Eric's '90 80 quattro mod & initial repair list
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6/2019
Notes:
Most of this work was done summer 2012, about 26K miles ago.  Items described as "new" were installed at
 that time unless otherwise noted.

Extensive use of stainless materials and fasteners has been made for longevity & maintainability.

Engine & related:
	AAN from urS6
		No internal mods
		Custom-modded intake manifold to clear side-mount radiator
		7A oil pan (also to clear radiator)
		Custom idle-control-valve and PCV plumbing
		Custom cruise-control-actuator bracket (works!)
		Custom serpentine idler pulley mount (replaces idler w/fan)
		P/S pump from early V6 A6 installed
		Custom sender keeps car's full oil-pressure-warning function + gauge
		(Real) RS2 exhaust manifold
		Volvo K24-7400 turbocharger rebuilt & installed in 2014
		Custom bracket for A/C compressor (but compressor not installed)
		Customized water manifold to work with side-mount radiator
		Front-mounted crossflow all-metal intercooler (mounted on custom stainless frame)
		Urquattro oil cooler

	Megasquirt MS3 engine-management system
		All optional features installed: MS3X expander board, real-time clock, dual knock-sensor board
		Wideband O2 sensor
		USB and CANbus cables accessible in passenger compartment
		SD datalogging card easily accessible from passenger footwell
		Bluetooth interface
		Wired to instrument cluster temp. gauge for more accurate reading
		Has MAP and MAF sensors so can be tuned to run on either (currently uses MAP)
		Modern coil-on-plug ignition
		4-port boost control solenoid (allows higher boost)
		Boost-per-gear function programmed to reduce boost in 1st and 2nd gear
		Reads and logs vehicle speed
		Capable of launch control but would need to add clutch switch

	PTFE (Teflon) fuel lines installed (can't rust!)

Other drivetrain:
	016 transmission & rear diff. (3.89:1 ratio) from 1983 urquattro
	Rebuilt (all new bushings etc.) shift linkage from 4KQ
	New 200 20V clutch, pilot & throwout bearings, slave cylinder
	Urquattro center driveshaft w/new center bearing
	Center diff lock linkage replaced w/stainless
	Center and rear diffs. both lock (together)
	Auto-unlock system in place but unlock speed raised to just over 30 MPH
	Diff-lock-status indicator in console has LED added to show status of center diff
	Outer CV joints w/tone rings for ABS
	About 20 inner CV joints were disassembled, bad parts disposed of, cleaned up, put back together using best parts
	  (Still have lots of spares that will go with car)
	Front halfshafts are coupe quattro rears
	Front wheel bearings from coupe quattro (new)
	Font hubs from UrS4 machined to fit (also have two spares)
	Rear halfshafts from FWD B5 A4, shortened
	Rear wheel bearings & hubs from B5 A4 (new)
	Stud kit installed (so lug nuts, not bolts are used)
	Porsche alloy lug nuts (amazingly light)

Exhaust:
	Iroz 3" downpipe, modded for optimal fit with 016 transmission (pipe is designed for 01E)
	3" sport catalytic converter
	Custom 304 stainless 3" to 2.5" reducing pipe after cat
	Magnaflow 2.5" stainless front muffler
	Pipe over rear axle is urquattro stainless, w/new stainless flanges and fasteners
	Magnaflow 2.5" stainless rear muffler
	400-series stainless 2.5" tailpipe (a but rusty but solid)

Suspension & related:
	Car has "late style" suspension with forged front lower control arms, 2-piece uprights
	Car came with coilover conversion, this was removed and sold
	Uprights from coupe quattro installed
	Uprights had rust removed electolytically, painted with POR-15 polyurethane paint (super-durable)
	New rear control arms w/bushings
	New rear ball joints
	New front ball joints (from coupe quattro, give 1 degree more caster)
	New Boge turbo gas shocks all around
	New H&R sport springs (3/4" lowering)
	New Meyle HD upper strut mounts (since replaced fronts w/Febi but saved the Meyle ones)
	Rear subframe cleaned up & painted (has since developed some surface rust)

Brakes:
	Stock rear calipers, ceramic pads
	Rear rotors from B5 A4 quattro
	276x25mm front rotors from coupe quattro, redrilled to 5-lug pattern
	"G60" calipers from coupe quattro, ceramic pads
	ABS (w/traction control) from 1995.5 urS6 installed
	ABS "off" switch installed
	Custom stainless bracket for ABS pump/valves installed
	Additional F-to-R brake line installed for 4-wheel ABS (rust-resistant cupronickel tubing)
	Wiring to shut off ABS/traction when diffs locked not installed (must turn off manually)

Wheels & tires:
	Winter wheels are urquattro standard rims
	Summer wheels are lightweight Fuchs forged
	Both are 14" x 6" I think?
	Winter tires: General Altimax Arctic, about 1/2 tread remaining
	Summer tires: Bridgestone Potenza RE-11, about 1/8 tread remaining (will probably need replaced after this summer)
	
Electrical and related:
	Battery (Optima, about 2 yrs. old) relocated to trunk
	Circuit breaker installed @ battery (with guard to keep cargo from hitting it)
	Battery tray under hood removed (cut metal sealed w/polyurethane and painted)
	Depo e-code headlights installed in 2013
	Headlights relayed, relays & related in weathertight box under hood
	Relay box also contains relays & fuses for Megasquirt
	Bulb-check relay for headlights installed but never wired to instrument cluster
	Alternator & starter power wiring new w/aircraft-grade PTFE-insulated wire
	Heavy studs installed under hood for power distribution
	All wiring done to high standards using automotive-grade high-temp wire, soldered & heatshrunk joints whenever possible

Interior / other:
	Speedo replaced with 160 MPH (odometer reading set when installed so is correct)
	Tach replaced with 7000 RPM redline
	VDO 25 PSI boost gauge installed (in pod on top of dash, w/illumination)
	Clock in instrument cluster replaced w/one from B4 90
	Bushings on front seats replaced to reduce slop
	Sony AM/FM/CD/MP3 stereo installed, can play MP3s from CD or thumb drive
	Cambridge Soundworks satellite speakers installed in front footwells
	8" Boston Acoustics sub installed in custom box that fits in ski passthrough in trunk
	Jensen amp for sub (fronts are powered from head unit)
	OE rear speakers are present but not connected
	Knee bolster above driver footwell replaced with parcel shelf
	Inside rearview mirror replaced w/one from B4 90 that has no deterioration and is a little larger