate the brakes.  The only problem is 
the lack of power brakes under left foot braking otherwise it just as 
good as with a N/A engine.  You might want to use a cylinder head out 
of a car with a vacuum pump but you would have to change the valves 
to sodium cooled.  I know someone who has done this to get rid of the 
hydraulic system on their Ur-q.

The biggest problem I had was pounding in the pass floor to allow the 
5kt downpipe (I didn't want to cut it).  It would fit fine but I 
wanted some more space between the hot downpipe and the undercoating.
I also used the stock Ur-q top part of the air cleaner housing to allow for 
the turn around of the fuel injection system.  Except for the 
aluminum spout on top of the air sensor plate and the aluminum bottom 
air cleaner housing my system looks exactly like the Ur-q system.
Becouse of it all the pipes are short and reduce turbo lag.
Another problem is finding a spot for the oil cooler.  This hoever is 
should be decided by the owner.  I modified the lower grill in the 
Coupe.
You might ask why I didn't do this to a quattro.  Well I used the 
Coupe as a test vehicle.  I wasn't afraid to take a grinder or a 
hamme to make things fit.  I am however amazed how easy the swap 
itself was and that I didn't have to make things fit.
Next summer is the quattro's turn to be turned into a monster.
Now that the Coupe is in the storage and I am driving the quattro I 
don't know weather to be happy that I am driving a quattro in the 
snow or sad becouse I no longer hear the sweet sound of a turbo 
whistle.

If you want it, do it.
HTH


Martin Pajak
quattro@rogerswave.ca
http://www.geocities.com/MotorCity/5939

1982 Coupe TURBO (473,150 km)
1984 4000s quattro (soon to be a rally car)
1986 4000s quattro (300,000 km)
1970 Porsche 911E Targa (for sale)