Automobiles Forum banner
361 - 380 of 413 Posts

·
Registered
Joined
·
440 Posts
Discussion Starter · #361 ·
Decided to curb my enthusiasm and fix a few more things before impetuously throwing the engine back in. Someone had spliced in a new piece of wire at some point; quite poorly.

image by Team Illuminata Motorsport, on Flickr

Fixed that.

image by Team Illuminata Motorsport, on Flickr

This, however, can wait. It sits on top of the intake which makes it easier to repair in situ.

image by Team Illuminata Motorsport, on Flickr

Found we are missing the heat shield over the right engine mount; the one that had failed. Of course its No Longer Available.

88d8fca54b29730e841a7e7696536fcc by Team Illuminata Motorsport, on Flickr

This is what it looks like in the flesh; OK on Google.

857199386a_857199386a_1 by Team Illuminata Motorsport, on Flickr

$_1 by Team Illuminata Motorsport, on Flickr

The we had a great idea; let's steal the one off the 83 in the corner. It was impossible to see but we managed to removing the mounting hardware, surprisingly. Even more surprisingly we managed to extract it without having to remove anything else!

Then, even, even more surprisingly it looked like this!

image by Team Illuminata Motorsport, on Flickr

image by Team Illuminata Motorsport, on Flickr

Obviously a cobbled together facsimile. What is odd, beside the strange tube is the fact that what's left of the original is still encased within. Obviously not going to work on the 85. Off to Audi Tradition to get reamed again.
 

·
Registered
Joined
·
440 Posts
Discussion Starter · #362 ·
Waiting for parts (drums fingers on desk)

Decided to find some things we will need to do before the car is ready to fire up. Getting ahead so to speak. The hydraulic "bomb" mounts need replacing as the leaking oil has softened them up and they have started to split. Fortunately we bought some new ones a while back. A good time to replace them.

image by Team Illuminata Motorsport, on Flickr

Fortunately the nuts weren't too rusty and didn't put up a fight. Sometimes leaky hydraulics has benefits.

image by Team Illuminata Motorsport, on Flickr

Uh oh! this must have happened in storage DOH. Let's hope they bend back without breaking off. Perhaps we should order a new one anyway.

image by Team Illuminata Motorsport, on Flickr

Old vs. new. A couple are still serviceable. We'll keep them for spares.

image by Team Illuminata Motorsport, on Flickr

And back together.

image by Team Illuminata Motorsport, on Flickr

And on the engine. Yes, it surprised us too. Well, we had to put it somewhere and the dodgy spade terminals we bent back into place will be safer here than back in the parts box. It shouldn't hinder engine installation and one more thing done :)

image by Team Illuminata Motorsport, on Flickr
 

·
Registered
Joined
·
440 Posts
Discussion Starter · #363 ·
Another update in less than a week. You guys must be feeling rather special now eh?

Just trying to find things to do while those damn heat shields arrive from Germany. Rummaged through the parts bins and found the old front brake lines that need replacing. Couldn't find any OE so decided to make these Centric ones look like OE by transferring the rubber rings over. What do they do anyway?

image by Team Illuminata Motorsport, on Flickr

We actually had some we pulled off the 83 car. That one's getting stainless lines so we just cut the old ones which made getting these off quite simple.

image by Team Illuminata Motorsport, on Flickr

However, getting them on the new lines was not so easy as they didn't want to expand over the fittings. Never mind, nothing a utility knife and some glue can't handle.

image by Team Illuminata Motorsport, on Flickr

image by Team Illuminata Motorsport, on Flickr

Wheel leave them to cure for a while eh.

image by Team Illuminata Motorsport, on Flickr

We only need one holder ring so we cut one off. We decided to use the Centric one as our original ones are already falling apart.

image by Team Illuminata Motorsport, on Flickr

Oh, is that the DHL truck?

.
 

·
Registered
Joined
·
440 Posts
Discussion Starter · #364 ·
When we last conversed we were finding things to do while we waited for a heat shield to arrive from Germany. Well guess what; it arrived, along with a few other bits and bob. we must say, it looks a lot better than what we pulled out of the 83.

image by Team Illuminata Motorsport, on Flickr

image by Team Illuminata Motorsport, on Flickr

It was quickly installed but as soon as it was on we thought "Uh oh, we might have to take it off to get the engine in" DOH! well, we had no idea what it looked like until it was here so how could we know it might be in the way. Oh well, another month wasted.

image by Team Illuminata Motorsport, on Flickr

So, not to waste any more time we quickly started to pop the engine back in. It was a little tricky to lift it into place as we had to guide it around a lot of stuff (but not that damn heat shield as we took it off) but eventually it lined up with the engine and subframe mounts and we bolted into place, hand tight for now.

image by Team Illuminata Motorsport, on Flickr

image by Team Illuminata Motorsport, on Flickr

This is the first time it's had an engine in it since February 2015! We have so much more room in the shop now.

What next then? We guess connect as little stuff as necessary to fire it up while refurbishing whatever is necessary. Stay tuned.
 

·
Registered
Joined
·
440 Posts
Discussion Starter · #365 ·
Started to put the car car back together yesterday. Unfortunately it's been two years since we last saw where everything went so it's a bit of a challenge. Fortunately we have an 83 in the corner to refer to. Unfortunately, because it's a Quattro you can't see anything LOL.

Still, we press on regardless.

Aligned the engine and torqued all the subframe, engine and transmission bolts. Well, the ones you can get a torque wrench on.

connected the hydraulic pipe to the bomb. This connection does not seem to rotate so we took the bomb off and rotated that instead. This is now the third time we have installed the bomb.

image by Team Illuminata Motorsport, on Flickr

Reconected the exhaust.

Reconnected the rear drive shaft.

Reconnected the shift linkage. Goes into all the gears but might need adjusting though.

Installed the right engine mount heat shield, again. It wanted to go in front of the oil cooler mounting tab so we mounted that too. I bet we take it off again later.

image by Team Illuminata Motorsport, on Flickr

image by Team Illuminata Motorsport, on Flickr

Installed the right transmission mount heat shield. Yes, we are missing a screw. It's like no other screw on the planet and seems to be NLA. Thanks Audi.

image by Team Illuminata Motorsport, on Flickr

Reconnected the clutch line.

image by Team Illuminata Motorsport, on Flickr

Not sure when we'll get chance to throw some more parts at it. Schedule is a bit full for the foreseeable future and the Tour de France is on TV six hours a day!
 

·
Registered
Joined
·
440 Posts
Discussion Starter · #366 ·
Le Tour be dammed; we're working the car! A bit.

Got the oil bollocks, er, we mean oil filters installed.

image by Team Illuminata Motorsport, on Flickr

and the front torque support/alternator mount. What does that do anyway?

image by Team Illuminata Motorsport, on Flickr

Installed the vacuum lines on the front diff actuator while it is still accessible. Looks like we may have guessed the orientation correctly.

image by Team Illuminata Motorsport, on Flickr

Axle, strut and brakes! Well, on one side at least but still......

image by Team Illuminata Motorsport, on Flickr

image by Team Illuminata Motorsport, on Flickr

image by Team Illuminata Motorsport, on Flickr

It's starting to look like a car again. Next year we'll install the strut on the other side ;)
 

·
Registered
Joined
·
440 Posts
Discussion Starter · #367 ·
More progress. Yes, we know. We are going nuts.

We had to put the other side's front suspension on. We couldn't help ourselves.

image by Team Illuminata Motorsport, on Flickr

The interesting thing now is that we could roll it off the hoist if needed. However, we swore it would only ever drive off. Let's see how that works out.

One exciting (to us) aspect of the suspension reinstall is that we think we may have found a solution for a problem that isn't really a problem. Due to the upper strut bushings compressing even when new, there is always a gap between the strut top and the body. We found some rubber washers in the plumbing isle that fill this gap perfectly and installed them today. Makes us warm and fuzzy inside.

image by Team Illuminata Motorsport, on Flickr

image by Team Illuminata Motorsport, on Flickr

We used two per side. One and a half would have been perfect.
 

·
Registered
Joined
·
440 Posts
Discussion Starter · #368 ·
Thankfully Some bright spark pointed out that the strut top has to be loose enough to rotate with the strut shaft so we removed one washer.

image by Team Illuminata Motorsport, on Flickr

Then we reinstalled the inner CV heat shield on the right side.

image by Team Illuminata Motorsport, on Flickr

These are the wires which have to find their way onto the starter. We are not sure where the two different style of spade connectors go. Any insight?

image by Team Illuminata Motorsport, on Flickr
image by Team Illuminata Motorsport, on Flickr

so we took a guess for now. Are we right?

image by Team Illuminata Motorsport, on Flickr

Reinstalled the alternator, intercooler and turbo intake hose.

image by Team Illuminata Motorsport, on Flickr

All that's really left is the radiator, hydraulic system, ignition system, throttle body, injection system and to connect a bunch of wires and vacuum hoses. How hard could it be?
 

·
Registered
Joined
·
440 Posts
Discussion Starter · #369 ·
Quite a bit of progress today.

Installed the front anti roll bar. Almost forgot it had one.

image by Team Illuminata Motorsport, on Flickr

Installed the new hydraulic pump belt. Of course we had to remove the pump to get the belt over the pulleys. Not a lot of room in front.

image by Team Illuminata Motorsport, on Flickr

Also installed the alternator belt though we didn't think we had one. Our car (WX) is supposed to use a 9.5x850 v-belt but we only had a 9.5x786 for the WR and GV model. Turned out that was the right one for our WX. Go figure. This one went on a lot easier than the pump belt though tightening the alernator pivot bolt was a challenge.

Alt belts by Team Illuminata Motorsport, on Flickr

image by Team Illuminata Motorsport, on Flickr

image by Team Illuminata Motorsport, on Flickr

Excited buy our belt success we looked in the parts box to see what else we could throw at the car. We decided to reinstall the hydraulic hoses and reservoir as it all goes on the left side of the engine bay and would be easier now rather than with the radiator in place. But first we had to locate and connect a few wires as these all reside under the hoses. The wiring connectors are beginning to find their own ways home but some are still troubling us. We are hoping those will become obvious soon enough.

First the oil reservoir. We thought we'd dismantle on the bench and see if any of the parts indicated on the parts diagrams needed replacing. However ours was empty inside. Is this right?

oil reservoir by Team Illuminata Motorsport, on Flickr

image by Team Illuminata Motorsport, on Flickr

It worked before so we reinstalled it.

image by Team Illuminata Motorsport, on Flickr

Then we reinstalled all the hydraulic lines.

image by Team Illuminata Motorsport, on Flickr

image by Team Illuminata Motorsport, on Flickr

Next time we think we'll put the cooling system back. Hopefully that wont be too long from now.
 

·
Registered
Joined
·
322 Posts
That's interesting...
Mine has a plastic screen in it, to keep large chunks of stuff out of the canister...but no filters as seen in the drawing.
I wonder if it was some kind of mod to remove the filter element...or just laziness on the POs part in tracking down a filter.

I'll have to ask around with other owners on that.
 

·
Registered
Joined
·
440 Posts
Discussion Starter · #371 ·
sepp said:
That's interesting...
Mine has a plastic screen in it, to keep large chunks of stuff out of the canister...but no filters as seen in the drawing.
I wonder if it was some kind of mod to remove the filter element...or just laziness on the POs part in tracking down a filter.

I'll have to ask around with other owners on that.
Sounds like mine: just a plastic screen.
 

·
Registered
Joined
·
440 Posts
Discussion Starter · #372 ·
STAY COOL AND QUATTRO ON.

Yes, we put the cooling system back in. Found some new old stock hoses in the parts bin too :)

image by Team Illuminata Motorsport, on Flickr

image by Team Illuminata Motorsport, on Flickr

image by Team Illuminata Motorsport, on Flickr

Starting to look together :)

image by Team Illuminata Motorsport, on Flickr

On an unrelated topic does anyone know which one of these two connectors goes to the warm up regulator and where the other one goes to?

image by Team Illuminata Motorsport, on Flickr

Next, the ignition system, perhaps.

image by Team Illuminata Motorsport, on Flickr

However, this little spring was left over from the distributor refresh. We can't figure out where it came from. It's not shown on the parts diagram. Any ideas?

image by Team Illuminata Motorsport, on Flickr

distributor by Team Illuminata Motorsport, on Flickr

We also found some new ignition leads in the parts bin. 200998031A
Right ones?

image by Team Illuminata Motorsport, on Flickr
 

·
Registered
Joined
·
1,864 Posts
The extra connector by the warmup regulator may be for the injector cooling fan. It sits close by there..
 

·
Registered
Joined
·
1,864 Posts
The extra connector by the warmup regulator may be for the injector cooling fan. It sits close by there..
 

·
Registered
Joined
·
440 Posts
Discussion Starter · #377 ·
When we left you we were trying to figure out where the little spring went in the distributor and contemplating reinstalling the ignition system. Well, just prior to our trip to Pebble Beach for the car events and elsewhere we did just that:

We pulled the distributor from our 83 and it turns out it goes right here:

image by Team Illuminata Motorsport, on Flickr

So we popped it in, reassembled the distributor and installed it on the engine. Timimg was still set so it was a doddle to line up at TDC.

image by Team Illuminata Motorsport, on Flickr

Then we turned our attention to the spark plug wires. The car is supposed to have a plastic tube to carry and support the wires but ours never had one. Fortunately we had picked up one in a parts haul a while back and now seemed the time to install it. This meant pulling the ends of each lead and pushing through it's a appropriate hole then reattaching the end. We used our old leads after testing them as the spare ones we showed you earlier proved not to be compatible.

image by Team Illuminata Motorsport, on Flickr

The carrier is attached to the valve cover screws with two plastic-clad metal brackets. We didn't have these and they are NLA but a trip to the hardware store produced something almost identical so we went with those.

image by Team Illuminata Motorsport, on Flickr

So now we have an ignition system:

image by Team Illuminata Motorsport, on Flickr

This week, schedule permitting, we'll start on the fuel inject system. Almost done!
 

·
Registered
Joined
·
440 Posts
Discussion Starter · #378 ·
YAY. Our pictures are back!

We had all our early pictures hosted on some servers that went away. Now we have them hosted more securely and have replaced all the broken links. As a bonus you can also see full size images for this and all our other builds here: https://www.flickr.com/photos/team_illuminata/albums
 

·
Registered
Joined
·
440 Posts
Discussion Starter · #379 ·
Feels like we are very close. Also feels like winter is approaching. Better get cracking.

Started cleaning the fuel injection system. Decided not to dismantle it and just leave well alone.

image by Team Illuminata Motorsport, on Flickr

Air filter housing:

image by Team Illuminata Motorsport, on Flickr

image by Team Illuminata Motorsport, on Flickr

image by Team Illuminata Motorsport, on Flickr

New injectors and seals

image by Team Illuminata Motorsport, on Flickr

image by Team Illuminata Motorsport, on Flickr

Battery!

image by Team Illuminata Motorsport, on Flickr
 

·
Registered
Joined
·
440 Posts
Discussion Starter · #380 ·
On a roll now :)

Jumped the fuel pump relay to drain some old fuel.

image by Team Illuminata Motorsport, on Flickr

image by Team Illuminata Motorsport, on Flickr

New filter

image by Team Illuminata Motorsport, on Flickr

Had to come up with a way to mount this thingy-me-jig as the mounting tabs were long gone.

image by Team Illuminata Motorsport, on Flickr

image by Team Illuminata Motorsport, on Flickr

Turbo inlet. Tight down there.

image by Team Illuminata Motorsport, on Flickr

and fuel distributor

image by Team Illuminata Motorsport, on Flickr

Our parts shelf is look quite bare now.
 
361 - 380 of 413 Posts
Top