BT Audi TT

[seth_3515]

Well, Its been almost a year in the making, but everything is coming together and hopefully be done very soon. I started with a 2001 Audi TT 180hp front wheel drive car. The block and head were rebuilt professionally by local hot rod shop. The transmission was also rebuilt professionally with an LSD and TDI 5th gear. I am doing the rest of the work and labor to put it all back together. The engine and tranny were finished last august and are now in the car. Next week I will be ordering my SEM intake manifold and new fuel lines and the setup will be complete! The 1.8t was the ATC narrowband. I already have a wideband ecu (AWW) and wiring harness (AWP). The wb ecu has already been flashed by Gonzo with a 870cc MAF'd file and all deletes.

Block:
82mm Wiseco pistons 8.5:1 c/r and Eagle rods- Engine builder took care of
Race coated rod and main bearings (oversized) - Engine builder
Polished and balanced crank
IE Dowel Kit
All ARP hardware- IE
New IE oil and water pump (metal fins)
IE manual timing belt kit- IE
Victor Reinz gasket kit- IE
Head was rebuilt to OE specs (sticking to small port and going with stainless valves)
ECS Lw power steering pulley
External Oil cooler
Green top CTS- ECS
034 Race mounts- 034motorsports
NGK plugs- ECS
Accessory belt for A/C delete- PAG
Supertech Stainless exhaust valves

Transmission:
Complete rebuild 02J 5-speed
Wavetrac LSD (ARP bolt kit)- IE
TDI 5th gear- used
IE Shift fork
Clutchmasters FX400 6-puck and lightweight flywheel (ARP bolts)- PAG
Redline MT90 fluid- ECStuning

Turbo System:
Pagparts Bottom mount manifold and downpipe-PAG
Precision 5857SP Ball bearing- BMP20TH
-3AN oil line with restrictor from PAG
ECS Exhaust nuts and Nordlock washers- ECS
HKS SSQV BOV- Previous build
Tial 38mm WG- used
Frozenboost AWIC kit (2.5" turbo to core, 3" from core to TB)-Frozenboost
42dd MAP flange
SEM Intake Manifold- CTS turbo
034 Fuel Rail and FPR adapter- 034motorsports
Walbro External Inline- previous build
Racetronix 79lb injectors
RS4 throttle body
Apexi AVCR EBC (boost by gear FTW)- previous build
Gonzo TUNING
Autometer wideband, EGT, Boost, and Oil Press. gauges- used

Suspension:
ST coilovers- HPAmotorsports
USRT solid subframe bushings-USRT
New brembo rotors and Hawk pads- MJMautohaus
Tyrolsport brake stiffening kit-USRT
Lightweight tubular LCA's-USRT
Stainless Steel Brake lines- ECS
All new poly swaybar bushings and steering rack


As of now, the motor is in the car. The suspension and brakes are finished (just have to tighten tie rods). The PAG bottom mount made it near impossible to fit a 4" to 3" 90degree reducer between the frame rails. There was a one inch lip the dug into the reducer. I pulled the motor again and took the cutter to the lip. After the lip was removed, I took the grinder to it to smooth out the edge where the fitting would sit. I initially wanted to keep the A/C, but since I am running the AWIC on the drivers side of the bay, the intake runs right where my A/C lines are at.. I removed the A/C stuff for now. I will make some new A/C lines, but after its running lol I have a couple questions/concerns I wanted to express as well.

-need a compressor housing o-ring for the turbo.. anyone know who carries these? -getting from PAG

-I am mounting the AWIC heat exchange in the A/C condensers spot. I have heard some concern for the TT's running hot, anyone have any opinions/suggestions? I was also considering a new (3 row) radiator to help with cooling. Is there anyone with any experience running an upgraded radiator on these cars?

-Initial start up- Priming the oil.. IIRC, I will need to unplug injectors; turn over with key for 30 seconds; plug in and fire up? Looking for a little more detail to make sure everything is sufficiently primed and ready to go.
- unplugging injectors to cut fuel and then cranking over to prime.

E

[AL@PagParts.com]

Good to finally see progress on your build. I always wonder about TT builds as they are bit different. I normally use a 4" to 3.5" cobra for the T3 and even vbanded bottom mounts (the latter pulling the turbo farther away from the frame rail which makes fitting any silicone inlet a non-issue). I should've suggested it but didnt know exactly what you were doing. Good luck w/ it all

[seth_3515]

Good to finally see progress on your build. I always wonder about TT builds as they are bit different. I normally use a 4" to 3.5" cobra for the T3 and even vbanded bottom mounts (the latter pulling the turbo farther away from the frame rail which makes fitting any silicone inlet a non-issue). I should've suggested it but didnt know exactly what you were doing. Good luck w/ it all

Thank you! I used the frozenboost reducer (probably coud have found a more compact one) since it was what I had and grinding the lip off took a whole 10 minutes I am really looking forward to getting this completed and have a working car again

[seth_3515]

Good to finally see progress on your build. I always wonder about TT builds as they are bit different. I normally use a 4" to 3.5" cobra for the T3 and even vbanded bottom mounts (the latter pulling the turbo farther away from the frame rail which makes fitting any silicone inlet a non-issue). I should've suggested it but didnt know exactly what you were doing. Good luck w/ it all

Also, do you guys carry the compressor housing o-ring for the 5857? I got a hold of precision and they said to use a vendor, but will sell one to me if I cant get one soon enough..

[AL@PagParts.com]

Sure, I have a garrett one. Should be the same

[Big_Tom]

dope, build Also LOL @ Grass City

[seth_3515]

Sure, I have a garrett one. Should be the same

I'll be in touch with you soon.

-Tom- don't hate on the city

[Dub-Nub]

can we get the pictures linked directly? i dont have a grasscity account

[seth_3515]

finally got it pics working..

[Chris164935]

Unplug the injectors to prime the engine/turbo with oil. This will keep the injectors from spraying fuel into the cylinders and possibly washing down the cylinder walls while cranking to prime the engine with oil.

[seth_3515]

Unplug the injectors to prime the engine/turbo with oil. This will keep the injectors from spraying fuel into the cylinders and possibly washing down the cylinder walls while cranking to prime the engine with oil.

Thank you! I should have realized injectors instead of spark plugs.. Thanks though!

- ordered SEM this morning from CTS

[seth_3515]

Well, I got paid today, but the USRT tubular control group buy ended a day or two ago.. I pm'd Scott so hopefully they will let me slip in on the group buy.. Fingers crossed!

[seth_3515]

Apexi avcr install-- few questions..

1) I have the Bentley manual and looked up the vss signal, rpm signal, and tps.
- now, I know the vss can be pulled from the back of the cluster as well, but my main concern is the tps and rpm signal has me worried.. I started on this yesterday after working on the car all afternoon. The first issue, I spliced into the rpm sensor instead of signal then was going for a green/brown wire. Well, when you pull the tape off red looks an awful lot like brown when it's used as the trace on the covering.. Stopped here, wasn't going to eff anything else up til I slept on it.

2) in the wiring diagram index, I used the 2000-2001 standard equipment diagram. My method was to find the signals on the index and use the colored wire that is linked to J220(ECM) in the index. I'm not new to electricity, but these wiring diagrams aren't the best in my opinion. Any help with this would be greatly appreciated! I'll post up pictures of my diagrams and the highlighted wires I think are correct.
-get off work at 12 and will post them up then.

- I really didn't want to take a chance and use a random guide on here with wire colors.. I'm pretty meticulous and second guessed myself, so I have come to the tex for support

[Dave926]

In to see how the gonzo bt file runs

[seth_3515]

In to see how the gonzo bt file runs

That makes two of us! I have The VagCom to run logs and try to remote tune. My goal is to get it running and get through the break-in period. Once that happens, I will get it on the dyno and let the real tuning begin

[mk4boost]

those awic's are so gangster...

good luck with the remainder

[seth_3515]

Well, I owe a huge thanks to Clay @ CTS for getting me an SEM manifold! It will be on its away along with a transition spacer and new injector inserts!

[seth_3515]

Battery talk-

Looking for a lightweight battery that will be relocated inside the cab behind the drivers seat. I am currently looking at Braille's line, but wanted to get some advice on CCA. I live in Oklahoma so its 110 degrees in the summer and <0 degrees during the winter. How many CCAs will reliable crank it over every morning?

[Gonzo@GonzoTuning]

I was wondering why I haven't heard from you in a while. Can't wait till you have this setup running so we can get the tune dialed in

[seth_3515]

I was wondering why I haven't heard from you in a while. Can't wait till you have this setup running so we can get the tune dialed in

Sorry man, been trying to get everything together with work and school as well :/

I shipped off my throttle body to FFE yesterday. Clay had a manifold but it was the 75mm flange, so Ed is gonna port it out and get it to work with his Hemi throttle body!! Thanks again guys!
The new fuel lines, brake stiffening kit, subframe bushings, and Defcons will be here thursday.. THe care will be done then except for the intake manifold and routing the piping!

[seth_3515]

--Just a side story for those wanting the ST coilovers..

- I ordered the setup from HPA motorsports (great price too!). Unfortunately, the product code on the FWD was for AWD. The picture in this thread is actually the wrong rear struts. Now, I didnt put these on for a month or two after ordering, so I didnt find out til weeks later.. I called HPA and got a hold of Darrell. He worked with the supplier to get me new rear struts and had prepaid shipping so I could send them the wrong struts back to them! Everything was handled quickly and professionally.. I highly recommend HPA for the great customer service and communication

[BlueSleeper]

Everything was handled quickly and professionally.. I highly recommend HPA for the great customer service and communication

Hahahahahahaha, that won't always be the case. They still owe me a couple $k, still have my spec clutch, ignored their own warrenty, and dragged me along for over half a year that they had a custom clutch for me.

[Justin@USRT]

Well, I got paid today, but the USRT tubular control group buy ended a day or two ago.. I pm'd Scott so hopefully they will let me slip in on the group buy.. Fingers crossed!

I know Scott said No, but check your pm. I think I have a solution

[seth_3515]

I know Scott said No, but check your pm. I think I have a solution

In Scott's defense he was trying to be fair to everyone, I cant blame him for that.. But I think the proposed solution is quite wonderful!

[seth_3515]

Hahahahahahaha, that won't always be the case. They still owe me a couple $k, still have my spec clutch, ignored their own warrenty, and dragged me along for over half a year that they had a custom clutch for me.

I cant speak for your situation, but Darrell was awesome to work with!

[seth_3515]

fuel lines will be here tonight! im really excited about this!

-6AN Twist-tite Blue lines
-6AN Twist-tite fittings
-5/16 barb to -6AN fittings- Replacing stock fuel filter with direct replacement from ECS and then stepping up to the -6AN line..

-this is only a temporary solution. After some breathing time, I will upgrade the intank fuel pump and run a surge tank with bosch 044 pump.

[seth_3515]

Need to order a few more fittings, but its almost there..




-AWIC heat exchanger in the A/C condensers place.

[Mindfault]

I like this

[seth_3515]

I like this

Thanks man! I appreciate it! hopefully I will have the manifold in a week or two and finally make some real progress

[Gonzo@GonzoTuning]

Is there someway I can convince you to run 830cc's instead of 870cc's? Lol I hate Siemens injectors.

[Mindfault]

^

[seth_3515]

yes if we need to, amy recommendations on brand?

[Mindfault]

Racetronix tri cone spray. They are a flowmatched set but whatever gonzo recommends!

[Big_Tom]

^

this

[seth_3515]

Racetronix tri cone spray. They are a flowmatched set but whatever gonzo recommends!

I'll definitely keep them in mind, but I'll go with the brand that gonzo has had the best experience tuning with (not sure which that is yet, he will chime in here today I'm sure)