Motor mount pics

Here are the pics that I promised.  I wish that they were better, but it is hard to fit my camera in there.  I will put up some more when I have them powder coated for the final installation.  First is the drivers side, second the passenger side.

Motor mounts finished

I finished up the motor mounts today and I think they came out pretty nice.  The actual isolation pad is made from polyurethane.  I figured that the weight of the motor would compress them some so I tried to compensate by hanging the motor a little higher than I wanted it to actually be.  After completing the mounts and lowering the engine into the car they didn't compress like I thought they would.  I have 1 inch of clearance on the p/s of the engine for the oil pan, but I'm worried that the hood isn't going to close now.  I really wanted the exterior of the car to remain unchanged.   I could probably have some of the isomounts shaved off at a machine shop and still use the current engine mounts. 
I also cut the reservoir off of the donor oil pan to make way for a 944 like sump.  Since I have a weeks vacation starting soon I should wrap that project up pretty quickly.
One last note is that I have located a HY35 and it is en route, so we'll get to see if that will fit under the hood also.  If rumors are correct I should be able to hit my horsepower goal of roughly 400bhp.  It will be months before we learn the reality of the situation though.  As there is much to complete first.  I will post pics of my mounts soon and the turbo when it arrives.

Slow going

I'm sorry that I haven't been getting a lot of info up here lately.  I have been working on it on the weekends when I can, but work and the holidays are really putting a dent in my schedule.  I have completed the p/s motor mount and the d/s motor mount is about 50% finished.  I'm using a polyurethane engine mounts that I am sure will compress under the weight of the engine, I just don't know how much.  I'm trying to get the engine close to the hood to leave more room for the oil pan.  I won't be happy if it doesn't fit under the hood.  Also I have changed my mind about the turbo.  I'm now searching for a serviceable Holset hy35 with a 9cm housing from a Cummings diesel truck engine.  I think this looks to be a very good match for this motor.  They have been used rarely on Audi's, but with good results.  Part of my reasoning is price.  Garrett = 1300 USD, Holset hy35 = approx. 200 USD.  The savings is almost the cost of the vems ecu or perhaps an lsd transaxle.  Reason 2 is of a surging issue that I keep hearing about with the Garrett turbo that I was after.  Reason 3 is that Garretts aren't really rebuildable, but a Holset is easy and cheap to rebuild. Reason 4 is that the Holset isn't water cooled, thus simplifying installation and allowing the removal of more weight and components from the AAN.  The final reason is that this car is all about taking the less traveled road so....why not.

The Oil Pan

I've probably mentioned this before, but without rereading my own blog I can't be for sure.  So that being said I'm sure that everyone knows that the nice aluminum pan that the AAN comes with won't work for this swap.  Well to be truthful there isn't one that will work with this swap, so we need to make one.  With Bullmoose's guidance I sought out the pan from a 10v I5.  These are made out of steel and will be easier to modify than the aluminum one.  It took awhile, but I finally located one on the eastern side of the US at Force 5 Auto. When buying one be sure to get the block to bellhousing brace also that is in the pics below.  I was also sent the oil pump pickup tube.  Hopefully I can use it to lengthen mine, as material to lengthen the tube with wasn't something that I had thought about yet, maybe I lucked out on this one.  Notice that you can see the part numbers in the second picture in case you need them.

 

Oil filter clearance

I began lowering the motor into the 944s engine bay last weekend.  Well the farther you lower it the more items you have to remove.  It is currently in position and bolted to the torque tube.  I think that if you made allowances with wiring and plumbing it would be possible to change a clutch in the future by moving the engine forward instead of the fiasco that occurs on a stock 944.  There is a large amount of room in front of the motor compared to the original engine.  So on to the topic of this post.  You will find that the oil filter will land right on the top of the steering rack.  Aah crap...that's what went through my mind.  So I removed the filter and lowered it to the right height.  While there isn't enough room for the stock filter there does appear to be room for a part made by Trans Dapt.  The part number is 1413.  They call it a 90 degree oil bypass adapter. Here is what it looks like.

You wont find the AAN listed in the applications guide, but cross referencing the AAN oil filter over to units that are listed in the guide indicates which model to use.  Turns out that the Audi uses a Ford oil filter.  I thought that was funny for some reason.  So the plan for oil filtration at this point is to relocate the filter while retaining the factory cooler and turbo connection points.  The filter will mount onto either these two items.

The 1028 vertical filter mount

or the 1045 horizontal filter mount

At this point I would imagine that I will be using the 1045, but I'll leave that decision until later.

Engine fitting

Well I was able to trial fit the motor into the 944 today.  It became really obvious that the stock exhaust manifold won't work unless you tilt the motor clockwise. (as viewed from the front of the car)  I know that the guy in Russia tilted his motor for some reason.  I assumed it was so that it would fit under the hood, but maybe it was to make use of the stock turbo manifold.  I'll have to go review the videos and see if I can tell.  I couldn't get the engine lowered into place completely due to clearance issues with the stock oil pan.  (I was told this would happen, but I still had to try.)  I would really like to modify the aluminum one for the final product, but I am currently trying to locate a metal one from a 10v I5 to determine how it will need to be modded.  If anyone can help me out with that drop me a line.  Measuring from the pilot bushing to torque tube mounting surface on both engines shows them to be within 1\16th of an inch.  I'm not sure but I think that will be close enough.  Other than that I didn't get anything else done worth noting.

944 powertrain is removed

Well I didn't intend to pull the tranny out at first, but this was one of those live and learn things. The motor basically has to be lifted straight up to be removed from the car. This means you have to move the torque tube rearward, which entails that the transmission must be removed. The clutch fork pivot pin and I duked it out for a while. I don't think that it had ever been removed before. Long story short I got it all pulled out in a day. Now for some clean up work and I'll start looking at part fitment. I'll have a business trip this week so I won't be able to get anything done with the project.