New Member, Old Car

[team illuminata]

I took the subframe back out so I could clean off thirty years of oil and grime from the engine bay with a toothbrush and some degreaser.




The photos really don't show the difference but it is quite a transformation. Before:






After:

[team illuminata]

Inspired by the clean engine bay I thought I'd go parts shopping. First thing to show up was this new hall sensor for the distributor. The old one broke the connector off during engine extraction but was marginal anyway. This one is meant for a Ford but seems to be a match. Not ready to disassemble the distributor right now though.




I managed to find a used coolant reservoir locally. This is after I cleaned it out. It is a slightly different shape on top but has the same part number. At least it's not in-your-face-shiny-new looking.




I thought it might be an idea to pressure test it so enlisted my bike pump. Gave it 22psi and a bath. No bubbles and it held that pressure overnight. I guess we pressure tested the pump too.








I sent off the steering rack for a refresh to Jorgen Automotive. They seem to be the authority in these matters and are only 45 minutes west of me. Sent it Monday, got it back Wednesady! Amazing turnaround. I specifically asked them not to bead blast the body as I wanted to retain the patina. Normally they would be like new when they are done.








I also sent out the turbo for rebuild but that won't be back till next week at the earliest.

Not sure what to tackle next. Might refurbish the wiper mechanism as it's slow and I can stand in the engine bay to work on it. I could open up troubleshooting the CIS system but that's probably too a big job for my current schedule, or I could add some relays to the headlights as they are a lot more accessible with the engine out. Damn, everything is a lot more accessible with the engine out on this thing.

[team illuminata]

I took the wiper mechanism out of the car today because it was running slow. Typical of this car: you can see it, can remove the bolts but have to jiggle the crap out of it to extract it! Will be fun putting it back.








The theory is that the spindle bearings and joints seize up over time. I sprayed the joints with grease and greased the pivots. I couldn't say that they were seized but I believe they are now free-er at least.




Another theory is that the gear lube gets old and dry but I have to drill out rivets to get inside. Not sure about that yet.




I then installed the replacement coolant reservoir.

[Nosliwe]

So im not the only one who installed a Audi 100 washer fluid reservoir instead of the 9.2L original one :D didnt refill mine for 3 years...
Never had a problem with my wipers so far, except that i managed to crack 2 in 5 years.

[team illuminata]

So im not the only one who installed a Audi 100 washer fluid reservoir instead of the 9.2L original one :D didnt refill mine for 3 years...
Never had a problem with my wipers so far, except that i managed to crack 2 in 5 years.

Do I have the wrong washer fluid bottle?

[team illuminata]

I reassembled the wiper mechanism today and put it back in the car. Seems to work.

https://youtu.be/6jk4rw96TQw


As I had to remove a couple of relays to make enough room I cleaned the fuse box and coated all the relay contacts with dielectric grease.



Inspired by my electrical prowess I might tackle adding relays to the headlights tomorrow. I seem to remember reading about a simple plug and play kit that was available. Anyone have a source?

[Nosliwe]

After some googling it appears that its 50/50 that got the same washer fluid reservoir as you or the huge one i had originally in my GT coupe. So i don't actually know if some of the Quattros came with the smaller ones from the factory.

[team illuminata]

After some googling it appears that its 50/50 that got the same washer fluid reservoir as you or the huge one i had originally in my GT coupe. So i don't actually know if some of the Quattros came with the smaller ones from the factory.

Thanks for looking into that. My Googling was non-conclusive.

[team illuminata]

Oops, seems like tomorrow turned into two months. Sorry about that. Got a little distracted by wheel sales, 911 mods and this:



An 83 that looks like it wants to be a rally replica build. I'll post a link to it's buid thread once we get stuck in. But first we have to finish this one right?


So what did we do lately in that regard? Well, we received our rebuilt turbo. Like with the steering rack we asked them not to bead blast the housings.






Then we tackled replacing the Hall sensor on the distributor as ours had brocken it's connector.










We did add the headlight relay kit we got from Germany but we haven't tested it yet so perhaps we'll address that in the next update. Hopefully not two months from now.

Happy New Year!

[Mr. Corey]

Very cool build thread!!!! Coming along nicely! I've been looking to get my hands on one of these for a while. Have you had any crazy issues not being able to find any specific parts for it?

[team illuminata]

Very cool build thread!!!! Coming along nicely! I've been looking to get my hands on one of these for a while. Have you had any crazy issues not being able to find any specific parts for it?

Thanks.

Some parts can be tough but the aftermarket is slowly picking up the slack. Brake lines, clutch line, shifter linkage, that sort of stuff. If you don't mind veering away from original the options open up. On our next build the sheet will be blank!

[team illuminata]

I didn't test the headlight relay kit today as I thought better of it. With so many wires detached from there things I didn't think it a good idea to introduce some live electrons. I did put back the lower console hiding the relays etc. and lubed the hood/bonnet pull handle so it no longer makes that awful noise.

What I next was take stock of what's left to do and what I need to do it. I'm actually close to the point where I will be stopped for lack of parts, some of them apparently hard to find. Here's what's still to do:

28 Refurbish CIS
29 Refurbish hydraulic system
31 Refurbish front struts tops, bellows
32 Install down pipe and turbo
33 Engine Oil
34 Transmission oil
35 Compression test
36 Attach sub-frame to transmission
37 Torque crank bolt
38 Clutch slave cylinder line
39 Install engine, trans, sub frame
40 Reconnect ancillaries
41 Bleed brakes
42 Hydraulic fluid
43 Fire up
44 Test drive
45 Alignment


and what I'm still missing:

CIS vacuum lines and god knows what else
Hydraulic lines, being remade by a friend
Strut Bellows 2 431412135
clutch slave cylinder hose 1 431721465 NLA
subframe bushings rear 2 857199419B discontinued
belt alternator 1 055903137G 9.5x850
front brake line 2 433837400A

any suggestions on where to get this stuff? Would prefer original Audi.

[team illuminata]

As I'm starting to run out of chronologically logical tasks I'm going to be jumping around a bit. First such worm hole leap: sub-frame bushings. Not all four though, just the front two. The rears are NLA and I haven't sourced an alternative yet. So here we go.....






Drill




Cut




Pry




Succeed




Sleeve still in :(




More cut and pry




Squeeze




Fail




Succeed a bit then fail




Win




Repeat.

[team illuminata]

After lots of back and forth and soul searching (as well as part searching) we made some part-ial progress:

CIS vacuum lines and god knows what else
I printed out four parts diagrams from vagpart.com and marched them up to the shop with the plan that I would go through each one and highlight (with a hiliter) everything that I wanted to replace. This would mostly be vacuum lines and clamps but there are quite a few different sizes and types so I wanted to make sure I got the right ones and didn't miss any. Well, guess what? I could barley even match the diagrams to my car! It's like the car and the diagrams are for two different cars, not even the same manufacturer. I found one common part; a bubble shaped vacuum bottle, and followed it's line back into the engine bay and at the first connector it departed from the parts diagram completely! We are going to have to rethink this approach. This is one of four vacuum line diagrams vs the real world.



Hydraulic lines, being remade by a friend
Still waiting on these. Might be a while.

Strut Bellows 2 431412135
I found they match a Porsche 944 part so ordered a pair from one of our customers: Pelican Parts. Will see next week if Porsche and Audi were on the same planet back in the 80s.

clutch slave cylinder hose 1 431721465 NLA
I got close but quit. I found an ATE hose that matched but it proved to be a unicorn. Couldn't find one anywhere. Then I got a quote from our local fancy custom line shop for braided stainless made from my original fittings but baulked at the price ($140) and the lack of originality, then decided the original one was in good enough shape and installed it on the clutch cylinder.

subframe bushings rear 2 857199419B discontinued
A friend pointed out that I could used the Audi 80 M12 version with a 10mm sleeve so I went on a quest for those. They proved only marginally less rare than what I need so I orderded two proper ones from Audi Tradition. They have to be shipped to my friend in Germany and then to me so probably 2017 before I see them LOL

belt alternator 1 055903137G 9.5x850
This can wait. I'm tired.

front brake line 2 433837400A
Hours more research and all I could find were aftermarket braided stainless or some really inexspensive rubber ones from Centric. I've ordered both. The centric ones look like the real deal apart from not having the rubber dongles on though it does have two mounting grommets. The OE mounting grommet should slide off over the ends if one of these doesn't work but there's no way the big rubber dongles will. I have a few spares from our 83 so will cut one and see if it is possible to glue them back together over the Centric lines.

[team illuminata]

Finally got chance to install the rear subframe bushings. To be fair I did have to wait for them to come from Germany. I might havre to wait for another one now. Read on.........

Easily removed the old bushings and cleaned up the holes.


But my previous method of pressing them in failed



So got the press out but that didn't help




Now the bushing is all squished




It seems that a) these bushing won't squeeze into a hole the same diameter as the body and b) why did the front ones press in so easily?

[team illuminata]

This didn't help



But this did

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

[team illuminata]

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.

image by Team Illuminata Motorsport, on Flickr

image 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.

image by Team Illuminata Motorsport, on Flickr


More bloody squeezing. GGRRR

image by Team Illuminata Motorsport, on Flickr

image by Team Illuminata Motorsport, on Flickr


Then I installed the turbo, manifold and down pipe.

image by Team Illuminata Motorsport, on Flickr

image by Team Illuminata Motorsport, on Flickr


Need to find a suitable hanger for here.

image by Team Illuminata Motorsport, on Flickr


This stainless steel beauty from Vibrant should do the trick.

image 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.

[team illuminata]

I went through my parts bin to see what still needs to bolt on the engine before it goes back in the car. I was worried I might miss something and I was right. Found this heat shield

image by Team Illuminata Motorsport, on Flickr


and a temperature sensor that goes in the back of the refurbished head but this plug won't come out and I'm afraid of rounding out the Allen socket. Worst case I have to drill it out and retap it but then the head would have to come off!

image by Team Illuminata Motorsport, on Flickr


Tried this to no avail

image by Team Illuminata Motorsport, on Flickr


So resorted the the impact gun which thankfully worked. I forget how effective they can be.

image by Team Illuminata Motorsport, on Flickr


Then I celebrated by reinstalling the subframe.

image by Team Illuminata Motorsport, on Flickr

[team illuminata]

Bought some inspiration over the weekend.

image by Team Illuminata Motorsport, on Flickr


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

image by Team Illuminata Motorsport, on Flickr

image by Team Illuminata Motorsport, on Flickr


Oil can gasket

image by Team Illuminata Motorsport, on Flickr


Bomb mounts

image by Team Illuminata Motorsport, on Flickr


Trans oil

image 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?

image by Team Illuminata Motorsport, on Flickr

[team illuminata]

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.

image 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.

image by Team Illuminata Motorsport, on Flickr

image by Team Illuminata Motorsport, on Flickr

image by Team Illuminata Motorsport, on Flickr

image by Team Illuminata Motorsport, on Flickr


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

image by Team Illuminata Motorsport, on Flickr


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

image by Team Illuminata Motorsport, on Flickr

[team illuminata]

It's the little things that take the most time. I thought I hadn't made a lot of progress but when I looked at all the photos I've taken lately I realise I've done a lot of small things including spending hundreds of Dollars on tiny pipe clips, vacuum hose and aluminium sealing washers! But first...

I installed the ground cable after stripping the threads and fixing with a Helicoil

image by Team Illuminata Motorsport, on Flickr

image by Team Illuminata Motorsport, on Flickr


Then went to install the steering rack but found one of the bulkhead plugs (top one of the three) and previously been pierced and bunged up with some sort of putty!

image by Team Illuminata Motorsport, on Flickr

image by Team Illuminata Motorsport, on Flickr


So I had to source a new one. Thankfully they are still available as Audi still use them.

image by Team Illuminata Motorsport, on Flickr

I realized it would be a lot easier to attach the hoses to the steering rack on the bench but how to determine the orientation so they line up later? It helps to have a 83 quattro project in the other bay to reference!

image by Team Illuminata Motorsport, on Flickr

image by Team Illuminata Motorsport, on Flickr

image by Team Illuminata Motorsport, on Flickr


Then hooked up the steering column inside the footwell. I think I may have got the steering wheel 180 degrees off but it was always going to need re-clocking anyway.

I think the next job is to replace all the vacuum hoses and clips but maybe I can find something else to do.

[team illuminata]

Replacing the vacuum hoses and clips is a PITA so I found something else to do. I replaced the air box mounts.

image 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:

ACTIVATED CHARCOAL CONTAINER by Team Illuminata Motorsport, on Flickr

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

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

1320. VACUUM HOSES WITH; CONNECTING PARTS; FOR PNEUMATIC DIFFERENTIAL; LOCK by Team Illuminata Motorsport, on Flickr


and the car:

image by Team Illuminata Motorsport, on Flickr

image by Team Illuminata Motorsport, on Flickr


This should be interesting.

[Nosliwe]

I did it the wrong way when engine swapping xD I placed the vacuum hose from the warm-up regulator directly into the intake like the N/A engine. Didn't work that well haha. Does the ur have a charcoal canister?

[team illuminata]

I did it the wrong way when engine swapping xD I placed the vacuum hose from the warm-up regulator directly into the intake like the N/A engine. Didn't work that well haha. Does the ur have a charcoal canister?

it does. First diagram; part #1.

[Nosliwe]

On the MC engine, the warm-up regulator doesn't even have a vacuum connection. So ill actually have to swap the whole thing for the right one.

[team illuminata]

In a moment of inspiration I found this on the underside of the hood. Doesn't help.

image by Team Illuminata Motorsport, on Flickr


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

image 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.

image by Team Illuminata Motorsport, on Flickr


Et voila! Piece of cake.

image 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.

image by Team Illuminata Motorsport, on Flickr

image by Team Illuminata Motorsport, on Flickr

image by Team Illuminata Motorsport, on Flickr


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

[team illuminata]

More tubes, more clamps, more money, more time. The four rings of (old) Audi ownership.

image 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:

image 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:

image 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.

image by Team Illuminata Motorsport, on Flickr


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

[team illuminata]

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.

[team illuminata]

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

[team illuminata]

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?

.

[team illuminata]

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.

[team illuminata]

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!

[team illuminata]

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 ;)

[team illuminata]

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.

[team illuminata]

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?

[team illuminata]

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.

[team illuminata]

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

[team illuminata]

Not had much time to work on the car lately what with work and domestic activities but here's a little video Winding Road did of the car a few years ago as motivation for us and a teaser for you. Soon be doing this again.


https://www.youtube.com/watch?v=UCaySv1Blok

http://<a href="https://www.youtube....CaySv1Blok</a>


<iframe width="560" height="315" src="https://www.youtube.com/embed/UCaySv1Blok" frameborder="0" allowfullscreen></iframe>

[team illuminata]

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!

[//Sporty]

still my all time favorite.