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85 URQ Joins

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 Post subject: Re: 85 URQ Joins
PostPosted: Thu Feb 04, 2016 10:39 pm 
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Aw man. That stinks. I saw somewhere that freezing them helps it go in better. I can't remember where I saw it but I'll try to find it.


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 Post subject: Re: 85 URQ Joins
PostPosted: Mon Feb 08, 2016 3:35 pm 
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This didn't help

Image

But this did

Image[/url]

Now I just need to order another one from Germany :(

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 Post subject: Re: 85 URQ Joins
PostPosted: Fri Mar 18, 2016 11:14 am 
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It's been over a month since I updated this thread so, even though not much has happened I will document it anyway. Actually, looking at my Flickr album there's been quite a lot of little incremental progress :)

First off I received a new and spare bushing from Germany and wasted no time pressing the last one home. You just have to make sure it is being pressed true then squeeze with confidence, after first lubing the sh*t out of it.

Imageimage by Team Illuminata Motorsport, on Flickr

Imageimage by Team Illuminata Motorsport, on Flickr


Then I replace the front strut bellows which arrived the same day as the bushings. Incidentally these are for a Porsche 944! Same part though.

Imageimage by Team Illuminata Motorsport, on Flickr


More bloody squeezing. GGRRR

Imageimage by Team Illuminata Motorsport, on Flickr

Imageimage by Team Illuminata Motorsport, on Flickr


Then I installed the turbo, manifold and down pipe.

Imageimage by Team Illuminata Motorsport, on Flickr

Imageimage by Team Illuminata Motorsport, on Flickr


Need to find a suitable hanger for here.

Imageimage by Team Illuminata Motorsport, on Flickr


This stainless steel beauty from Vibrant should do the trick.

Imageimage by Team Illuminata Motorsport, on Flickr


Next job is to attache the subframe then it's ready to go back in the engine bay. However, the engine bay is not yet ready to accept it as I still need to reinstall the steering rack and refurbish the CIS system. I may reuse the existing hydraulic lines as my supplier's are not in production yet and I want to be driving this in April.

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 Post subject: Re: 85 URQ Joins
PostPosted: Mon Mar 28, 2016 12:32 pm 
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Bought some inspiration over the weekend.

Imageimage by Team Illuminata Motorsport, on Flickr


It inspired me to go on a spending spree. Ordered air box grommets/mounts and filter.

Imageimage by Team Illuminata Motorsport, on Flickr

Imageimage by Team Illuminata Motorsport, on Flickr


Oil can gasket

Imageimage by Team Illuminata Motorsport, on Flickr


Bomb mounts

Imageimage by Team Illuminata Motorsport, on Flickr


Trans oil

Imageimage by Team Illuminata Motorsport, on Flickr


and about $300 worth of vacuum hose, clips and copper washers!

As I can now see light at the end of the tunnel I also turned the engine round on the hoist so it's ready to go in. A little optimistic perhaps?

Imageimage by Team Illuminata Motorsport, on Flickr

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PostPosted: Sat Apr 02, 2016 11:05 am 
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I thought I'd check as many sensors as I could before popping the engine back in. Seems like a reasonable plan. There are like twenty separate temperature sensors on this engine! OK, there's six but still........

Fortunately Audi stamped the range or trigger point on them. Well, most of them.

Imageimage by Team Illuminata Motorsport, on Flickr

I didn't check change over temperature. I just had hot water or no water but I think I proved they all do something so I'm going with that.

Imageimage by Team Illuminata Motorsport, on Flickr

Imageimage by Team Illuminata Motorsport, on Flickr

Imageimage by Team Illuminata Motorsport, on Flickr

Imageimage by Team Illuminata Motorsport, on Flickr


This one tested good too but didn't want to go home :(

Imageimage by Team Illuminata Motorsport, on Flickr


Need to find a seal washer for this one. How hard could that be?

Imageimage by Team Illuminata Motorsport, on Flickr

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 Post subject: Re: 85 URQ Joins
PostPosted: Fri Apr 29, 2016 1:52 pm 
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Replacing the vacuum hoses and clips is a PITA so I found something else to do. I replaced the air box mounts.

Imageimage by Team Illuminata Motorsport, on Flickr


Of course that didn't take very long so it was back to replacing vacuum hoses and clips. Step one, I think. Is to figure what hoses and clips to buy from Audi. Just look at the parts diagrams and the car and figure out what applies. How hard could it be? How about "Bloody impossible!"? OK, not that bad but quite a lot does not match my car. I think I'm going to order as much vacuum line and hose clips as I think I need and just start replacing what physically matches. Of course allof the shaped rubber hose are NLA.

The parts diagrams:

ImageACTIVATED CHARCOAL CONTAINER by Team Illuminata Motorsport, on Flickr

Image4. VACUUM HOSES; VALVE HOUSING; BREATHER VALVE by Team Illuminata Motorsport, on Flickr

Image15. AUXILIARY AIR SLIDE; COLD STARTING VALVE by Team Illuminata Motorsport, on Flickr

Image1320. VACUUM HOSES WITH; CONNECTING PARTS; FOR PNEUMATIC DIFFERENTIAL; LOCK by Team Illuminata Motorsport, on Flickr


and the car:

Imageimage by Team Illuminata Motorsport, on Flickr

Imageimage by Team Illuminata Motorsport, on Flickr


This should be interesting.

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 Post subject: Re: 85 URQ Joins
PostPosted: Mon May 02, 2016 6:51 pm 
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In a moment of inspiration I found this on the underside of the hood. Doesn't help.

Imageimage by Team Illuminata Motorsport, on Flickr


I marked up the parts of the diagrams that resemble my car and went for it.

Imageimage by Team Illuminata Motorsport, on Flickr


The approach is going to be to reinstate everything that's missing in line with the parts diagrams, replace everything thats still there in line with the diagrams and just replace everything that's not in line with the diagrams with the best guess parts and assume it's right as it worked before.

Started with the vent flap as it was the most accessible and matches a diagram. The adjacent lines I tackled next do not match anything. It seems to help disconnecting them if you first cut the old tube along its length to free it from the fragile plastic connectors.

Imageimage by Team Illuminata Motorsport, on Flickr


Et voila! Piece of cake.

Imageimage by Team Illuminata Motorsport, on Flickr


Inspired by my success and the fact that I appear to only have purchased a fraction of what is needed I decided to tackle the charcoal canister. This appeared to want to be on the bench though so, not wanting to annoy it I obliged.

Imageimage by Team Illuminata Motorsport, on Flickr

Imageimage by Team Illuminata Motorsport, on Flickr

Imageimage by Team Illuminata Motorsport, on Flickr


of course I'm missing the clamps so progress has halted, again.

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 Post subject: Re: 85 URQ Joins
PostPosted: Tue May 03, 2016 5:39 am 
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Following this project. Nice work. Could I trouble you for the P/Ns for the Ford hall sensor please?
Thanks, Chris

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 Post subject: Re: 85 URQ Joins
PostPosted: Tue May 03, 2016 6:31 am 
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A1QSHIP wrote:
Following this project. Nice work. Could I trouble you for the P/Ns for the Ford hall sensor please?
Thanks, Chris



sure: http://www.rockauto.com/dbphp/x,carcode ... ickup.html

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 Post subject: Re: 85 URQ Joins
PostPosted: Wed May 18, 2016 10:28 am 
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More tubes, more clamps, more money, more time. The four rings of (old) Audi ownership.

Imageimage by Team Illuminata Motorsport, on Flickr


Still, I think we are done with vacuum hoses :)

Charcoal canister is back on/in the car :) and replaced most of this:

Imageimage by Team Illuminata Motorsport, on Flickr

The "S" shaped hose is NLA as is the little stubby that's actually a reducer, so I left those in place.

This section is all done too:

Imageimage by Team Illuminata Motorsport, on Flickr


And I finally figured out the arrangement for the warm-up regulator after referring to and stealing some from my 83. Not sure why I didn't think of this before.

Imageimage by Team Illuminata Motorsport, on Flickr


What shall we do next; put the engine back in maybe?

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 Post subject: Re: 85 URQ Joins
PostPosted: Tue May 24, 2016 1:53 pm 
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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.

Imageimage by Team Illuminata Motorsport, on Flickr


Fixed that.

Imageimage 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.

Imageimage 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.

Image88d8fca54b29730e841a7e7696536fcc by Team Illuminata Motorsport, on Flickr


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

Image857199386a_857199386a_1 by Team Illuminata Motorsport, on Flickr

Image$_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!

Imageimage by Team Illuminata Motorsport, on Flickr

Imageimage 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.

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 Post subject: Re: 85 URQ Joins
PostPosted: Sat Jun 11, 2016 2:37 pm 
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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.

Imageimage 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.

Imageimage 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.

Imageimage by Team Illuminata Motorsport, on Flickr


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

Imageimage by Team Illuminata Motorsport, on Flickr


And back together.

Imageimage 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 :)

Imageimage by Team Illuminata Motorsport, on Flickr

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 Post subject: Re: 85 URQ Joins
PostPosted: Wed Jun 15, 2016 7:42 am 
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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?

Imageimage 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.

Imageimage 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.

Imageimage by Team Illuminata Motorsport, on Flickr

Imageimage by Team Illuminata Motorsport, on Flickr


Wheel leave them to cure for a while eh.

Imageimage 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.

Imageimage by Team Illuminata Motorsport, on Flickr



Oh, is that the DHL truck?

.

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PostPosted: Thu Jun 30, 2016 6:10 pm 
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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.

Imageimage by Team Illuminata Motorsport, on Flickr

Imageimage 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.

Imageimage 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.

Imageimage by Team Illuminata Motorsport, on Flickr

Imageimage 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.

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 Post subject: Re: 85 URQ Joins
PostPosted: Sun Jul 10, 2016 12:29 pm 
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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.

Imageimage 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.

Imageimage by Team Illuminata Motorsport, on Flickr

Imageimage 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.

Imageimage by Team Illuminata Motorsport, on Flickr


Reconnected the clutch line.

Imageimage 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!

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 Post subject: Re: 85 URQ Joins
PostPosted: Thu Jul 14, 2016 11:10 am 
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Le Tour be dammed; we're working the car! A bit.

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

Imageimage by Team Illuminata Motorsport, on Flickr


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

Imageimage 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.

Imageimage by Team Illuminata Motorsport, on Flickr


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

Imageimage by Team Illuminata Motorsport, on Flickr

Imageimage by Team Illuminata Motorsport, on Flickr

Imageimage 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 ;)

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PostPosted: Fri Jul 15, 2016 6:42 am 
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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.

Imageimage 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.

Imageimage by Team Illuminata Motorsport, on Flickr

Imageimage by Team Illuminata Motorsport, on Flickr

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

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PostPosted: Wed Jul 20, 2016 3:40 pm 
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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.

Imageimage by Team Illuminata Motorsport, on Flickr


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

Imageimage 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?

Imageimage by Team Illuminata Motorsport, on Flickr
Imageimage by Team Illuminata Motorsport, on Flickr


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

Imageimage by Team Illuminata Motorsport, on Flickr


Reinstalled the alternator, intercooler and turbo intake hose.

Imageimage 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?

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 Post subject: Re: 85 URQ Joins
PostPosted: Sun Jul 24, 2016 1:17 pm 
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Quite a bit of progress today.

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

Imageimage 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.

Imageimage 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.

ImageAlt belts by Team Illuminata Motorsport, on Flickr

Imageimage by Team Illuminata Motorsport, on Flickr

Imageimage 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?

Imageoil reservoir by Team Illuminata Motorsport, on Flickr


Imageimage by Team Illuminata Motorsport, on Flickr


It worked before so we reinstalled it.

Imageimage by Team Illuminata Motorsport, on Flickr


Then we reinstalled all the hydraulic lines.

Imageimage by Team Illuminata Motorsport, on Flickr

Imageimage 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.

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 Post subject: Re: 85 URQ Joins
PostPosted: Mon Jul 25, 2016 3:17 pm 
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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.

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 Post subject: Re: 85 URQ Joins
PostPosted: Mon Jul 25, 2016 6:43 pm 
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sepp wrote:
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.

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 Post subject: Re: 85 URQ Joins
PostPosted: Wed Jul 27, 2016 2:21 pm 
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STAY COOL AND QUATTRO ON.

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

Imageimage by Team Illuminata Motorsport, on Flickr

Imageimage by Team Illuminata Motorsport, on Flickr

Imageimage by Team Illuminata Motorsport, on Flickr


Starting to look together :)

Imageimage 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?

Imageimage by Team Illuminata Motorsport, on Flickr



Next, the ignition system, perhaps.

Imageimage 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?

Imageimage by Team Illuminata Motorsport, on Flickr

Imagedistributor by Team Illuminata Motorsport, on Flickr


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

Imageimage by Team Illuminata Motorsport, on Flickr

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PostPosted: Mon Aug 01, 2016 12:18 pm 
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The extra connector by the warmup regulator may be for the injector cooling fan. It sits close by there..

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PostPosted: Mon Aug 01, 2016 12:33 pm 
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The extra connector by the warmup regulator may be for the injector cooling fan. It sits close by there..

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Image <- "The Twins" Image

91 20vt Avant (The Couch Rocket...So fast in such comfort..)
83 URq ("Roland" Think: 'The Gunslinger'.. Just gets the job done.. )
85 4kq ("Rusty", because he is. Best winter car *ever*!)


(Plenty Many Audi Pictures: http://www.frankdekat.com/pics/audi/Audipics.html )


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 Post subject: Re: 85 URQ Joins
PostPosted: Mon Aug 01, 2016 12:39 pm 
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I sprinkle rubber on my Cherios
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Joined: Wed Jun 01, 2011 4:55 am
Posts: 391
Katman wrote:
The extra connector by the warmup regulator may be for the injector cooling fan. It sits close by there..


Thanks Frank. I think that's it.

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Paul Eddleston
TIM Team Illuminata Motorsport
http://www.teamilluminata.com
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