[BWW] I've collected the parts long enough, time to finally do the work. [BWW]

Andy_FL · 12-21-2004, 04:56 PM

120K on the clock and some things are due for a change. Here's a before shot of the engine bay:

MOTOR MOUNTS:
I went ahead and replaced both sides. I decided just to stick with 1.8T mounts (vs. upgrading to 2.8/S4) for a few reasons.....mostly due to cost--1.8T mounts were $90 for BOTH where the 2.8 mounts are currently priced at ~$100 each. Apparently they may be dropping down in price as soon as another manufacturer starts cranking them out (in Jan '05). I also don't ever (ok rarely) launch the car hard ....so no need for the extra stiffness IMO (I'm squeezing every last mile outta this stock clutch!). Nice tech article here by HS and WJM. Very straightforward and even easier when you have the bumper/lock carrier off. :-)
Driver side:

Passenger side:

Dead...

And installed...

ACCESSORY BELTS AND TENSIONERS:
What about the timing belt? Well, that's for another day down the road (I already updated the tensioner and belt about 40K ago). My A/C tensioner was making a nasty rattle--replaced. I was getting some rattle from my serpentine tensioner also, so I replaced it as well.

Serpentine = top, A/C = bottom:

Time for new belts too! Replaced all 3: main accessory, A/C, and PS/water pump.

COOLANT FLANGE:
There's a coolant flange on the back of the head--it's where the coolant temp sensor resides and a few cooling lines come together. Well as you can see in the pic, I had a slow leak.

Flange removed:

Looks like it was coming from the connection of the hose at the bottom of the flange. May not have needed to replace the flange really, but it was only $7.

New one ready to go back in:

VALVE COVER GASKET:
Again. This was one of the first repairs I ever made on the car, back when I got it around 65K. So, that one lasted another 60K, fair enough I guess. Main seepage at the front corner, but there was slight seepage pretty much all around on the left side. Nothing to the VC replacement really, but here's a comparison of the valvetrain at around 65K [EDIT: The head was replaced at 50K, so there's only 15K on the head in this picture] (yes there is oil in it):

And currently, ~120K [EDIT: Actual mileage on the head is 70K since it was replaced at 50K] (sorry, had the shakes):

Pretty stark difference huh. I don't know what the previous owner used, but I've been using a Mobil Drive Clean Plus synthetic blend every 5K.

INTAKE MANIFOLD:
I also went ahead and removed the fuel rail, injectors, and intake manifold to clean everything up.
A few pics from that...

Fresh o-rings for the injectors:

Cleaned up and ready:

PCV TUBE:
Well, I never saw it until I started to put the car back together, but my PCV (positive crankcase ventilation) tube coming off the block has broken. Great!

This is where it goes...

PCV system removed...

Luckily, in stock at the dealer..

Back in business:

And finally, no maintenance interval is complete unless you change that pollen filter.

I think that's everything. Next up will be a few cans of Seafoam--one in the gas and one through the vacuum lines. Then new Denso plugs and an oil change to top it off.

Remember how the engine looked before?

Well with the help of a case of brake cleaner, here it is now! No, I'm only kidding--just SimpleGreen and elbow grease. New expansion tank really makes it shine doesn't it?

Andy

KMHPaladin · 12-21-2004, 05:01 PM

invisiblemonster · 12-21-2004, 05:02 PM

TANMAN · 12-21-2004, 05:03 PM

**Kris Hansen** · 12-21-2004, 05:12 PM

Audi4orce · 12-21-2004, 05:14 PM

Great work Andy. I guess u gonna keep the A4 another 120K miles? Hell u should!!
Got a question about the serpentine belt tensioner...can that part be removed from the top with out messing with the lock carrier?? Mine is making noise too...well i thing thas that and not the "other tension".
Thanks
DG

EDness · 12-21-2004, 05:15 PM

i love posts like this...not like the usual noob questions we see everyday.

I put seafoam in my beater(oil and gas) this past weekend. The car seem to idle better...but i think it's just my head.

RKA · 12-21-2004, 05:16 PM

Andy_FL · 12-21-2004, 05:36 PM

Well, not really. :-) It was down for a week because I didn't end up working on it at all after work. From Sunday to Saturday, I probably put 8-10 hours into it, and I don't work fast.

Andy

Andy_FL · 12-21-2004, 05:41 PM

At the most, you might need to slide the carrier into service position.

A long extension or screwdriver can help pinpoint the noise, if you're not sure of where it's coming from. Good luck.

Andy

12-21-2004, 04:56 PM	#1
Andy_FL AudiWorld Super User Account #: 12690 Join Date: Nov 2000 Posts: 9,791	[BWW] I've collected the parts long enough, time to finally do the work. [BWW] 120K on the clock and some things are due for a change. Here's a before shot of the engine bay: MOTOR MOUNTS: I went ahead and replaced both sides. I decided just to stick with 1.8T mounts (vs. upgrading to 2.8/S4) for a few reasons.....mostly due to cost--1.8T mounts were $90 for BOTH where the 2.8 mounts are currently priced at ~$100 each. Apparently they may be dropping down in price as soon as another manufacturer starts cranking them out (in Jan '05). I also don't ever (ok rarely) launch the car hard ....so no need for the extra stiffness IMO (I'm squeezing every last mile outta this stock clutch!). Nice tech article here by HS and WJM. Very straightforward and even easier when you have the bumper/lock carrier off. :-) Driver side: Passenger side: Dead... And installed... ACCESSORY BELTS AND TENSIONERS: What about the timing belt? Well, that's for another day down the road (I already updated the tensioner and belt about 40K ago). My A/C tensioner was making a nasty rattle--replaced. I was getting some rattle from my serpentine tensioner also, so I replaced it as well. Serpentine = top, A/C = bottom: Time for new belts too! Replaced all 3: main accessory, A/C, and PS/water pump. COOLANT FLANGE: There's a coolant flange on the back of the head--it's where the coolant temp sensor resides and a few cooling lines come together. Well as you can see in the pic, I had a slow leak. Flange removed: Looks like it was coming from the connection of the hose at the bottom of the flange. May not have needed to replace the flange really, but it was only $7. New one ready to go back in: VALVE COVER GASKET: Again. This was one of the first repairs I ever made on the car, back when I got it around 65K. So, that one lasted another 60K, fair enough I guess. Main seepage at the front corner, but there was slight seepage pretty much all around on the left side. Nothing to the VC replacement really, but here's a comparison of the valvetrain at around 65K [EDIT: The head was replaced at 50K, so there's only 15K on the head in this picture] (yes there is oil in it): And currently, ~120K [EDIT: Actual mileage on the head is 70K since it was replaced at 50K] (sorry, had the shakes): Pretty stark difference huh. I don't know what the previous owner used, but I've been using a Mobil Drive Clean Plus synthetic blend every 5K. INTAKE MANIFOLD: I also went ahead and removed the fuel rail, injectors, and intake manifold to clean everything up. A few pics from that... Fresh o-rings for the injectors: Cleaned up and ready: PCV TUBE: Well, I never saw it until I started to put the car back together, but my PCV (positive crankcase ventilation) tube coming off the block has broken. Great! This is where it goes... PCV system removed... Luckily, in stock at the dealer.. Back in business: And finally, no maintenance interval is complete unless you change that pollen filter. I think that's everything. Next up will be a few cans of Seafoam--one in the gas and one through the vacuum lines. Then new Denso plugs and an oil change to top it off. Remember how the engine looked before? Well with the help of a case of brake cleaner, here it is now! No, I'm only kidding--just SimpleGreen and elbow grease. New expansion tank really makes it shine doesn't it? Andy __________________

12-21-2004, 05:01 PM	#2
KMHPaladin Member Account #: 58238 Join Date: Jun 2003 Posts: 13,784	wow, you've been busy. looking good. __________________ Current: 2006 A4 2.0tqm Quartz Gray/Black Premium \| Sunroof \| Bilstein PSS9 \| AWE Exhaust \| DTM Edition Front Bumper O.Z. Superleggera III 19x8.5 \| Toyo T1R 235-35-19 \| RNS-E \| Hardwired 8500 Previous: 1997 A4 2.8qm 12v Europa Blue/Gray

12-21-2004, 05:02 PM	#3
invisiblemonster Member Account #: 59261 Join Date: Jul 2003 Posts: 5,046	my expansion tank looks like your old one, I need to pick up a new one, looks great

12-21-2004, 05:03 PM	#4
TANMAN Member Account #: 67044 Join Date: Dec 2003 Posts: 19,923	Very nice work. Impressive! How ong did that take you? __________________ AWOT's People of Color: Soul Brotha numba tree. "I believe that banking institutions are more dangerous to our liberties than standing armies. If the American people ever allow private banks to control the issue of their currency, first by inflation, then by deflation, the banks and corporations that will grow up around the banks will deprive the people of all property until their children wake-up homeless on the continent their fathers conquered." - 'Thomas Jefferson' 1802

12-21-2004, 05:12 PM	#5
Kris Hansen Chief of Goat control Account #: 20 Join Date: Oct 2000 Posts: 66,547,960	Great work Andy!!!

12-21-2004, 05:14 PM	#6
Audi4orce Member Account #: 13510 Join Date: Dec 2000 Posts: 4,908	Damn....U da Man!!!! Great work, Talk about "keeping up with maintance" Great work Andy. I guess u gonna keep the A4 another 120K miles? Hell u should!! Got a question about the serpentine belt tensioner...can that part be removed from the top with out messing with the lock carrier?? Mine is making noise too...well i thing thas that and not the "other tension". Thanks DG __________________ AW Member since:3/27/99 A4 1.8tqm, 99.5 (born on date 3/99) Mileage as of 2/06/09: 71K miles <sunroof delete> Mods: GIAC 1.0bar chip, BBS CH 18"s, TT 710N valve, S4 oil cooler, OEM A6 strut bar, A8 brake upgrade, B6 rear brake upgrade, Snub mount, S4 engine mount, AWE boost gauge, Fog light mod, S4 grill, S4 wheel liners, Arm rest LED light+coin holder, Sunglass holder, Debadged, Lic plate mod w/t Audisport lic frame, Exhaust tips, Oils: Amsoil/Motul/German Castrol(engine). RedLine MT90 (Trans/Axle), GL5 Oem (rear diff). -2004 Jeep Grand Cherokee V8-For Sale -2002 Ducati 998- Superbike Previous own cars: 97 Gti-vr6 DE--88 Scirocco 16v-- 86 Scirocco 8v--86 240 Volvo

12-21-2004, 05:15 PM	#7
EDness Member Account #: 45653 Join Date: Nov 2002 Posts: 17,258	very nice! i love posts like this...not like the usual noob questions we see everyday. I put seafoam in my beater(oil and gas) this past weekend. The car seem to idle better...but i think it's just my head.

12-21-2004, 05:16 PM	#8
RKA Member Account #: 2062 Join Date: Mar 2000 Posts: 67,038	Never seen a better kept car! Nice work! __________________ 2005.5 A4 Avant 2.0T Quattro 6MT APR 91/93/100 \| APR Exhaust \| 19" BBS RS-GT's \| Carbonio \| Hotchkis \| Partridge-in-a-pear-tree Others: 2006 TL on the block 2001 S4 sold 2000 A4 sold * September 11th, 2001 - Never Forget *

12-21-2004, 05:36 PM	#9
Andy_FL AudiWorld Super User Account #: 12690 Join Date: Nov 2000 Posts: 9,791	A week. Well, not really. :-) It was down for a week because I didn't end up working on it at all after work. From Sunday to Saturday, I probably put 8-10 hours into it, and I don't work fast. Andy __________________

12-21-2004, 05:41 PM	#10
Andy_FL AudiWorld Super User Account #: 12690 Join Date: Nov 2000 Posts: 9,791	Definitely should be able to get it from the top. At the most, you might need to slide the carrier into service position. A long extension or screwdriver can help pinpoint the noise, if you're not sure of where it's coming from. Good luck. Andy __________________

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