New Member, Old Car

[team illuminata]

Sorry about the lack of updates. Been busy with domestic stuff and wheel sales. I did manage to cobble together a list of parts. Some of the part numbers might be right.

URQ parts by Team Illuminata Motorsport, on Flickr

If you have any of these or any correction or even something I've missed please let me know.

[team illuminata]

I've ordered around $1000 of parts from Jeff at Sunset Porsche-Audi and ECS but I'm missing a few hard to find NLA type pars. Perhaps you can help?


clutch slave cylinder 1
hall sender 1 035905065a
intake manifold bolt 1 N0147112
subframe bushings rear 2 857199419B

Anyone have any of these or a source let me know. Keen to slap this thing back together.

[team illuminata]

Uh oh, parts list just got bigger due to ECS's overly ambitious inventory system.

Now need:

clutch slave cylinder 1
hall sender 1 035905065a
*intake manifold bolt 1 N0147112
subframe bushings rear 2 857199419B
*cam belt cover rear 1 035109143
*head gasket 1 035 103 383 J
* lower cam belt cover 1 069109110

Parts marked * are going to hold me up :(

Anybody have any ideas?

[team illuminata]

Parts are starting to show up now. Going to be out of excuses soon.

Unfortunately I think these injector holders and the one injector are going to be wrong for this head.

10730823_4877057900829_2305598962791364810_n by Team Illuminata Motorsport, on Flickr


But all this stuff is going to be appropriate.

10641147_4896544827990_8614829789583874774_n by Team Illuminata Motorsport, on Flickr

[sciblades]

great build thread keep up to good work!

[team illuminata]

great build thread keep up to good work!

Thanks. Glad you like it.

[team illuminata]

Uh oh. One these things is not like the other.

14021_4902690701633_2807930600885551481_n by Team Illuminata Motorsport, on Flickr


The old engine mount on the left is 431199381N. The new one I ordered is 431199381J

Which one should I be using?

[Ruffiano]

the thing on the right is a transmission mount, not an engine mount.

[team illuminata]

the thing on the right is a transmission mount, not an engine mount.

It looks like on doesn't it? I think it is an earlier engine mount though.

[Ruffiano]

Please do not try to run that as an engine mount, you will have a bad time.

[team illuminata]

Please do not try to run that as an engine mount, you will have a bad time.

Yes, I don't think I will.

[team illuminata]

I may be back on Quattro duty! The brief disruption to service was caused by us taking on more space and building a new home for the cars. There's space for a red Quattro too:



That done I got stuck into the Quattro this week. Cleaned up the injector holders, added new seals and reinstalled the cam. Whatever next?

10421360_4983024029916_5750247918984850872_n by Team Illuminata Motorsport, on Flickr

10547650_4983023989915_8188935954119229409_n by Team Illuminata Motorsport, on Flickr

10417466_4983024109918_2381330989501507744_n by Team Illuminata Motorsport, on Flickr

10405371_4983024069917_6905935358714217510_n by Team Illuminata Motorsport, on Flickr


Rigged up idler pulley puller. Very effective.

1898048_4988955498199_3503304297882499277_n by Team Illuminata Motorsport, on Flickr


Installed new seal and pulley and reinstalled the oil pump.

10516841_4995859950806_7764989237165593525_n by Team Illuminata Motorsport, on Flickr

10418930_4995859870804_8554211402051516207_n by Team Illuminata Motorsport, on Flickr


I couldn't find any marks to line up right now so this is a close to #1 at TDC as I could eyeball:

10801853_4995860030808_8338472303711305872_n by Team Illuminata Motorsport, on Flickr


and with #1 valves all closed that should be close enough for now right? Head is on but not torqued down yet.

1796693_4995860710825_8579514944658249121_n by Team Illuminata Motorsport, on Flickr


Missing some parts so will have to work on other aspects of the project over the holiday. Is it true it's best to use TWO crankshaft seal cover gaskets to move the lip of the seal out of the old wear groove?

10251926_4995859990807_8421117288609436862_n by Team Illuminata Motorsport, on Flickr

[team illuminata]

I've been thinking about how to set valve timing on this engine. The manual says to align the mark on the flywheel with the indicator on the bell housing and the mark on the camshaft pulley with the top of the head. I really don't want to have to install the gearbox before I can set timing; is there another way? There is also mention of setting the mark on the crankshaft pulley with a boss on the oil pump but I have read this can be unreliable. Does anyone know the number of teeth on the belt between the two marks once the cam belt is on?




One more question: does the black seal go on the plastic or on the brass?






I did make some progress this weekend but got distracted by some bright and shiny things that turned up:






Once that bit of fun was over I started to refurbish the engine's tin ware. Degreased, wire brushed and treated with rust eater:




Tomorrow I'll source some POR15 and finish them in black.

[team illuminata]

So, true to my word, I did bolt some things to other things today. Got the cam belt cover on. I would say "back on" but the engine didn't have one before!




and the cam pulley, crank pulley and cam belt.




and the valve cover




and even the oil pick up tube!




However, I'm not sure the timing is right yet so everything is still loose. What do you think, close enough:








I'm thinking maybe 1 tooth off on the cam end. Will it still turn safely one tooth out?

[team illuminata]

Got some new engine mounts yesterday. These should do the trick.




Bolted the oil pan on. Had to replace a few missing screw!




Then bolted some things onto the left side




and then to the right side




I'm going to try to make one of these heat shields because I can't find one anywhere. Does anyone know what color they were painted?



Last thing today I moved the car off the hoist and staged it in our showroom. The 911 that was there needs transmission work and has to be running soon so it's time to switch focus. I do intend getting the intake and exhaust mounted and mating up the transmission first though. If nothing else just to make some room in the shop. Cars in bits seem to take up a lot of space.

[team illuminata]

I made this heat shield today. Still needs paint. Silver or black?

[team illuminata]

Much progress today:

Painted the heat shield and installed it. Yep, went with silver for more heat reflectance.




Replaced the seals in the transmission while the paint was drying.








Installed the exhaust manifold and turbo.




and the down pipe.




I tried to install the waste gate but I'm going to need new studs. They don't semm to have part numbers though. How do I order them?

[team illuminata]

I had a very productive afternoon then suffered what may or may not be a major setback. Read on.

I installed the intake manifold.




engine mounts




Then was installing the chains to lift it off the engine stand when it suddenly spun over and knocked off the down pipe!




As you might imagine I was quite devastated but upon inspection I think I may be alight. There's a slip fit and a weld just after the turbo which is where it broke. I think I can get it welded back together. The orientation is critical though so I left the rest of it bolted to the turbo. I'm going to wait till I get the hardware for the wastgate, dry fit it all then mark the orientation before having someone weld it up. Hopefully.


I had a cup of tea then carried on. Installed the flywheel next




then the clutch




followed by the clutch release bearing




Fortunately I got my chain lengths just right so they lined up pretty well.




and slid together without much of a fight.




I checked the timing marks and it was spot on :)




so put the timing cover on for the first time since I have owned the car.




So, I have now bolted together as many parts as I could and so I'm going to take a break for a few weeks while I fix the transmission in my 911. More broken German stuff!

[sciblades]

getting close keep up the great work

[team illuminata]

OK, so a few weeks turned into a few weeks. It happens. Would really like to drive it this summer so cracking on. Today replacing the prop shaft seal.








Once this is back together this is all that's left on my list:

15 Rear trans seal
16 Refurb power steering system
17 Refurb CIS
18 Clean engine bay
19 Replace brake line
20 Refurb strut tops
21 Fix down pipe
22 Install waste gate
23 Trans oil
24 Attach subframe
25 Install engine, trans, sub frame
26 Reconnect ancillaries
27 Fire up
28 Test drive
29 alignment

Piece of cake.

[Ruffiano]

Keep workin!

[team illuminata]

Replacing the diff lock actuator today I managed to brake the clip that attaches it to the actuator rod. NLA but ECS say they have one. We will see.

[team illuminata]

I'm thinking the next phase should be to refurbish the hydraulic system before I pt the engine back in. It powers the steering and brakes and seems to be wet in its entirety. What is typically replaced. Should I refurbish the steering rack too?

[team illuminata]

I was going to replace the rear brake line yesterday then this happened.






So I said F-it and went to the track instead. I did come back later and straightened my spool of exotic Audi brake line.




Need to make it look like this somehow:










I guess i'm going to need some new tools; and a new tool box.

[team illuminata]

Heavily invested in brake line tools now. Worked though. I just need some more brake projects to justify the investment.




I started at the master cylinder end and taped the new line to the old line as I went. The flare went well but I couldn't get the first bend as close to the fitting as the factory but it looks OE enough in my opinion.




I'm glad I replaced the rear brake line as it fell apart after it saw it's replacement and cried tears of brake fluid.




To my surprise it actually fir very well. I mean, it should right considering it was virtually a copy of the original. Things like this generally do not go this well for me though. I had to replace a few clips with new unfortunately.




Me bleedin' bleed nipples are bleedin' rusted to buggery in the rear and as I replaced the rear brake line I now have to bleed the buggers! #URQuattroFun






Later; I need a break from brakes. Next up: Transmission linkage stabilizer which is NLA, of course and then the hydraulic system.

[sciblades]

Keep up the good work

[team illuminata]

Time to address the shift link stabilizer. Number 35 in this diagram. The plastic sockets on the ends wear and it is NLA (No Longer Available).




Mines a little loose so let's build a new one.








Now it's NPA (NO Problem Anymore)

[team illuminata]

Decided to take out the steering rack, hydraulic pump, accumalator and reservoir en masse. Seems as if every bit of it is leaking.


Steering rack










At brake master cylinder




Et voila!




Now what?

[teach]

Now what?

...not sure, but I have enjoyed your thread very much. My sentiments are similar to onlyaudis: You've done a LOT of good work...on a car that was a good example to begin with! It is nice to see it being done well. Don't ask me about my old Audis...as you well know, there is ALWAYS something to be done!

[Brian@vossen]

That car looks sweet. Have to love the classics!

[team illuminata]

My apologies, it's been a while since I have updated this thread and that's because it's been a while since I worked on the car. My wife's A3 booted the Quattro off the hoist a while back and I've since been too busy with the parts business to get it back on. Well that change this weekend when I found the hoist vacant along with my schedule. So on it went, again.




I am waiting for a friend to figure out how to replace the hydraulic hoses while using the original fittings so I thought I'd tackle bleeding the brakes which, of course required freeing up the rusted bleed nipples in the calipers. Well I only broke two off, left front and left rear!




How do I fix these? I imagine it involves removing the calipers which I managed quite easily on the left front but the left rear is fighting me. I managed to unhook the handbrake cable from the lever but the outer sheath looks like it's fused to the caliper in it's seat.






I'm also struggling to get the brake union on the inner fender separated.




I left them soaking in PB Blast overnight. Think that will work?

[team illuminata]

More progress but nothing picture worthy, sorry. I managed to free up both the handbrake cable and the brake line union yesterday but was less successful with the brake calipers. Unless you count that I was able to remove the rear caliper and place it on the bench that is.

So I cut a slit in the front caliper's bleed screw, or at least what was left of it. The stub was protruding about 4mm so there was quite a bit to work with. I had hit it with PB Blaster again when I got there so that had had an hour to soak in. I heated it as much as I could with a propane torch then with CFC Freeze Off and then heated again. I then hit it with my impact screwdriver and guess what? No, it didn't come right out; it broke right off flush with the caliper :(

Needless to say I didn't move on to the rear caliper.

So what's next, drilling it out and re-tapping, reverse drilling? New car?

[PRY4SNO]

Jesus.

Long shot would be an electrolysis bath... that would possibly loosen enough of the corrosion to get them free.

[team illuminata]

Jesus.

Long shot would be an electrolysis bath... that would possibly loosen enough of the corrosion to get them free.

Never heard of that

https://youtu.be/54ADeB6V1rQ

[team illuminata]

I found a few hours to work on the car today. I basically pulled off more parts. Gotta start installing parts.

Tried EasyOut on one of the seized bleeders. FAIL




So turned my attention to the CIS injection system because you can never have enough parts on the floor.












Then started thinking about getting the downpipe welded back together. If you remember it separated after the engine stand let go and allowed the engine to rotate! This meant reassembling everything on the engine so I could mark the orientation which might be important.

[team illuminata]

SUCCESS! Las night, with a lot of help from my mein Freund Werner and some Rojo Red lubrication we drilled out the seized bleeder screws from the brake calipers.

We first established a pilot hole all the way through the bottom of the bleeder then chased that with a tap drill being carful to stop once we reached the end of the threads.



Because the tip of the bleeder was smaller than the tap drill it was left loose in the bottom of the hole and after cleaning out the threads was easily extracted.








Obviously a lot of debris found it's way into the piston chamber, especially as we cleaned out the other threads too, so we dismantled them with a view to giving them a thorough cleaning and any needed replacement parts. Right now they look to be in good condition though so I'll probably just reassemble them.

[team illuminata]

While waiting for parts to come in I decided it might be a good idea to take inventory of all the spare parts I already have and make a list. This was prompted by the realization that I have recently ordered parts that I already have in my collection of parts bins! Let the list making begin.

Used parts:




New parts: (yes, we sell Corbaeu seats)




Take offs (used to be on the car)




Turns out I have a lot of spare parts, 129 separate items if I include take offs and lumping together most of the removed AC stuff. I tried to figure out part numbers for everything and got pretty close. I did discover that about a dozen parts I inherited from the PPO (previous previous owner) aren't actually for a UR Quattro so that was good to know.

[team illuminata]

Finally got my Unicorn clips from Germany. AKA actuator clips. I only need one but got a few spares.




All the bits needed to make the center diff actuate.

[team illuminata]

Installed

[team illuminata]

Popped the waste gate back on the other day. Doesn't seem to use a gasket!




Then this arrived. Can you guess what it is?




Repaired down pipe curtesy of Thompson Racing Fabrication (TRF)




I don't know much about welding but it can't be easy to weld stainless steel to cast iron. Apparently Audi didn't do a good job the first time.



I'm not installing it yet as the engine will want to lean on it while it's sitting on the dolly.

I did remove the leaking coolant reservoir though Yep, the more parts I install the more I remove. Even with the engine out Audi found a way to make it difficult to remove. This is leaking from the seam around the top. Any ideas about repairing it or does it have to be replaced. Can it be replaced?