My first AR

[ShelbyM3]

Does anyone have any information on whether or not priming the new oil pump is necessary? Outside of pulling fuel pump fuse and building oil pressure before firing up.

Also, upper oil pan plug. Mine won’t stay in any longer and I’d like to replace it. Can’t find anything on it. I know it’s not crucial, but I’d like it in there. Any leads or ideas on a plug?
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[ShelbyM3]

Started on some block prep.
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WD and elbow grease with a scotch brite pad.
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More elbow
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Fancy internet trick to help prevent scoring. Wound up with one cylinder with a small Knick down low in the stroke that I can feel. I’m not gonna sweat it too much. Most faired very well given all the crap I cleaned off.
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Worst of it, because I am far from perfect. Just having fun, Bud.
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[Epevs]

if your doors won’t shut unless they are slammed likely the lock mechanism lube has turned chunky… pull the door panel off and take apart the mechanism to re lube it, you can find plenty of diy videos on youtube

[ShelbyM3]

if your doors won’t shut unless they are slammed likely the lock mechanism lube has turned chunky… pull the door panel off and take apart the mechanism to re lube it, you can find plenty of diy videos on youtube

Sweetheart alert! I’ll look into that. Thanks for the tip and reading that far back!


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[ShelbyM3]

Kids went to the zoo for the first time without me, I’m really torn up about it honestly, so I put my free time to good use.

Block deck prepped. Found a new to me tool from Lisle for this and wow. I don’t know how I’ve never used this before.

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Serviced the oil distribution pipe under the valley pan and replaced the oil check valves. My o-rings for the distribution pipe had been magically changed into plastic. I cut them off. Audi=Alchemy!

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Gasket and breather cover

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And side note, I don’t know if y’all significant other mocks you, but I wrote this note some 13 months ago and I needed it today!

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[mc_hotmail]

@ShelbyM3 How long have you been working on this allroad? I lose track.

[ShelbyM3]

@ShelbyM3 How long have you been working on this allroad? I lose track.

Tooooooooo long. Thanks for opening up that wound I’m just over here living my life of quiet desperation.


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[ShelbyM3]

Got some wrench time after we hosted a yard sale this weekend. Heads on, 2022.

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[green2man0]

How'd you like torquing them up? I had to read the procedure a few times to make sure it was correct....the last 90 degrees was a little nerve racking

[ShelbyM3]

It was a solid ab workout. I knew the procedure was correct, but I was definitely wondering if anything was going to snap on me. It’s a hell of a torque spec for a head bolt. I’m looking forward to the crank bolt soon…!


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[ShelbyM3]

Progress on the bench…

One of my most annoying struggles with this project has been parts verification and sourcing. I recently took a gamble and I think it payed off. Time will tell.

Coolant after run pump hoses have been NLA from day one, for my particular setup. I’ve recently found out there are 2 setups, cool and warm weather. I have the warm weather. I think that’s why there’s a check valve, to prevent the pump from cycling warmer block coolant as much and send most the coolant to the turbos. Wild ass guess!

I took a gamble on vag# 078121082H and here’s what I got:

OEM setup with the check valve: 078121082L and 078121082K
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078121082H
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If I remove the check valve from the equation, the H hose is almost an identical match to L and K put together. I’m thinking I’ll slice H in half and send it.
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This site helped immensely https://audi.7zap.com/en/usa/audi+a6.../1/121-121068/

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[RPMtech147]

Nice long term thread. When I read the title I thought about assault weapons and that no reasonable person should own them.



Sorry, off topic. My bad.

[ShelbyM3]

Nice long term thread. When I read the title I thought about assault weapons and that no reasonable person should own them.



Sorry, off topic. My bad.

It’s very true. Poor choice on my part, I don’t know if I can change it. I never intended for that thread to become this, but alas.


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[Caddylack]

What is an "assault" weapon?

[ShelbyM3]

I flipped my 01E onto the bell housing last night to pull trans mounts off and when I flipped it back over I found this…
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At first I thought it was a pressure plate finger, but it’s too small. Weird! I am very curious where it came from and would like to think it was contributing to my clutch disengagement thud while shifting. I’ll have to do some digging around and see if I can tell where it broke off of.


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[Calif_Kid]

I've never worked on an 01E clutch, but looks like that may be a clip for the clutch release fork - either for clips that locate the fork or for the fork to the throwout bearing.

- Jim

[ShelbyM3]

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I’ve been looking back at old pictures and the piece has been there the whole time. It’s right under the clutch fork in a little recess. I’ll find the old throw out bearing and fork and look them over.

Thanks Jim!


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[ShelbyM3]

I got yelled at for this. Worth it!

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[ShelbyM3]

Cleaning up the grim off the frame rails I noticed some cracked power steering cooler lines. Do any of you have any experience with these lines and or have a solution to them failing that’s a DIY? Thanks.

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One line plugs into the reservoir while the other hooks up to the steering rack.

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[V1nny]

I flipped my 01E onto the bell housing last night to pull trans mounts off and when I flipped it back over I found this…
IMG_0210.jpg

At first I thought it was a pressure plate finger, but it’s too small. Weird! I am very curious where it came from and would like to think it was contributing to my clutch disengagement thud while shifting. I’ll have to do some digging around and see if I can tell where it broke off of.


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did you figure out what it is?

[ShelbyM3]

did you figure out what it is?

I sure did! I’m trying to piece it all together here, but I think I have a timeline.

I think someone replaced the clutch, because it looks really good, and left the flywheel and pressure plate. Both have pretty good hot spots relative to the clutch's appearance. Car has 175,000 on the chassis. When I purchased it it shifted fine, eventually I developed a loud thud during clutch disengagement.

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I imagine the pressure plate failed partially or entirely and that piece was left in the bell housing during the clutch job. The pressure plate eventually caused the throw out bearing to fail and the pilot bearing to seize, as far as my finger can tell.

I flipped the flywheel over to the crank side and saw a bunch of small damage to the surface. I think the pieces were bouncing around for a while.

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I imagine my factory trans is fine, aside from the synchros being worn. Makes me feels better at night. Ha! Piece of mind for a future rebuild on the bench with JHM components.


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[ShelbyM3]

Nice. Will it fit the intake manifold of a V6 or inline 4?

I did end up doing my intake manifold. It didn’t submerge entirely, but I did each runner down with part sticking up out of the tank and it cleaned really nicely.


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[ShelbyM3]

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H->K&L
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Few things cleaned and assembled closer. Woof.


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[ShelbyM3]

Put my intake manifold back together with the rail, injectors, clips, and all the vacuum lines. Made a discovery! Can’t believe I never noticed it before, but I guess it was missing so…

Homemade cap, yeow! I used to do this crap when I was younger. Made me grin.
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Anyway, where’s it go!? Don’t know! Anyone with leads on where hose 25, circled in red, goes? Comes off below the fuel pressure regulator. The diagram says “see illustration” and that’s it. Womp.
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Thanks!


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[ShelbyM3]

It goes to the secondary air pump system. Thanks Russia!


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[ShelbyM3]

Last minute to do on the intake manifold. Replaced the check valves on the fuel rail. One was working fine and one happened to be blown. Waited for parts and some time. Done.

Vag# 078905291B
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[rah253]

Last minute to do on the intake manifold. Replaced the check valves on the fuel rail. One was working fine and one happened to be blown. Waited for parts and some time. Done.

Vag# 078905291B
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That looks to be the easiest thing you had to deal with so far lol. Glad to see you made some serious progress! I got caught up with new carrier, marriage and honeymoon this year, finally getting back to normal again with some time to get online and checking out some of my favorite threads! Keep up the good work...when time allows lol.

[ShelbyM3]

That looks to be the easiest thing you had to deal with so far lol. Glad to see you made some serious progress! I got caught up with new carrier, marriage and honeymoon this year, finally getting back to normal again with some time to get online and checking out some of my favorite threads! Keep up the good work...when time allows lol.

Thank you for that. Positive encouragement goes a long ways! It’s been a huge struggle to justify spending hours in the garage when my wife and I work full time and I am a very active dad to our two boys under 2, as my wife works until 2:00am some nights. Soon enough it’ll be done, but until then I’ll keep carving out time and posting my progress here.
Congratulations on the marriage! Happy for you two!


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[ShelbyM3]

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Intake manifold is on and harness had a rough degreasing before I put into place.


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[Kevo1288]

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Intake manifold is on and harness had a rough degreasing before I put into place.


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Looking very good man! I will have my motor out for regasket, vacuum system refresh, clutch and timing in a month or so! Looks like youre moving right along.

[ShelbyM3]

Looking very good man! I will have my motor out for regasket, vacuum system refresh, clutch and timing in a month or so! Looks like youre moving right along.

Thanks!
If you haven’t already, start getting parts. Depending on how deep you want to go, things are getting much harder to source. Over the years I’ve watched as multiple parts went No Longer Available on me sitting in a shopping cart while I was saving funds.


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[ShelbyM3]

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[ShelbyM3]

4am connector terminal de-pin was a success…

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Buddy grabbed me one off a vehicle in Utah. I destroyed mine because it was filled with grease and rocks that I couldn’t get out so it snapped. Anyway, dinked around on the bench and figure it out.
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Got the old connector off and found a sliced wire. So many Easter eggs it’s fantastic.
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Quick Tesa tape wrap and she good.
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Also got the coolant reservoir sensor pinned out for a cheap one off Amazon. Fits like a very tight glove! Nabbed an extra because it’s used for multiple things and the housing loves to crack.
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Great success. I should work like this more often.

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[ShelbyM3]

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Early Christmas gift to myself. This little unit will be a lifesaver before and after install. My first ever 2.7T I worked on at 19 we had a boost leak at the banjo fitting off the passenger’s side turbo. What a shit spot! Stoked to have nice tools now.


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[ShelbyM3]

http://Camshaft seal update info<br ...d.php?t=940080

Well piss. FCP refunded me the seals from my kit, I’ve ordered Elring replacements from ECS, and looks like I’ve got a redo ahead of me. This damn car and parts, I swear to Christmas! And to top it off, my 07/2002 build uses the old style E part number cam bore plugs, not the updated F part number. Wtf!?


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[ShelbyM3]

I’m still mad about the camshaft seals. So much of me wants to just send it and replace them in a few thousand miles in the vehicle, if they leak.
Anyway, spring is sprung. Cool. Here’s my subframe I took out today.
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Plan B, rear support brace attaches to the rear subframe plates, not the subframe itself.
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Loose
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Out
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So much more room to get inside the bay!
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Next up
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[quattroskier]

Cleaning up the grim off the frame rails I noticed some cracked power steering cooler lines. Do any of you have any experience with these lines and or have a solution to them failing that’s a DIY? Thanks.

Did you make any headway on the power steering hoses? mine have the same issue.
https://audi.7zap.com/en/usa/audi+a6.../422-422060/#8
I haven't fully verified it but 4Z7 422 891 A looks to be the part # for the return hose from the rack to the cooling tube. not seeing any legit sources for a new replacement.
4B0 422 891 E looks to be the hose from the cooling tube to the reservoir. same story there, not finding a source for new that looks legitimate.
Since they are just return pressure I'm tempted to find generic hose sizes that will work but haven't taken measurements yet.

[ShelbyM3]

Did you make any headway on the power steering hoses? mine have the same issue.
https://audi.7zap.com/en/usa/audi+a6.../422-422060/#8
I haven't fully verified it but 4Z7 422 891 A looks to be the part # for the return hose from the rack to the cooling tube. not seeing any legit sources for a new replacement.
4B0 422 891 E looks to be the hose from the cooling tube to the reservoir. same story there, not finding a source for new that looks legitimate.
Since they are just return pressure I'm tempted to find generic hose sizes that will work but haven't taken measurements yet.

Negative. I came up empty handed in my searches for those part numbers. I kinda think it’s one of those things that is a DIY from here on out.
I did stumble upon a few people that mentioned doing essentially what you said. If my memory serves me correctly, it was RS6 guys that had the most discussion on it. Most developed leaks near the core support and a new line was spliced in with a barbed butt connector.


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[quattroskier]

sounds good. I'll let you know if I get around to figuring it out.

[ShelbyM3]

Pressure washer made short work of subframe scrubbin’
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Wow those pictures show up like trash. Dang…