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1983 Audi Quattro - Updating A Classic (w/video)

580hp TT RS engine swap in a vintage chassis

Greg Emmerson
Jun 13, 2014 SHARE

There are few cars as iconic as the original Audi quattro. It arrived at a pivotal moment in the company's history and it's not a stretch to suggest that Audi's continued existence and its current remarkable health can be directly attributed to it.

Taking all-wheel drive out of the farmyard and giving it to the performance market was a stroke of genius. That it was fitted to a car with such a gloriously muscular appearance that went on to dominate the World Rally Championship didn't hurt either.

Its Audi five-cylinder turbo engine was another unique selling point and, before long, driving enthusiasts had embraced the quattro, granting it a special place in our collective imagination.

1983 audi quattro iroz billet cam cover 09 Photo 2/14   |   Iroz fabricated the billet cam cover and dual-plenum intake manifold to give a retro feel

Nostalgia is a remarkably strong emotion and most of us already have the Audi quattro on our bucket list. We'll overlook its tendency to understeer and pretend they don't cost a small fortune to service and maintain. Yet their biggest problem is simply that it now represents 30 year-old technology. Even the rosiest spectacles can't overlook the improvements that have been made in efficiency, handling and construction during the intervening years, although we acknowledge that its age can also be its charm.

1983 audi quattro A2 rally style rear spoiler 04 Photo 3/14   |   1983 Audi Quattro - Updating A Classic (w/video)

Somebody who fell under the Audi quattro's spell was Hank Iroz. The 29 year-old owner of Iroz Motorsport, located next to Las Vegas Speedway, wasn't even born when these cars first came to prominence, but that didn't impede him.

Owning a self-described "basket case" while in college, Hank had to learn quickly about maintenance for his 1981 coupe. He soon mastered the basics and began trying to make it faster. Before long, word spread among the owners of the 400 or so quattros left in the US, and the demand for his custom parts would pay his way through school.

1983 audi quattro hank iroz josh lofquist 13 Photo 4/14   |   Hank Iroz and Josh Lofquist from Iroz Motorsport in Las Vegas, responsible for building this Frankenstein quattro

Iroz Motorsport
Returning to Vegas two years ago, Hank's business plan was already mapped out, so he found a workshop and began specializing in fabricated and machined parts for the five-cylinder quattro, producing a range that includes intake and exhaust manifolds, engine mounts, etc. A lot of his Iroz Motorsport business is wholesale to other Audi tuners but the small team also services and tunes a range of VW/Audi vehicles, making good use of the in-house chassis dyno.

During our visit, there was a row of five-cylinder Audi models outside the workshop, and a number of quattros inside. We'd come to see the '83 quattro belonging to Sean McLane - a local man who also owns a Lancia Integrale, among other things.

Originally a 2.2-liter 10-valve model, Sean's coupe was in great condition. And while it formerly had a number of performance upgrades, it's now totally unique...

1983 audi quattro VEMS display 10 Photo 5/14   |   VEMS standalone ECU has Bluetooth function that allows dash-mounted Android tablet to relay engine parameters

At some juncture, Hank learned that the quattro's 01E transmission could bolt to the TT RS 2.5-liter, five-cylinder turbocharged motor. This was interesting because the 2.5L is basically half the Lamborghini Gallardo's V10 - an engine capable of producing 550hp and revving to 8500rpm.

Compared to the Audi quattro's five-cylinder, the TT RS engine has a vastly superior head design with excellent flow characteristics. Hank reasoned it would be cheaper and easier to tune the 2.5L than the quattro's popular 20v motor, even allowing for the cost of the conversion kit. And being a relatively new powerplant, the 2.5L should be around for a while, helping to guarantee a plentiful supply of parts.

Even more interesting is that the Gallardo's V10 was also the basis of the EA855 (07K) 2.5L five-cylinder with multipoint injection used in the VW Rabbit and Jetta. In this guise, it's a rather feeble 170hp economy motor that doesn't have the benefit of direct injection. Yet it shares the same basic architecture as the Audi and Lambo versions, making it popular for VW turbo builds. What's more, it's incredibly cheap when compared to the Audi engine, allowing TT owners to rebuild damaged engines far more affordably once the rotating assembly has been strengthened with forged components.

1983 audi quattro enkei PF01 wheel 05 Photo 6/14   |   Porsche big brakes, lightweight Enkei wheels and grippy Continental DW tires

After a brief discussion, Hank and Sean decided to install a 2.5-liter turbo motor into his '83 10v. An intense eight weeks of work saw the car ready for an event called "Battle Born quattro" last August. It's an annual gathering Sean organizes in Las Vegas, designed to tempt quattro owners out of hibernation and onto the racetrack.

In addition to the relative ease of tuning - a standalone ECU, big turbo, injectors and ancillaries saw 590hp - the 2.5L had all its timing chains mounted on the rear once it was fitted longitudinally into the quattro engine bay: it sat transversely in the TT RS, but the older car didn't have enough space to allow that...

The lighter, shorter engine saves 65 lb over the quattro 20v motor, putting less weight over the long nose, helping to improve weight distribution and handling. Using a VW block, it was dressed for battle with forged Mahle pistons, rods and a TT RS forged crank. The compression ratio is a relatively high 9.5:1 because the engine runs on E85 ethanol to maximize output. With a custom flywheel and clutch, the engine and transmission were united, but the oil pan fouled on the sway bar and crossmember. So Iroz Motorsport fabricated a baffled pan with seven-quart capacity to allow sufficient clearance.

1983 audi quattro european headlights 06 Photo 7/14   |   1983 Audi Quattro - Updating A Classic (w/video)

The oil filter needed to be remotely mounted to gain more space, now residing in the driver's side fender. The engine could then be lowered onto the custom Iroz mounts.

For the exhaust, the company used its own equal-length headers, incorporating a Tial blow-off valve and V-band connector. It has matching stainless steel downpipes that were V-banded to an aluminum exhaust system. The latter helped reduce weight, gave a pleasing exhaust note and, we have to say, looked tough sitting in the S1-replica rear bumper.

The turbocharger is a Forced Performance HTA 3582R. It's based on the Garrett GT35R but uses a billet compressor wheel for strength at high boost. It develops most of its power from 4000-7500rpm and, while Hank admitted he could have gone bigger to produce more power, Sean liked its drivability.

Rather than run everything on the quattro's original electronics, Iroz Motorsport installed a VEMS V3 standalone ECU that allowed them to tune for the E85 fuel. Hank has worked with this system before and likes both its flexibility as well as the Bluetooth functionality. It can be mated to any Android device, so the Audi has a tablet mounted in the center console that monitors every engine parameter, from boost to fuel pressure, and can even provide touchscreen navigation, etc.

1983 audi quattro EA855 long block 02 Photo 8/14   |   The TT RS and Sean’s quattro share the same 2.5L, five-cylinder engine, although the Ur has the cheaper VW block

With a thirst for E85, a MagnaFuel ProStar 750 mechanical pump was fitted, along with huge injectors to supply sufficient fuel for the high horsepower application.

With the hood open, you can't help but admire the custom Iroz intake manifold and billet cam cover. These were retro touches requested by Sean as a tribute to the car's roots. In fact, Hank told us the intake is a rally-style dual-plenum design that was popular in the '80s but is no longer necessary with modern software. Yet it looks marvelous with "Turbo" engraved in the original font.

Out of sight is a custom intercooler and radiator, stacked in the nose with end tanks fabricated using the in-house CNC machine.

So how much power does it produce? On the Iroz dyno, the coupe put down 586hp at all four wheels, with 530 lb-ft of torque. Assuming a conventional 25% transmission loss, this 1983 Audi quattro has about 740hp at the crank at 28psi. However, this represents a relatively early state of tune, with Iroz aiming for 600awhp and 650 lb-ft at 35psi with software revisions.

As it stands, the car is frighteningly fast, as can be witnessed in our online video alongside the TT RS that can be found at www.europeancarweb.com

Application
We were genuinely shocked to see the 31 year-old car had such brutal acceleration, but Iroz had done his homework. The transmission's innards, for example, were from the B5 Audi RS4, while the stock locking rear diff will be swapped for a Wavetrac unit to help in the turns.

The stock axles remain, Hank claiming these were over-engineered in the '80s and very capable. In fact, he's expecting low 10sec quarter-mile times out of the box given the car's power and its 2800 lb weight.

The suspension consisted of custom coilovers using Koni dampers and 2Bennett Automotive springs. It also had delrin bushings throughout and was fitted with the four-piston calipers and 330mm rotors from a 996 Porsche 911 Turbo. At the rear it made do with single-piston Audi V8 calipers and 289mm rotors thanks to a Tilton bias valve.

1983 audi quattro iroz exhaust manifold 08 Photo 9/14   |   Equal-length exhaust headers and custom engine mount

The wheels were 17x8" Enkei PF01s that tip the scales at just 17.5 lb per corner. However, the quattro showed its age when they could only be fitted with 225/45 R17 Continental ExtremeContact DW tires under the blistered fenders. Fortunately, the German rubber seemed to give the car ample grip during our visit, allowing the all-wheel drive system to hook up instantly.

Finished in its original Helios Blue, Sean had fitted a Sport quattro-replica fiberglass hood, along with an A2-style (second-gen Group B) rear spoiler. The bumpers were also rally-style and, along with the wider wheels and lowered suspension, these gave the quattro a decidedly beefier appearance that recalled the vehicle's remarkable motorsport history.

The mint interior was largely unmolested, save for the touchscreen in the console that had required the radio be removed and the heater controls repositioned. In fact, Sean pampers the 85000-mile car, insisting it hasn't seen rain since 2004 - not an impossible feat given his Vegas location, yet somewhat missing the point of the quattro. However, it's an indication of his devotion to this rare machine.

1983 audi quattro forced performance HTA3582R turbo 03 Photo 14/14   |   Running at 28psi, the Forced Performance HTA 3582R turbo produces 586hp, 530 lb-ft at the wheels, with more to come

Conversion kit
With the EA855 07K VW 2.5L engine never being offered for sale outside North America, Iroz Motorsport is currently exporting 5-6 every week to Europe for turbo builds. At about $5000 each, these are considerably cheaper than the $12-15000 you'd spend on a TT RS long block.

If you want an engine built to a similar specification as the one in Sean's car, with its standalone ECU, big turbo, downpipes, software, etc, Iroz Motorsport would relieve you of about $20,000. Installed in a quattro, you're looking at closer to $30,000.

If you want to have a go yourself, the conversion kit costs about $2000. It includes the oil pan and filter housing, engine mounts and flywheel. And while the hard work has been done for the quattro, the 2.5L motor can be retrofitted into many different vehicles, including Mk5 and Mk6 Volkswagens. Hank suggested an Audi TTS would make an ideal candidate, building it to 600hp and using its quattro drivetrain to create a TT RS rival for a lower price. The possibilities are potentially endless and we're only just starting to see the 07K's full potential.

Audi TT RS 11 Photo 11/14   |   1983 Audi Quattro - Updating A Classic (w/video)

TT RS
To put the quattro conversion into context, Iroz Motorsport persuaded Los Angeles resident, Derek Powell, to bring his TT RS to Vegas.

Finished in Panther Black Crystal paint with Premium Package trim, the car has APR's popular 100-octane, stage one software upgrade. Enjoying regular track days, Derek also fitted 034 Motorsport's rear sway bar and Integrated Engineering camber plates. Fitted with Carbotech XP-10 brake pads, the car usually wears Miro 111 wheels and Toyo tires. However, these were sacrificed at a recent Laguna Seca track day, so the stock wheels were equipped with 255/35 R19 ExtremeContact DW tires for this occasion.

Audi TT RS 12 Photo 12/14   |   1983 Audi Quattro - Updating A Classic (w/video)

With its superior weight distribution, modern electronics and AWD system, the TT RS would run rings around most Ur quattros on the track. However, this TT would need APR's 600hp stage three upgrade to live with Sean's coupe under acceleration on the road or at a drag strip. And that might be something Derek is considering, as he continues to exploit the dynamic performance of the TT RS.

Sadly, a faulty injector curtailed our plans to obtain a performance comparison between the two Audis, but we'd like to thank both Sean and Derek for allowing us to enjoy their vehicles.

1983 audi quattro iroz oil pan 07 Photo 13/14   |   Iroz oil pan and FMIC clearly visible

Tech Spec
1983 Audi quattro
Owner Sean McLane Las Vegas, NV

Engine
2.5L five-cylinder 20v EA855 long block with Iroz Motorsport stage 3 conversion using 9.5:1 Mahle pistons, DMF connecting rods, TT RS crankshaft, Calico-coated ACL bearings, ARP hardware, Integrated Engineering titanium retainers and high-lift valve springs, Iroz dual-plenum intake manifold, Forced Performance HTA 3582R turbo, Iroz intercooler and radiator, Hallman manual boost controller, VEMS V3 standalone ECU with EFI Express/Iroz harness, MagnaFuel ProStar 750 fuel pump, Fuel Injector Clinic 1600cc injectors, Iroz -8AN rail and line kit, Aeromotive FPR, Iroz equal-length exhaust manifold with TiAL V-band inlet and 44mm MV-R wastegate, Iroz turbo-back exhaust with aluminum rear section, Iroz 7-quart, baffled oil pan with trap doors/windage, Mocal 19-row oil cooler with Iroz filter relocation kit, -10AN lines, 034 Motorsport vortex catch can, Iroz billet cam cover

1983 audi quattro forced performance HTA3582R turbo 03 Photo 14/14   |   Running at 28psi, the Forced Performance HTA 3582R turbo produces 586hp, 530 lb-ft at the wheels, with more to come

Drivetrain
01E close-ratio six-speed manual transmission with Iroz Motorsport B5 RS4 gearset conversion, Iroz lightweight flywheel, Southbend stage 5 clutch, high-bias 80% split center differential, 034 Motorsport delrin rear differential bushings

Brakes
996 Porsche 911 Turbo four-piston calipers, 330mm Racing Brake two-piece grooved rotors front, Audi V8 single-piston calipers, 289mm slotted and drilled rotors rear, Tilton proportioning valve

Suspension
custom coilovers with Koni dampers, 2Bennett Automotive 8" 350 lb f, 9" 380 lb r springs, 21mm rear sway bar, 034 Motorsport aluminum subframe bushings and delrin control arm bushings, Comp Brake UK spherical top mounts, seam-welded subframes

Wheels & Tires
17x8" Enkei PF01 wheels, 225/45 R17 Continental ExtremeContact DW tires

Exterior
SGI Sport quattro-style hood, A2 rally-style rear spoiler, AM Cars rally bumpers, European headlights, clear Euro signals

Interior
updated '84 dash, Google Nexus 7 tablet for VEMS display, GPS and multimedia

Thanks
Iroz Motorsport (irozmotorsport.com)

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By Greg Emmerson
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