allroad single turbo build

[spacecadet]

pulled off fuel rail, found some fuel that seemed to be seeping out of the rail around where its brazed. Definitely not safe, but I doubt it was causing miss fires.

Pulled off intake manifold, found some potential vacuum leaks, though they held fine @ 22psi pressure test, ill be welding them shut this time to eliminate variable.

pulled off valve cover.

with crank at top dead center, cam notches line up with cap arrows. This is the cam chain timing I have. I checked it 1000000 times but if anyone could please verify it.



did leak down with valve cover off:
3: 6% 6:50% air coming out of intake valves
2: 6% 4:10% noticable out of intake
1: 20% air comming out of intake valves 3:10%

as the queen of hearts would say, off with their heads.
Half tempted to pull the block to and go 3.0L.

[spacecadet]

Okay talked myself off the 3.0l ledge. gonna stick to 2.7 lol

- - - Updated - - -

Can anyone confirm if you can put the heads back on the block with the block in the car with ARP head studs?

[spacecadet]

poor poor headless 2.7

[spacecadet]

Welp machine shop fessed up to botching the valve job. They will refund me the cost of the rebuild and a little extra for my time.

Don't know what to do now. On the one hand they seem to be willing to stand by their work and do right by customer. On the other hand I dont really want to do it all over again so I might find a shop that has build 5v heads before/a lot.

Pulled some 2.8 heads at the junkyard today.

[Audibot]

Ouch! Well, at least they didn't leave you completely high and dry!

[spacecadet]

Anyone know where the wire for pin 39 clutch switch is in the manual harness?

[spacecadet]

its pin 14 on the white plug under the ecu if anyone else needs this.

[spacecadet]

2.8 heads are at different machine shop that was recommended by a few VW/audi people i talked to. Fingers crossed.

Also dropped off supertech valves, iconel exhaust, and IE springs.

[spacecadet]

I finally gave up on finding s6 recaros.

Pulled these seats today

Old seat(I've since turned it into little sim cockpit):


New seats, helper approved:

[SleeperAvant]

Nice work. Regarding the brakes, I'm looking to do the same upgrade from rotorlabs.

[spacecadet]

getting bored waiting for heads so made a video sealing off the back of the intake manifold.

[spacecadet]

Found an unmolested greed allroad at junkyard today so pulled the hood

old hood:


new hood:

[spacecadet]

Nice work. Regarding the brakes, I'm looking to do the same upgrade from rotorlabs.

I got mine from them. I have machine tools and I could not beat their price sourcing the parts myself and doing the labor. I'm not sure how they do it.

[SleeperAvant]

I got mine from them. I have machine tools and I could not beat their price sourcing the parts myself and doing the labor. I'm not sure how they do it.

Yeah, being that they are "part-time" it blows my mind. The only way that I know of that they could get that kind of pricing is buying their supplies in large volume.

[spacecadet]

Got my heads back. they look nice.

Building them the lifters i ordered from IE 5 of the exhaust lifters do not fit, different part numbers.

I'm getting so sick of company mess ups pretty frustrated.

stuck again until lifters resolved.

[spacecadet]

IE overnighted me the correct lifters.
-got heads built.
-got drivers head installed
-dropped an arp stud down the water jacket on passenger side so decided to call it quits for the day on the car to avoid compounding mistakes.

[spacecadet]

ITS RUNNING NO MISSFIRES!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!

excited and re-motivated!!

[spacecadet]

Maiden voyage complete! Drove around house up and down some hills loading the motor up as much as possible.

Things discovered:
-alignment is terrifying.
-not shifting as smoothly as I'd like, but did improve noticeably just from first drive.
-to loud. not obnoxious but I thought resonator going into muffler would be nice and quiet but it still is to loud for my sleeper goal. Might weld in a glass pack section, might put a silencer on.

Things forgot:
-the rear diff is still welded, completely forgot. Oh the joys of driving around with a locked rear end....
-forgot to hook up clutch switch, though seemed no side effect.

Terrifying moments:
-Header wrap smokes when breaking in.... I thought for sure the whole thing was about to go up in flames lol.

Not sure how I'm going to make it 750 miles before taking this dam 1.5lb spring out!

[spacecadet]

Welp just went to fill her up and I'll be damed if every drop i pumped in did not end up on the ground underneath the car!

the gas station guy was pissed.

[spacecadet]

Sigh I do not want to pull the tank out.

[spacecadet]

Huzzah! fuel leak was because i pinched the gasket on the fuel pump cover.

[SteelyS6]

Glad to hear it's running, keep up the battle! Terrifying alignment is, well terrifying! Experienced this when I got my allroad, every bump felt like I was going to shift into the next lane.

[spacecadet]

Did some driving last night to get some break in miles. I'm ~160 miles in.

Stoped at a light, a hooptie pulls up next to me, and is making a very noticeable metal on metal chirping. Light goes green, he pulls away, and the noise persists. FUCK!

Pull into a parking lot. Oil pressure good, running fine. Pop hood and there is a distinct metal on metal touching noise. I can clearly hear its external to the motor and assume its from something in the accessory chain, so I roll the dice and drive back home.

Pull serpentine belt off, noise persists.
Pull front pulley off, noise presists but different now.
Pull off timing covers and what do we have!

My fucking timing idler pulley decided it actually wants to be a hole saw.





Looks like the actual roller sleeve slipped forward on the bearing and went to town.

Thankful i caught it before any timing incidents could occur, and at least its into my covers it cut and not my block.

Anyone ever seen anything like this? I thought maybe I installed it incorrectly, but it was never present until yesterday. Also, you cant install that bearing wrong because its indexed. So what to do now.

[spacecadet]

I'm hoping i can get ECS to replace the part and my timing covers. we shall see.

[spacecadet]

ECS will just replace the failed part.

I ordered a new tensioner, relay arm, tensioner bearing and idler bearing because im paranoid and some how new parts have less chance of failure? sigh

gonna go try to pull some timing covers today.

[spacecadet]

Timing covers acquired.

[spacecadet]

Found an EUU diff car local cross checked VIN and ratio is 37:9. should be good there now no more chirp and semi tractor turn radius!

[spacecadet]

timing and front end put back together with new parts. diff put in. back on the road!

Its so much nicer driving without locked diff!

I got in a little traffic pin today where i needed to gun it to get over and i hit boost..... holy poop she took off. Hopefully my clutch forgives me.

I need to figure out how to code my abs module now.

[spacecadet]

blast dropped it off to be aligned this morning. there no point in aligning it because the tie rod end links are shot. Oh well i just like complaining.

Looking into control arm kits, might even switch to nice coil overs from the XS power chineseium ones that are on there.

[spacecadet]

slave cylinder has developed a leak

[spacecadet]

After struggling with the special hell that is the stock slave cylinder connection for the better part of a day, I gave up on it.

I removed the fitting from my slave cylinder, machined it down in length and bored it out to accept 3/16th line. Cut the line and flared it onto the fitting. Curse what ever that stock connection is.

Break in miles complete. I've been boosting all over! pretty fun. Going to put in my 16lb spring tomorrow.

[spacecadet]

Oh I also raised it about 2". night and day difference in ride quality.

[spacecadet]

hmm i under estimated how difficult getting waste gate springs in is.

[spacecadet]

Okay, so I was able to get some threaded rod at the store, cut it into 3 peices, thread that into the waste gate, then use a nut on each to push it down onto itself, huzzah!

Now I need to figure out why my banks are out of trim ~3%. I replaced injector orings, intake manifold gaskets, and 02 sensor still they seem to be off.

[spacecadet]

Small update, got fuel trims figured out.

I've been driving, tuning and enjoying the car!

going from a little TDi golf to this thing, the power is still terrifying lol.

Got some control arms and tie rods coming here soon I'm gonna put on.

Still need to figure out the ABS module.

[spacecadet]

Okay, I had to remove the clock spring i pulled from the junkyard as it was the wrong part number, remove the long wire/spinning part off it, and put it on the old one that was in the all road. thats done, got ride of steering angle implausible signal.

Now if i could just figure out how to get the abs/esp system test to run lol. Drove around in circles in a parking lot for about 30 mins, finally left when i noticed a bunch of people in the soccer field were watching me lol.

[BenjaminR]

Nice work! Glad you are staying persistent. Giving us all a little motivation.

[spacecadet]

Got the ABS system test to run finally.

I had this error as well in my ABS module.

01423 - lateral acceleration sensor (g200) 35-00

That's all it was, no actual error, no text description, nothing. At first I just assumed since the 35-00 matched that of the system test that it was part of that. After failing at getting the system test to work for probably an hour I decided to pull the acceleration sensor to see if it would throw different errors.

I pulled the sensor, came up with implausible/short circuit errors for it and the other sensor in the unit. That led me to believe that maybe I had just hit a weird state.

Plugged the senor back in, the odd g200 error code did not come back, and the system test executed on the first attempt in the parking lot this time.


ABS feels nice.


Now I need to replace my turbo oil drain, i have a 90 AN fitting right off the drain, and I think it it causing some oil to push the seals under boost. I think ill just get a barb fitting and slide the hose over it on the turbo side, cant use an AN straight as its to long and has clearance issues.

[spacecadet]

Fixed turbo oil drain, no longer burning oil after big boost.

Put one of these in the secondary exhaust:



It quieted it wayyy down, a level I'm now happy with. Defiantly a hit to the mid-range power based on the ol' butt dyno, but ill take it for the new noise level.

[spacecadet]

the front wheel hub upper control arm pinch bolt can suck a fat one.