From: marcus hutchinson [marcus3@mediaone.net]
Sent: Thursday, March 29, 2001 4:17 AM
To: 928
Subject: [928] Re: Marcus Hutchinson

>
> >
> > I would like information from someone who has BTDT.
> > Marcus Hutchinson, are you out there? Mark Anderson said you've done
this.
> > What are all the parts needed, how did you do it? Did it add much power?
> > Thanks,
> > Rick
> > 85 AT irisblau
>
>
Hmmm Been There, Done That, ok, ok I get it :)


The S4 manifold will bolt on easy enuf to the 85 32V, there is a few things
to do/change

1. Your fuel injectors will need S4 style rubber 'O' rings, they about $3.00
for each injector

2. You will need to change out the fuel rails to S4 style so they will bolt
onto the intake manifold
it's upto you if you want to get the fuel rail covers, they look nice and
help to keep injector noise low.

3. The S4 Idle valve is a 3 wire valve, the 85 is a 2 wire, use your 85 Idle
valve, you will also need
to use the 85 valve clamp, as the S4 one is bigger.

4. The vacuum hoses are a little different, If you can get hold of the 85
diagram and the S4 diagram,
the differences will become clear and the change over will be easier. I have
some if you need 'em.

5. The Flappy valve is controlled by the "brain" on an S4, the 85 does not
have this option, The flappy
opens and closes around 3500RPM, I built a unit to control it, basically a
frequency to Voltage converter
if you don't want to go that far, just get the flappy to stay open all the
time. Note: the flappy gets it's vacuum
from the brake booster vacuum system, not the 6way "Tee" under the Mass Air
Sensor. Also get the hose
from the intake manifold to the brake booser, the 85 one will not work.

6. You will need the S4 style rubber gasgets to seal the intake manifold to
the heads, the 85's uses paper,
and get S4 bolts, washers.

7. Throttle body cable is trickey, you need the plate and wheel that carries
the throttle cable up to the
bracket that connects all the cables from the gas pedal, cruise control and
transmission, this plate with the
pulley on it bolts on the back of the engine, behind the fuel pressure
regulator, get the cable too!
it will become obvious when you go to do this, the bolt holes only line up
to one pair of  bolts, thank the gods this part
fitted on an 85 block otherwise the whole project would have become a
nightmare!
Get the bracket for all the cables that bolts on the side of the S4
manifold, remove the one at the front of
the engine, this part is not needed anymore, you can use your old cables,
just have to loop them over the brake
booster, the gas pedal was not any stiffer and the cruise control and
transmission cables were ok like this too.

8. When the old manifold is removed, you will see 2 studs rising from the
engine block, with rubber mounted
bolts on top, one each side, the 85 throttle body bolts onto these ...
(if they are still intact) remove the rubber and cut the studs off, the S4
throttle body will not clear these studs,
the S4 block does not have them, do not worry about how far you have to cut
them down, they wont leave
holes in the block, it's solid, BTW, cutting these off means there is no
going back :)

9. I never tested the difference between the 2 manifolds because I
supercharged the car and got even more BWAAAHHH!
the reason I swapped the manifolds in the first place was to get room to
install the intercooler unit...

10. I own an S4 so it was very simple, I just parked the cars next to each
other

see  www.marcus3.com for a pic of how it looks


Marcus

78 Euro
85 S Widebody, Supercharged
89 S4