A6 2.7T Engine Rebuild

[julex]

I snapped about 5 of these bolts in my career. They are made "Soft" on purpose so that you snap a bolt and not screw (haha) up the thread in housing.

[PluschakovP]

I snapped about 5 of these bolts in my career. They are made "Soft" on purpose so that you snap a bolt and not screw (haha) up the thread in housing.

haha that's why it stripped that easily... man. yeah next time im just gunna tighten until it stops on its own. do like another 15 degrees and that's it. i am not breaking another bolt haha

[ACTION]

NICE!! I'm really liking this thread and build. Thanks for sharing your humor, you are a trip. I also like the fact that you have no problem saying you are ole skool. I don't have anything close to your technical skill. But I have changed front, rear rotors and pads.....Hey I went to prep school, no auto shop! I also changed spark plugs and coil packs, fuel injectors as well. Okay I said all that to give you kudos on the build and your skill set. I'm rockin’ 3 car seats in the back of my allroad stage 3-. I also went with the 01e 6 speed swap. I have 18 inch OZ Canyons and did the 2Bennet coilover program 3 years back. I once smoked a black dodge Caliber srt4 that had a sticker on the back window that read, "You just got beat by a Wagon"! For rear BBK calipers check out Ebay.de. They carry a lot of caliper brackets for Porsche to Audi set ups. Can’t wait to see the final product. Welcome to the club.
Kyle

[Zachariah]

I'm a student too and don't nearly have the balls to tackle what you just did....good work!

[PluschakovP]

thanks guys, im a normal 19 yr old with limited experience with cars... pretty sure if i can do it anyone can. you just need to watch a lot of youtube vids of many diff things and put it into use. you'll be surprised that you know so much more than you think.

[Asmir02]

thanks guys, im a normal 19 yr old with limited experience with cars... pretty sure if i can do it anyone can. you just need to watch a lot of youtube vids of many diff things and put it into use. you'll be surprised that you know so much more than you think.

Totally agree dude, special if you wanna save lots of money. People always tell me leave to pro but screw the pro they rip me off bad.

[PluschakovP]

Totally agree dude, special if you wanna save lots of money. People always tell me leave to pro but screw the pro they rip me off bad.

yep, this was a $5,500 job for a mechanic... lol i was like mhmm buh bybe, ill do it myself and if i f it up, then ill just buy a new motor and still save more money than to let them do it.

[ECS Tuning-Audi]

yep, this was a $5,500 job for a mechanic... lol i was like mhmm buh bybe, ill do it myself and if i f it up, then ill just buy a new motor and still save more money than to let them do it.

I hope that bolt works out for you! It will be good to see this job concluded.

I am in my twenties, and about a decade ago, the engine threw a rod in my first car - a 1983 Pontiac Phoenix. I was pissing and moaning to my dad about needing a new car, and how much I loved the thing. His response: why don't you just put in another engine? So, with the help of the Haynes manual, I did. Haven't taken a vehicle to the shop since. Threads like Paul's here remind me that anything can be fixed if you're comfortable with a wrench!

[PluschakovP]

ETA is this coming up Tuesday, the 16th!

See you then.

[PluschakovP]

Putting the wire harness back on.


Wire harness on, just need to do Timing Belt.


Timing Belt Without Lock Bar


Align the Crank to Top Dead Center (TDC)


Align both cams to marker ticks. Look closely in pictures below.
(Courtesy picture of gearhead1186)


(Courtesy picture of gearhead1186)


(Courtesy picture of gearhead1186)

I'll install Timing Belt after motor is back in the car.

See you then guys.

[Scotty@Advanced]

^ why would you want to go with new rods? The OEM ones are forged and can handle 600whp easy.

I believe the rods are powdered metal not forged.

[PluschakovP]

I believe the rods are powdered metal not forged.

"Originally Posted by TheBlueMartin
^ why would you want to go with new rods? The OEM ones are forged and can handle 600whp easy.

I got used OEM rods from another motor since one of mine got badly scratched. I also got a Used crankshaft from another motor as well since it was scratched as well.

[Asmir02]

PluschakovP do you know how to align the camshaft pulleys without the special tools or markings?

[fukinavit]

I believe the rods are powdered metal not forged.

no, the rods, pistons and crank are all forged in this lump.

[PluschakovP]

PluschakovP do you know how to align the camshaft pulleys without the special tools or markings?

well i didn't mess around with the pulleys. but i know that the bigger ovals on the pulleys should be pointing towards each other, and then with you valve covers off, align the cams with the markings (the pictures i posted), then put the pulley on. That's how I would do it if the camshaft pulleys were not aligned.

no, the rods, pistons and crank are all forged in this lump.

Well the OEM crank is Induction Hardened. The rods and pistons - I have no answer, but they can handle a lot of power.

[ECS Tuning-Audi]

How did the bolt work out? Did it?

[PluschakovP]

How did the bolt work out? Did it?

i havent got it yet. should be here in probably like an hour. I AM REALLY HOPING IT'S RIGHT.... got plans to put motor back in and start her up for tomorrow haha. if not, oh well... wasnt meant to be then

[ECS Tuning-Audi]

I hope it's right too! Keep my fingers crossed for you!!

[PluschakovP]

How did the bolt work out? Did it?

It is a 3 hole banjo, wrong size though...

Won't be working on my car for a while until I get this bolt. What a pain in the gluteus maximus.

[PluschakovP]

Waiting for Bolt I was like:




Bolt came I was like:

[awdjunkies]

Waiting for Bolt I was like:




Bolt came I was like:

Lmao!! great representation my friend!!

[walky_talky20]

What bolt did you purchase?

From your diagram, it looks like you need bolt #30. The banjo bolt on the compressor housing of the passenger side turbocharger. I ran it through vag-cat and got the part number:

N90183603
http://www.ecstuning.com/Search/N_90183603/ES469289/

Which one did you order?

EDIT: It looks like you ordered/received bolt #6. Part number:
N0210717
http://www.ecstuning.com/Search/ES466874/ES466874/

That would be the banjo bolt for all the coolant connections - which is a larger bolt. Check out the end of the bolt shafts. Yours is a small hole in the end. The coolant bolt is wide open on the end. How did your dealer and ECS mess this up?

[PluschakovP]

What bolt did you purchase?

From your diagram, it looks like you need bolt #30. The banjo bolt on the compressor housing of the passenger side turbocharger. I ran it through vag-cat and got the part number:

N90183603
http://www.ecstuning.com/Search/N_90183603/ES469289/

Which one did you order?

EDIT: It looks like you ordered/received bolt #6. Part number:
N0210717
http://www.ecstuning.com/Search/ES466874/ES466874/

That would be the banjo bolt for all the coolant connections - which is a larger bolt. Check out the end of the bolt shafts. Yours is a small hole in the end. The coolant bolt is wide open on the end. How did your dealer and ECS mess this up?

Actually both of those bolts in the links you gave me are wrong... it's the "wrong bolt for the right application."
I've ordered 5 of each #6 and #30s... it's a truly strange situation. so what I did was I just went to the machine shop, and my buddy helped me make my own bolt. It fit perfectly :)


Top: Bolt I made for $0.92
Bottom: OEM Bolt that came off driver side turbo.

[walky_talky20]

Actually both of those bolts in the links you gave me are wrong... it's the "wrong bolt for the right application."
I've ordered 5 of each #6 and #30s... it's a truly strange situation. so what I did was I just went to the machine shop, and my buddy helped me make my own bolt. It fit perfectly :)

Wow, that is strange. Glad you got it worked out. Great work.

[PluschakovP]

Wow, that is strange. Glad you got it worked out. Great work.

thanks man :) lol it had me fooled for 3 weeks... haven't done much work on the motor cuz of this bolt. I'm glad i finally realized, oh hey, i can make this bolt myself! lol. i look forward to posting more pics soon. hopefully gunna spend a 12 hour day on the motor tomorrow!

Is Lubro Molly 5w-40 Full Syn a good oil for the 2.7T? Anyone use it?

[fukinavit]

well i didn't mess around with the pulleys. but i know that the bigger ovals on the pulleys should be pointing towards each other, and then with you valve covers off, align the cams with the markings (the pictures i posted), then put the pulley on. That's how I would do it if the camshaft pulleys were not aligned.



Well the OEM crank is Induction Hardened. The rods and pistons - I have no answer, but they can handle a lot of power.

yes, forged and induction hardened, pretty sweet standard crank i'd say.

[PluschakovP]

yes, forged and induction hardened, pretty sweet standard crank i'd say.

yeah, prolly one of the best quality cranks around for sure. audi's are such beautiful cars, they really do a good job with them i'd say. Audi fan for life :)

[African2.7T]

Excellent job but its just a minor set back with the bolt, im sure you will have this ready to go soon .

[PluschakovP]

The day started off a little like this.










She's in at this point.

(Putting motor in with axles on is a pain in the ass guys... take them off if you can before lol.)


Getting ready to do timing belt.






Had to take the tensioner off and compress it then put it on again. This is just a pic of the process.







Didn't get the chance to start it... Going to hook up the rest of the sensors and hopefully get her started.

[PluschakovP]

It's hard to keep tabs of all the pics I've taken. This is my first thread so I'm a noob with forums and all that.

[PluschakovP]

She runs.


After having the car since January of 2009, I finally have rebuild it and it's been like a 4 month process to rebuild the motor itself. Never worked on motors before, so I am so proud of myself at this point. Looking back I definitely could have been more organized, but hey, she's running :) can't complain haha.

Thanks for all the help and support guys!

[awdjunkies]

She runs. First Start-Up Video Here:

http://www.youtube.com/watch?v=W--6TPRAtGw


After having the car since January of 2009, I finally have rebuild it and it's been like a 4 month process to rebuild the motor itself. Never worked on motors before, so I am so proud of myself at this point. Looking back I definitely could have been more organized, but hey, she's running :) can't complain haha.

Thanks for all the help and support guys!

YAY!!!! I'm sitting here watching the video going, "Come on, come on baby!!!" lol Congrats dude!!!!

[Asmir02]

Thats how my audi sound like on the start and i stopped after few seconds afraid of killing something in the motor. Is it normal for car to do that after u have done work on the motor?

[PluschakovP]

Thats how my audi sound like on the start and i stopped after few seconds afraid of killing something in the motor. Is it normal for car to do that after u have done work on the motor?

yes, because the oil has all sank down and it tanks several seconds before all the oils get spread throughout the engine. the first rattle you hear is the camshafts because they are the last to get oil up there, so they will rattle for a few seconds. everything else will work itself out eventually after the motor balances out what places need more oil.

[PluschakovP]

Oil light came on, but i have the perfect amount of oil in. Does that mean oil pressure isnt right or there's oil not getting somewhere?

[PluschakovP]

Oil light came on, but i have the perfect amount of oil in. Does that mean oil pressure isnt right or there's oil not getting somewhere?

Fixed it. I forgot to hook up the sensor on top of the upper oil pan, right by the oil filter area. Plugged it in and it went away.

[PluschakovP]

Put the whole car tonight tonight. Ran it for like almost a good hour at just idle then all of a sudden it shut off. First suspicion was timing belt snapped or something. Looked and yeah, timing belt looked like it either ripped or just popped off the teeth. So i'll be taking apart the front end again.

Anyone know why this could've happened?

[fukinavit]

Put the whole car tonight tonight. Ran it for like almost a good hour at just idle then all of a sudden it shut off. First suspicion was timing belt snapped or something. Looked and yeah, timing belt looked like it either ripped or just popped off the teeth. So i'll be taking apart the front end again.

Anyone know why this could've happened?

if thats the case then you will also be pulling off the heads and putting in new valves, this is a interference motor, so there would have been contact and definatley valve/piston damage. sorry to hear that but the timing belt job is super critical and it sounds like you bit off more than you can chew. The new belt should never have snapped so if it slid off then something wasn't aligned or incorrectly assembled. sorry dude, but all that work was for nothing.

[PluschakovP]

if thats the case then you will also be pulling off the heads and putting in new valves, this is a interference motor, so there would have been contact and definatley valve/piston damage. sorry to hear that but the timing belt job is super critical and it sounds like you bit off more than you can chew. The new belt should never have snapped so if it slid off then something wasn't aligned or incorrectly assembled. sorry dude, but all that work was for nothing.

it stopped immediately. like nothing was smacking or nothing. it just stopped so it's not like the crank kept going without the valves going. it all stopped at the same time. i doubt it bent anything. it was just a clean stop. so im hoping nothing got ruined? if the motor is indeed jacked up... well i'm parting the car out. So i'll keep you guys posted so if someone needs A6 parts... lol.

ALSO...

i was running the motor for nearly an hour with all the fluids in. she was purring like a kitten. idle was perfect, revs were amazing. never took it past 3000rpms... but it was amazing. the Timing belt either broke or fell off while the motor was idling in my garage. i havent got a good look at the belt yet.

[brewmastr]

sounds like you over tensioned the timing belt or your crankshaft end play is not correct and the belt is not running straight on all the gears, if the belt "ripped" that is the only thing that would cause a new belt to do this, the belt needs to have a certain amount of flex to it, the bentley manual very specifically lays this out, that you should be able to turn the belt 90 degrees on the long stretch that runs straight. I wont go into too much detail just because you simply should have this manual doing this scope of work. just recheck all of this stuff and try again. sucks dude.