Re: MC Transplant into CGT (lots of ?'s)

[Marc A Swanson <mswanson@cisunix.unh.edu>]

-----Original Message-----
From: Alan Kramer <ackramer@hotmail.com>
To: quattro@audifans.com <quattro@audifans.com>
Date: Wednesday, August 25, 1999 2:25 PM
Subject: MC Transplant into CGT (lots of ?'s)


>Hi all,
>    I'm planning on doing the turbo swap this winter on my '83 CGT.  I've 
>read all the web pages on 4kq turbo conversions, but I've still got a few 
>questions as I prepare to do this:
>
>1)  $500 for MC turbo engine, turbo, and other accessories delivered to
my 
>door.   Although I don't get the experience of pulling it myself, I don't 
>have to spend the time either.  And no disposal of another parts car.
Good 
>deal?
>

Yeah.. not bad.  I bought a whole parts car for my conversion since that
allowed me to see where everything came from.  I paid $800 for the car
w/177k miles.

>2)  '83 CGT = CIS; '87 MC Turbo = CIS-E, correct.  Therefore new
distributor 
>required.  Can I use the CIS-E Fuel distributor from my '85 CGT parts
car?

No.  There are many more fuel outlets coming from the MC fuel distributor
than you CGT distributor. 
 
>Should I use the fuel distributor from the 5k instead or is it just too
wide 
>to fit anywhere?

You can use the 5k fuel distributor just fine.. requires serious hacking
to the 4kq airbox bottom.  The alternative is to buy a TQC airbox top and
turn the fuel distributor/air plenum around 180 degrees and use the TQC
aluminum air spout over the plenum OR use some custom piping.

>
>3)  Are the fuel rejectors (ok, injectors) on the turbo motor the same as 
>those on non-turbo motors?

Not sure.., I can only say that I think so.  Be sure to replace those
seals on the injectors whatever you do.

>
>4)  What is the stock exhaust diameter on the 5kt?  Probably larger than
the 
>N/A 5 cyl. 2" on the CGT, right?

Not much if any.  Keep in mind that the 5kt downpipe will not fit without
hammering in the passenger floor.  Best to use a TQC downpipe or something
custom. 
>
>5)  Electronics:  All I need is the "brain" behind the glove-box and the 
>right wiring harness, right?  Assuming all the appropriate senders are
still 
>on the engine.


Sort of.  If you choose not to use the 5kt left side wiring harness, then
you will have to make up some custom stuff to work with the after run
coolant pump and a few other bits that I am forgetting.

>
>6)  Can I use the flywheel and clutch from the '83 CGT?  I think it has
one 
>reference pin on the flywheel, not 2 like the one on my '85.  Also it's a 
>215 mm clutch.  I realize the difference in clutch disc area is about
10%.  
>Does ir really matter?

I can't say this for sure, but from what I have heard, there is a
durability difference between the 5kt flywheel/clutch and the CGT/4kq
flywheel/clutch.  Do you really want to put everything together only to
have the clutch tear itself apart? 

>
>7)  Where's the best (only) place to mount the inter-cooler?
>

depends on if you want to use the 5kt intercooler.  This is not easy.  It
CAN be fit behind the grill, but you will have to sacrifice some serious
metal and the hood latch(I think) in which case you would have to make
something up to get the hood to catch.  The other option is to get
something smaller such as the TQC intercooler which will fit in numerous
places such as either behind the grill or down low where about where the
horns are on the CGT/4kq


>8)  Should I add any additional cooling capacity (oil, etc...?)
>

DEFINATELY keep the 5kt or some other oil cooler.  That turbo will get the
stuff quite hot.

>9)  Is the following *rough* estimate on doing a partial rebuild of the 
>turbo motor (myself) close?  Have I forgotten to do anything?  Should I
do 
>something else?  If the motor's fine as is, do I really need to do all
this? 

I would.. at very minimum do what you are suggesting (except the valves..
shouldn't need to replace those and they are very expen$ive).  I am far
more paranoid and will end up sinking way more money than I probably
should on the bottom end etc.

 >(probably, at least...) >
>Head:  Lifters, Valves, Valve Seats:  $250

hmmm... seems a bit low..

>T-belt / WP:  $150

about.. I got those + accessory belts + 3 oil filters + Cam + Crank seals
from Rod at The Parts Connection (www.thepartsconnection.com) for $120.

>All gaskets and seals:  $200

  if you take off the exhaust manifold or the intake manifold, add a
coupla bucks.

>All cooling hoses:  $150

maybe a bit high if you are stringent with $$

>OXS:  $50

  I think there is a cheaper source for these (Rod?).

>
>BTW, the rest of the car runs and looks brand new, hence I think I can 
>justify the expense of doing this conversion.

Sounds like you have good reason to do it.

>
>I appreciate any thoughts on the subject.
>

Hope this helps

Regards
-Marc-
87 4kcsq  awaiting turbo
87 5ktq   donor