A6 2.7T Engine Rebuild

**Calimus** · 12-01-2010 06:02 PM

Good luck. With the plugs out, turning the motor over from the crank with a 1/2" ratchet should take very little effort. Anything that feels like you have to put some elbowe grease into it should pretty much be a sign that things are not well and to stop. Best of luck to ya.

**PluschakovP** · 12-01-2010 07:45 PM

Originally Posted by Calimus

Good luck. With the plugs out, turning the motor over from the crank with a 1/2" ratchet should take very little effort. Anything that feels like you have to put some elbowe grease into it should pretty much be a sign that things are not well and to stop. Best of luck to ya.

yep, i rotated the crank the first time i put the timing belt on and it rotated easily. so this time, i just gotta do the same exact thing right? put the new belt on, and rotate it by hand. if it's freely rotating then it's safe to try and crank it with the starter right?

**Calimus** · 12-01-2010 11:08 PM

Safe would be used very loosely in this case, but aside from just diving in to a head pull, yea, it's about as close as you get. Remember to keep the spark plugs out, even when/if you make it to trying to turn the car over with the starter. Also remember to pull the fuse for the fuel pump less you get 6 fuel sprinklers which will make a hell of a mess.

If by some chance you don't feel any resistance and you give it a try with the starter, don't do it a lot until you have the compression tester. If there is some minor damage, you want to try and limit it as much as possible. So try and keep it to doing the compression test. The engine will spin over at a higher rate with the plugs out as it won't be building compression so just a short 2-3 second turn of the key will spin the motor over several revolutions. Just do it enough to to get a reading per cyl (again, a count to 5 once you hit the key should be enough to get an accurate reading on the tester). Write down the readings so you can keep track and compare. Post up the results here and we'll see what you have.

Again, check the entire path for the timing belt as well. Make sure nothing is touching it that shouldn't be and make sure all tensioner/idler pulley's are turning smoothly. If you managed to dodge a bullet the first time, I don't think you want to chance it a second time. I'm not sure there are enough rabbit's feet out there to pull it off. :)

**PluschakovP** · 12-18-2010 03:25 PM

Put my new Timing Belt on. Hand cranked it couple times. Seemed fine. Started it. See for yourself.

http://www.youtube.com/watch?v=lOO209W7h_g

I am happy.

**walky_talky20** · 12-18-2010 10:01 PM

You definitely lucked out big time. Having it fail at idle is about the best scenario you can hope for as it is just about the only time that you can get away without damage. Still a slim chance, though. Also, realizing what happened and not trying to restart the engine with a broken belt *really* helped. You almost surely would have bent valves if you had done that.

Glad this turned out to be just a learning experience and not an expensive or project-ending disaster.

Now be super careful from now on, because I think you used up all of your luck for quite a while. ;)

**Calimus** · 12-18-2010 11:21 PM

Yup, big time luck on this, but glad it turned out that way. If you were a cat, you would have just used up 8 lives for sure. Can't wait for the next update to be that you're driving it full time. My hats off to you for taking on such a project in the first place at your age and even more so for not giving up despite the potential damage that could have been done. Now, put the rest of that machine together and get some road time.

**PluschakovP** · 12-19-2010 09:55 AM

Originally Posted by walky_talky20

You definitely lucked out big time. Having it fail at idle is about the best scenario you can hope for as it is just about the only time that you can get away without damage. Still a slim chance, though. Also, realizing what happened and not trying to restart the engine with a broken belt *really* helped. You almost surely would have bent valves if you had done that.

Glad this turned out to be just a learning experience and not an expensive or project-ending disaster.

Now be super careful from now on, because I think you used up all of your luck for quite a while. ;)

Originally Posted by Calimus

Yup, big time luck on this, but glad it turned out that way. If you were a cat, you would have just used up 8 lives for sure. Can't wait for the next update to be that you're driving it full time. My hats off to you for taking on such a project in the first place at your age and even more so for not giving up despite the potential damage that could have been done. Now, put the rest of that machine together and get some road time.

thanks guys! yeah im definitely taking all my time now putting it back together. i broke the pvc pipe looking thing that connects to the vacuum check valve so ill need to replace that. also the dumb breather hose cracked and now im either gunna just reconnect it with another piece or just buy a whole new one...

anyhow, im so happy that i got lucky. lol and yeah i realize that i used up all my luck.

im surprised that this project went this well, because this is the first time ive ever dealt with a motor :)

**Vinchenzo51** · 12-19-2010 10:49 AM

oh thank god it worked out for you

i started to feel really bad for you and your project, lol

hope to see her on the road soon doing some snow donuts

**PluschakovP** · 12-19-2010 12:24 PM

I'll be working on the A6 all of this week guys. Hopefully I'll get some major progress on it.

**onyrmom** · 12-19-2010 09:40 PM

Congrats!

**PluschakovP** · 12-22-2010 03:08 PM

Good:

The car is running really smoothly :)

Bad:

I think I forgot to tighten a bolt on one of the turbos. Antifreeze is slowly trickling down from the turbo. Does anyone have a diagram of what turbo lines carry antifreeze, oil, and air? I need to tighten that sucker up! I haven't looked under. It's prolly pretty obvious, but I haven't got on my hands and knees yet.

Okay, so besides the leaky turbo line, the last thing I need is gaskets for the axles to tranny, and tranny to drive line gasket. Anyone know what I'm talking about? ... and know where I can get them? The dealer can't find what I'm talking about so I'm on my own to find those gaskets, or at least know the exact name of them, if they have a special name.

Thanks for all the help guys. This has been one crazy project, I must admit... I think it's because of the fact this is my first motor build though so hopefully it'll go more smoothly when I reseal my A4 2.8L motor.

**Asmir02** · 12-22-2010 06:12 PM

why did u remove the video I wanted to see it

**PluschakovP** · 12-22-2010 08:00 PM

Originally Posted by Asmir02

why did u remove the video I wanted to see it

ill repost tomorrow and put links on first post of this thread. had some problems.

**BigBlack315** · 12-22-2010 08:37 PM

I applaud you on this rebuild you are dedicated

**PluschakovP** · 12-23-2010 10:37 AM

Originally Posted by BigBlack315

I applaud you on this rebuild you are dedicated

thank you :) it's been challenging heh

**PluschakovP** · 12-23-2010 10:53 AM

For 2002 A6 2.7T 6 speed MT.

2 of these, axle to tranny

And 1 of these, driveline to center diff

**Calimus** · 12-23-2010 03:43 PM

Unless Audi does something different, there are no gaskets for the CV shaft connection to the drive cups. You repack some axle grease into the cup (don't fill up though) and then bolt them back together. Now, there are seals on the inside of those cups that are still connected to the trans. However, unless you removed them (they look like a funky bottle cap), they should still be there and unless you are leaking gear oil out of them, they should be fine.

As for the drive shaft, I don't know anything about that as of yet. Hopefully someone that's been in there before can speak up.

**PluschakovP** · 12-23-2010 07:41 PM

Originally Posted by Calimus

Unless Audi does something different, there are no gaskets for the CV shaft connection to the drive cups. You repack some axle grease into the cup (don't fill up though) and then bolt them back together. Now, there are seals on the inside of those cups that are still connected to the trans. However, unless you removed them (they look like a funky bottle cap), they should still be there and unless you are leaking gear oil out of them, they should be fine.

As for the drive shaft, I don't know anything about that as of yet. Hopefully someone that's been in there before can speak up.

I think I might've found what I was looking for at JHM.

http://jhmotorsports.com/shop/catalo...ec08d9d471f593
http://jhmotorsports.com/shop/catalo...ec08d9d471f593

They seem a little expensive though...

**Calimus** · 12-23-2010 08:45 PM

I'll be damned. I've never seen gaskets for the drive axles. 30 bones does seem pricey, but if it's needed, might as well do it right.

**PluschakovP** · 12-23-2010 09:46 PM

Originally Posted by Calimus

I'll be damned. I've never seen gaskets for the drive axles. 30 bones does seem pricey, but if it's needed, might as well do it right.

That's true! I learned my lesson of going the cheap way (hence the timing belt) lol. I'll double check and probably get those ordered soon. Gotta tighten a few bolts then I'll get the gaskets and bring the project to an end.

I need to schedule a State Patrol Inspection to get my Title and License Plates still! I almost forgot...

**Calimus** · 12-24-2010 10:33 AM

Good deal. I myself have some wrenching to do over the holidays myself. PS rack that was leaking a bit totally let go on Monday. Replacement rack arrived this morning. Gonna freeze my ass off since the garage is currently full of a cabriolet and 4 motorcycles, so I get to work in the driveway and for the first time since 93', we are looking to get snow for Xmas. Good times.

**PluschakovP** · 12-24-2010 10:40 AM

Originally Posted by Calimus

Good deal. I myself have some wrenching to do over the holidays myself. PS rack that was leaking a bit totally let go on Monday. Replacement rack arrived this morning. Gonna freeze my ass off since the garage is currently full of a cabriolet and 4 motorcycles, so I get to work in the driveway and for the first time since 93', we are looking to get snow for Xmas. Good times.

haha oh man. if you had a truck i could borrow i'd clean out the second half of my garage and u can park that sucker in it! but you live way out in Georgia lol. you seriously havent gotten snow in 17 years?? im so sorry :( i couldnt live without snow.
well im off to tighten that loose line on the turbo and see what else needs to be done. I'll try and get some pics.

**PluschakovP** · 12-24-2010 05:26 PM

I got the chance to climb under and there was no bolt loose. All it was, was my exhaust leaking a little bit of water because it's not fully tightened still. It was like a rusty light brown/green color which made me think it was antifreeze from the turbo, because there was a little bit of antifreeze over the turbo cuz I was clumsy and spilled some while I was pouring it in. Man I scared myself.

Here's the progress so far guys. Just a couple more things to do and I can lower it down and drive it a little bit. Such a mess in my garage, sheeshh... I'm embarrassed lol.

-MERRY CHRISTMAS-

Missing Fog Light :s it got broken when the previous owner crashed it.

**Calimus** · 12-24-2010 07:32 PM

Awesome progress! Trust me, once you really get a chance to drive it for a few days, you will love it.

An yea, I live in the northern part of Ga and we have had snow over the years, but we generally get it in late Jan to Feb. So white Christmas's are very rare. I really do need to unjunk my garage though. I've gotten slack over the last 3-4 years and it's time I got back to serious business where that's concerned. Besides, with as long as it takes the A6 to warm up in the winter, I'd rather it have a head start from being in the garage.

**PluschakovP** · 12-24-2010 11:57 PM

Originally Posted by Calimus

Awesome progress! Trust me, once you really get a chance to drive it for a few days, you will love it.

An yea, I live in the northern part of Ga and we have had snow over the years, but we generally get it in late Jan to Feb. So white Christmas's are very rare. I really do need to unjunk my garage though. I've gotten slack over the last 3-4 years and it's time I got back to serious business where that's concerned. Besides, with as long as it takes the A6 to warm up in the winter, I'd rather it have a head start from being in the garage.

lol yeah i know what you mean.. expect none of the junk in the garage is mine. at least i was able to get the job done so i'm thankful :)

can't wait to get the gaskets ordered and get her on the road...

What's a good break in period for the Rod/Main Bearings? 1,000 miles?

**Calimus** · 12-25-2010 08:06 AM

The bearings should be fine after 200-400. Those are generally a work or don't work type of item from my experience. But give them a bit before you flog the car much at all.

**PluschakovP** · 12-25-2010 10:29 AM

Originally Posted by Calimus

The bearings should be fine after 200-400. Those are generally a work or don't work type of item from my experience. But give them a bit before you flog the car much at all.

Ooh I hope it's a work type situation for me lol. I would really hate taking this motor apart again. I'm anxious to get into my A4 2.8L already lol.

**PluschakovP** · 12-25-2010 01:11 PM

Found the Axle gaskets. They're Technically called, CV Joint Gaskets, or CV Shaft Flange Gaskets. Weird...

http://www.usautoparts.net/catalog/i...v+joint+gasket

Anyways, I've ordered from US Auto Parts before, and they're fabulous. $25.40 for both gaskets+shipping. Not bad at all.

**Calimus** · 12-26-2010 10:30 AM

Good deal. I'll add them to my parts source list. An am I getting this right that you've picked up two Audi's with various issues? If so, props to you for taking on that much challenge. If you're smart, you will stop at two though. I'm a glutton for punishment with 5 VW's, 1 Audi and 2 Yamaha's. It's like a never ending cycle of repairs. However, some of that work is fun and most of is is rewarding.

**PluschakovP** · 12-26-2010 10:42 AM

Originally Posted by Calimus

Good deal. I'll add them to my parts source list. An am I getting this right that you've picked up two Audi's with various issues? If so, props to you for taking on that much challenge. If you're smart, you will stop at two though. I'm a glutton for punishment with 5 VW's, 1 Audi and 2 Yamaha's. It's like a never ending cycle of repairs. However, some of that work is fun and most of is is rewarding.

well my daily driver is the a4. the second gear went out on me and the motor is a little leaky so after the a6, im going to reseal a4 and i'll probably be done with working on Audis. i got the a6 just to have another car but it broke down. so then this thread happened because of it :)

**Calimus** · 12-26-2010 01:06 PM

Ahh, got ya. Well, with 2 audi's, you'll always ride in style but no doubt, they require more maint then your average bear. However, with they will last virtually forever if you keep them taken care of.

If I had those two, I'd use the A4 for most daily duties and winter beater and use the A6 for some of the summer months and long trips since that's what it's really designed for. I really liked my jetta for taking long trips, but the A6 is a whole 'nother level for sure. Taken a few medium length trips in it and can't wait to do a nice long trip.

**PluschakovP** · 12-26-2010 08:59 PM

yeah the A6 definitely drives more smoothly than the A4.

So while I wait for the gaskets for the CV Joints, I ordered something for myself just for fun. Figure it'd be fun to install a Boost Gauge into this A6. Found it on eBay. Got a pretty good deal. Looks like it'll be nice, and it matches the color scheme of the interior of the A6. I think I'm going to take out the vent on the far left, by the steering wheel, and custom fit a hole and put it right there. any other ideas where to put it?

**Calimus** · 12-26-2010 09:22 PM

I've been thinking about where to stick a boost gauge as well. I'm not a fan of removing an air vent. Down here in the south, you want all the air-ways you can get. I think when I do the rack replacement this week I'll be looking for a good mounting point.

**PluschakovP** · 12-26-2010 10:00 PM

very true! i dont really want to tinker around with vents but it seems like the cleanest place to put it. if you find a good spot, let me know :)

what kind of gauge are you going to install?

**Calimus** · 12-26-2010 10:11 PM

I have a New South Indigo in my wife's Turbo S Beetle, so I'm thinking of going with that again. It's a blue light gauge so it's going to stand out a lot against the red in the Audi. I might search around for something different, not sure yet.

**PluschakovP** · 12-26-2010 10:19 PM

that's awesome. do you know what Fuse I should connect the power to if i want it to be on at all times?

i figure it's best if it's on at all times.

**Calimus** · 12-26-2010 10:37 PM

Not in the A6 I don't, I haven't looked yet. I'll try to have a look at the fuse panel tomorrow.

**PluschakovP** · 12-26-2010 11:10 PM

Originally Posted by Calimus

Not in the A6 I don't, I haven't looked yet. I'll try to have a look at the fuse panel tomorrow.

ok thank you! of all things, i am dumb-founded when it comes to dealing with electrical type things... i dont know very much about that stuff at all.

**PluschakovP** · 12-26-2010 11:13 PM

Here's a video of a B8 S4 with a vent gauge, kind of how I'm thinking of doing mine.

http://www.youtube.com/watch?v=rf0tllIr7VA

**PluschakovP** · 12-28-2010 07:38 PM

The car runs great. Gears switch perfectly. Since the tires have been sitting for nearly a year they are not a perfect circle so the car is jumpy. I hear a little rattle somewhere like something is rubbing but I'm not sure. I will check it out when I get time this Thursday. At least the car runs, tranny works, tires spin. No CEL's. I'm happy.

Here's what I did today...

Didn't get a picture of how I connected the axles to the tranny completely.

But she's all done, for the most part. Just going to lift her up again, make sure everything is Perfect-O, and hope for the best.