Story started few years ago with me buying 1993 164 24v with blown engine. Car was in good condition, perfect candidate for engine swap. Last owner said that engine with motronic was swapped from QV.
Old, blown engine:
After few attempts to find original donor engine, I decided to opt for 166 engine which was available.
Removed old one, restored front subframe (removed rust, primed and painted), placed 166 engine on using engine brackets from 166, for now everything looks right and I can see no potential problems space wise.
To solve rpm sensor problem (sensor on 166 reads form flywheel), I laser cut timing crown from 4mm steal and plan to screw it on original 164 flywheel. Concept is proven to work with other flywheel from automatic gearbox.
Rear engine mount bracket must be used from 166, because oil inlet for filter doesn't fit with 164 bracket , there is a gap on engine block side. Also oil radiator hoses must be used from 166 because of a different connection angles on 166 bracket.
All intake part of engine comes form 164.
We connected it to 164 motronic, attached hoses and tested it while engine is still on the ground under the car, and it works. Idle seems a little high, but I don't want to run the engine too long, don't trust the old timing belt and tensioner, plus there is no cooling at this stage.
Engine start video: http://youtu.be/djiDMB89w-w
Next I plan to change water pump and belts and only then bolt it on.
Donor cars involved:
166 1998 engine donor
166 (burned down)
164 12v 3.0 1993
and unknown valve 164 3.0 1995 which I plan to buy today (owner says it has only minor cluch problems)
Whole intake manifold was full of small metal shavings from old blown engine. It was a close call. Had to disassemble and clean it. This could be perfect keying, or lucky charm. I bet I wouldnt realize why exacly my new engine blew up on first start.
