Spring Metamorphosis hits AudiWorld....
03-30-2007, 08:27 PM
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Spring Metamorphosis hits AudiWorld....
Spring is in the air, so I thought it would be a good time to provide an update on the metamorphosis of Ming II into Ming I.
For those of you new to the saga, back in February, I purchased a clone of the A6 I already had from another AudiWorld member. The key difference was that the new A6, (known now as Ming II) had the sport package and a six speed manual....Items I desperately desired. If you missed that chapter (it's still new to you), you can <a href="https://forums.audiworld.com/a6/msgs/690694.phtml"> click here for a quick review</a>
So what have I been doing for the past five weeks? After a week for vacation, I started by addressing the Air Bag light on the dash.
<b> Phase 1) Airbag Controller Replacement </b>- VAG-COM identified the problem as a memory error (6335 memory issue) in the Air Bag Controller. Time to find a new controller, so I called Shokan who wanted $485 plus shipping for a used part, then Force5 who wanted $160 for a used part...so I went with that. Out of curiosity I did contact the Clair Parts internet store....they wanted $293 for a new part. I'll have to keep them in mind next time. Of course, ordering the part was the easy part....it took me nearly three hours to remove the rear console, radio, HVAC controls and ashtray and then the front console to reach the airbag controller that lives under and behind the ashtray. Never could have done it without the Bentley.
<img src="http://pictureposter.audiworld.com/81787/airbag.jpg">
Once I had the new airbag controller in place, I had to code it correctly for Ming II with the VAG-COM. The recode from the 00406 to 00307 went flawlessly....no issues, but I still had the Air Bag light on the dash with VAG-COM showing four codes for "resistance too low" A few drops of Stabilant 22 electrical contact solution were placed on the connection and.... no more Air Bag light! Not wanting to risk reassembly with out a test drive, I put about 30 miles on the car (with no heat!) in zero degree weather, still no light, so the console went back in. Putting everything back together was much quicker, only taking about two hours.
<b>Phase 2) "The full Monty" (Timing belt, et al) </b>- Next on the list was bringing Ming II up to date with a large preventative maintenance effort, "the full Monty" as 4driver4 described it, and he wasn't kidding. With his patience and expertise I was able to replace:
- Timing belt
- Serpentine belt
- Cam seals
- Cam adjuster seals
- Throttle Body Boot
- F Hose
- Valve cover gaskets
- Water Pump
- Thermostat
- Belt tensioners
- Coolant
- and a few clips and connectors that I destroyed in the process
<img src="http://pictureposter.audiworld.com/81787/img_1592.jpg">
You guys were very helpful in identifying a <a href="https://forums.audiworld.com/a6/msgs/695436.phtml"> mystery hose for me,</a>, the infamous "F" hose, which I replaced as a precautionary measure. You also assisted with <a href="https://forums.audiworld.com/a6/msgs/696275.phtml"> the placement of the Expansion Tank overflow hose.</a>
I was never lonely during this process as I watched 4driver4 working in the other garage bays on his fleet of somewhat operating A4s, but he was able to get one of them going and shocks replaced on the Miata as I toiled away on various Ming iterations. He works just a little faster. This phase took almost two weeks.
<b>Phase 3) "The Transformation" </b> - This is where Ming II becomes Ming I; all the "stuff" you've shamed me in to purchasing over the years transitions to the new car. This was probably the most challenging phase of the project as the talk of "when are you going to finish" and "you're going to Tom's again?" started to be heard, and I had the "door blade" incident (full disclosure below), but the job needed to be completed and we pressed on. This phase took about a week.
3a) Rear Bumper Covers Swapped - First we swapped rear bumper covers because I needed to have the cut valance on Ming II to work with the Magnaflow tips. Again using the resources here, I found a post explaining <a href="https://forums.audiworld.com/a6/msgs/274403.phtml"> how to remove the rear bumper cover</a>
3b) Exhaust Systems Swapped - With the rear bumper covers swapped, it was time to swap the exhaust systems; yes the entire exhaust from the cat's back, which just happens to be one piece, was swapped between the cars. It was pretty simple, simply loosen the sleeves and disconnect the hangers.
3c) Sway Bars Swapped - I had the H-Sports on Ming I, so we removed the Sport Sways (PSK) from Ming II, put my original stock sways from Ming I back on Ming I, and then installed the H-Sports on Ming II.
3d) Front Bumpers Swapped - We never put the front bumper back on Ming II after the "full monty", so we took the front bumper off of Ming I and installed it on Ming II, and moved Ming II's over to Ming I. I wanted to keep the Ming I front bumper because it did not have a license plate holder bolted on like Ming II. No holes, no plugs, no worries. The front belly pans were also swapped with the front bumpers. One item of note with the front bumper: To fasten the bumper to the fender, there are three threaded studs that extend from the bumper through holes in the fender where they meet. You put nuts on the studs to attach the bumper. On the passenger side, 4driver4 discovered that job is much easier if you remove the spring that holds the A/C hose in place. Getting that out of the way gives you a clear shot to the nuts.
<img src="http://pictureposter.audiworld.com/81787/img_1597.jpg">
3e) S6 Mirrors, 4.2 Door Blades and Wheels/tires - Just a simple swap of these components between the cars, leaving the stock stuff on Ming I, right? Not quite. The mirrors were a piece of cake <a href="http://www.audipages.com/upgrades/chromemirrorold.html"> using the instructions for swapping the covers I found on AudiWorld. </a> <a href="https://www.audiworld.com/tech/ext59.shtml"> If you're interested in how I refinished the aluminum mirror last year, click here.</a>
The door blades were a different story. On both cars, the heads of the screws had become rusted and fragile. After breaking one, I got out the Sea Foam, and let that work on the remaining screws while I washed the Volvo, hoping that they would come out in one piece. Final score: GBW 5, rusty screws 3. I spent the evening first attempting to cut a slot with the Dremel and unscrewing the remaining part of the screw (which didn't work), then drilling out the rusty screws. Hmmmm....I still remember the quote from Boston Driver on the door blades "One of the easiest mods here!!!"...ha!
3f) Windshield - I got a smokin' deal on a new windshield (in appreciation for my past business and folks I've sent to them)...so now I have a perfect windshield on Ming II, to match the new windshield Ming I received in January!
<img src="http://pictureposter.audiworld.com/81787/img_1620.jpg">
So there you go, another chapter of AudiWorld induced sickness comes to a close. It's been a fun project and I really enjoyed doing the timing belt job; I learned a ton about the car in the process. While it would have been a lot easier and much faster to send this job out to get it done (as I did for Ming I in August 2006), doing it myself was very satisfying and enjoyable.
Of course, I had lots of help; Boston Driver and 4driver4 played key technical assistance roles, Bac2h moral support, and many of you helped with my questions and the "how to" posts available in the archives. And while Mrs. GBW and Mrs. 4driver4 never turned a wrench, they were extremely patient throughout this epic adventure.
Soon, in a classified near you, Ming I will begin its search for a new home, and I'll turn my attention fully to Ming II. Hmmmm.....Toy Guy Short Shifter, painted calipers, Melange Audi Winter Mats, Bluetooth kit.....Hmmmm.........
For posterity......
The Last Family Picture:
<img src="http://pictureposter.audiworld.com/81787/img_1623.jpg">
Ming II
<img src="http://pictureposter.audiworld.com/81787/img_1624.jpg">
Ming I
<img src="http://pictureposter.audiworld.com/81787/img_1626.jpg">
For those of you new to the saga, back in February, I purchased a clone of the A6 I already had from another AudiWorld member. The key difference was that the new A6, (known now as Ming II) had the sport package and a six speed manual....Items I desperately desired. If you missed that chapter (it's still new to you), you can <a href="https://forums.audiworld.com/a6/msgs/690694.phtml"> click here for a quick review</a>
So what have I been doing for the past five weeks? After a week for vacation, I started by addressing the Air Bag light on the dash.
<b> Phase 1) Airbag Controller Replacement </b>- VAG-COM identified the problem as a memory error (6335 memory issue) in the Air Bag Controller. Time to find a new controller, so I called Shokan who wanted $485 plus shipping for a used part, then Force5 who wanted $160 for a used part...so I went with that. Out of curiosity I did contact the Clair Parts internet store....they wanted $293 for a new part. I'll have to keep them in mind next time. Of course, ordering the part was the easy part....it took me nearly three hours to remove the rear console, radio, HVAC controls and ashtray and then the front console to reach the airbag controller that lives under and behind the ashtray. Never could have done it without the Bentley.
<img src="http://pictureposter.audiworld.com/81787/airbag.jpg">
Once I had the new airbag controller in place, I had to code it correctly for Ming II with the VAG-COM. The recode from the 00406 to 00307 went flawlessly....no issues, but I still had the Air Bag light on the dash with VAG-COM showing four codes for "resistance too low" A few drops of Stabilant 22 electrical contact solution were placed on the connection and.... no more Air Bag light! Not wanting to risk reassembly with out a test drive, I put about 30 miles on the car (with no heat!) in zero degree weather, still no light, so the console went back in. Putting everything back together was much quicker, only taking about two hours.
<b>Phase 2) "The full Monty" (Timing belt, et al) </b>- Next on the list was bringing Ming II up to date with a large preventative maintenance effort, "the full Monty" as 4driver4 described it, and he wasn't kidding. With his patience and expertise I was able to replace:
- Timing belt
- Serpentine belt
- Cam seals
- Cam adjuster seals
- Throttle Body Boot
- F Hose
- Valve cover gaskets
- Water Pump
- Thermostat
- Belt tensioners
- Coolant
- and a few clips and connectors that I destroyed in the process
<img src="http://pictureposter.audiworld.com/81787/img_1592.jpg">
You guys were very helpful in identifying a <a href="https://forums.audiworld.com/a6/msgs/695436.phtml"> mystery hose for me,</a>, the infamous "F" hose, which I replaced as a precautionary measure. You also assisted with <a href="https://forums.audiworld.com/a6/msgs/696275.phtml"> the placement of the Expansion Tank overflow hose.</a>
I was never lonely during this process as I watched 4driver4 working in the other garage bays on his fleet of somewhat operating A4s, but he was able to get one of them going and shocks replaced on the Miata as I toiled away on various Ming iterations. He works just a little faster. This phase took almost two weeks.
<b>Phase 3) "The Transformation" </b> - This is where Ming II becomes Ming I; all the "stuff" you've shamed me in to purchasing over the years transitions to the new car. This was probably the most challenging phase of the project as the talk of "when are you going to finish" and "you're going to Tom's again?" started to be heard, and I had the "door blade" incident (full disclosure below), but the job needed to be completed and we pressed on. This phase took about a week.
3a) Rear Bumper Covers Swapped - First we swapped rear bumper covers because I needed to have the cut valance on Ming II to work with the Magnaflow tips. Again using the resources here, I found a post explaining <a href="https://forums.audiworld.com/a6/msgs/274403.phtml"> how to remove the rear bumper cover</a>
3b) Exhaust Systems Swapped - With the rear bumper covers swapped, it was time to swap the exhaust systems; yes the entire exhaust from the cat's back, which just happens to be one piece, was swapped between the cars. It was pretty simple, simply loosen the sleeves and disconnect the hangers.
3c) Sway Bars Swapped - I had the H-Sports on Ming I, so we removed the Sport Sways (PSK) from Ming II, put my original stock sways from Ming I back on Ming I, and then installed the H-Sports on Ming II.
3d) Front Bumpers Swapped - We never put the front bumper back on Ming II after the "full monty", so we took the front bumper off of Ming I and installed it on Ming II, and moved Ming II's over to Ming I. I wanted to keep the Ming I front bumper because it did not have a license plate holder bolted on like Ming II. No holes, no plugs, no worries. The front belly pans were also swapped with the front bumpers. One item of note with the front bumper: To fasten the bumper to the fender, there are three threaded studs that extend from the bumper through holes in the fender where they meet. You put nuts on the studs to attach the bumper. On the passenger side, 4driver4 discovered that job is much easier if you remove the spring that holds the A/C hose in place. Getting that out of the way gives you a clear shot to the nuts.
<img src="http://pictureposter.audiworld.com/81787/img_1597.jpg">
3e) S6 Mirrors, 4.2 Door Blades and Wheels/tires - Just a simple swap of these components between the cars, leaving the stock stuff on Ming I, right? Not quite. The mirrors were a piece of cake <a href="http://www.audipages.com/upgrades/chromemirrorold.html"> using the instructions for swapping the covers I found on AudiWorld. </a> <a href="https://www.audiworld.com/tech/ext59.shtml"> If you're interested in how I refinished the aluminum mirror last year, click here.</a>
The door blades were a different story. On both cars, the heads of the screws had become rusted and fragile. After breaking one, I got out the Sea Foam, and let that work on the remaining screws while I washed the Volvo, hoping that they would come out in one piece. Final score: GBW 5, rusty screws 3. I spent the evening first attempting to cut a slot with the Dremel and unscrewing the remaining part of the screw (which didn't work), then drilling out the rusty screws. Hmmmm....I still remember the quote from Boston Driver on the door blades "One of the easiest mods here!!!"...ha!
3f) Windshield - I got a smokin' deal on a new windshield (in appreciation for my past business and folks I've sent to them)...so now I have a perfect windshield on Ming II, to match the new windshield Ming I received in January!
<img src="http://pictureposter.audiworld.com/81787/img_1620.jpg">
So there you go, another chapter of AudiWorld induced sickness comes to a close. It's been a fun project and I really enjoyed doing the timing belt job; I learned a ton about the car in the process. While it would have been a lot easier and much faster to send this job out to get it done (as I did for Ming I in August 2006), doing it myself was very satisfying and enjoyable.
Of course, I had lots of help; Boston Driver and 4driver4 played key technical assistance roles, Bac2h moral support, and many of you helped with my questions and the "how to" posts available in the archives. And while Mrs. GBW and Mrs. 4driver4 never turned a wrench, they were extremely patient throughout this epic adventure.
Soon, in a classified near you, Ming I will begin its search for a new home, and I'll turn my attention fully to Ming II. Hmmmm.....Toy Guy Short Shifter, painted calipers, Melange Audi Winter Mats, Bluetooth kit.....Hmmmm.........
For posterity......
The Last Family Picture:
<img src="http://pictureposter.audiworld.com/81787/img_1623.jpg">
Ming II
<img src="http://pictureposter.audiworld.com/81787/img_1624.jpg">
Ming I
<img src="http://pictureposter.audiworld.com/81787/img_1626.jpg">
03-30-2007, 08:59 PM
#3
AudiWorld Expert
Hey, that's great! So I guess you decided not to swap the trunk for the M5 spoiler?
Probably just as well...it is not as easy as you think (with the wiring harnesses), but it is not impossible. Congrats on the transformation! So, when will Ming I be ready for sale??? And, BTW, we never shamed you into anything...peer pressure...yes...shame...no!!!
Can't wait to see the new ride on the 18th!!!
Can't wait to see the new ride on the 18th!!!
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03-31-2007, 04:21 AM
#8
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Yes, trunk looked tough...but not as tough as getting the AW Classified Ad down to 200 words, only
to find that the real limit is 1,000 characters! Took me an hour just to get the advertisement down to the limits; toughest part of the entire project!
Anyway, when I looked at Bentley to see what was involved, from the wiring, to the alignment, to the lock assembly, etc, etc, etc...I realized that this was not an easy job and that I'd be doing it at least twice. I'd already pushed my "time" limits with prior aspects of the metamorphosis, so I decided not to do it.
I have emailed Billy to get a replacement lined up...no response yet....
And most importantly, thanks for all your help!
Anyway, when I looked at Bentley to see what was involved, from the wiring, to the alignment, to the lock assembly, etc, etc, etc...I realized that this was not an easy job and that I'd be doing it at least twice. I'd already pushed my "time" limits with prior aspects of the metamorphosis, so I decided not to do it.
I have emailed Billy to get a replacement lined up...no response yet....
And most importantly, thanks for all your help!
