team illuminata

After ordering some new (correct) spark plugs and injector seals I brought the car into the main shop and started a concerted poking around to try to figure out why it wont idle. You'd think this might have something to do with it. air temperature sensor.

1380266_3601111562968_2085144460_n by Team Illuminata Motorsport, on Flickr


I removed the throttle body and cleaned it out paying particular attention to the air bypass screw which I think allows it to idle.

1384214_3601111202959_1110913873_n by Team Illuminata Motorsport, on Flickr

1379411_3601110882951_514109356_n by Team Illuminata Motorsport, on Flickr

1393772_3601111042955_284031253_n by Team Illuminata Motorsport, on Flickr

I made some interesting observations:

There's a hole in the throttle plate.
The air bypass screw was fully closed
The arm that actuates the idle and full throttle micro switches was loose. Wouldn't operate the full throttle switch at all. I peened it firm with a small hammer.
Both switches appear to function as intended and are wired correctly.

I put it all back together but it didn't make any difference to the idle, even after backing out the air bypass screw a full turn


.

team illuminata

I had a little time yesterday so I pulled the injectors with a view to installing new seals. Here is what I found:

#1
1385836_3615180274677_1405646058_n by Team Illuminata Motorsport, on Flickr

#2
1378814_3615180474682_146302874_n by Team Illuminata Motorsport, on Flickr

#3
1394226_3615180674687_248095721_n by Team Illuminata Motorsport, on Flickr

#4
524074_3615180874692_1625075050_n by Team Illuminata Motorsport, on Flickr

#5
1393345_3615181074697_468793322_n by Team Illuminata Motorsport, on Flickr


I was surprised only #2 was really torn up though the rest look quite done. Of course the most alarming discovery was on #4 which is missing a tip! Looking at it it may have been off for some time but where is it and how long is any bodies guess. If it fell off into he intake port it can't be good right? Could it get past a valve into a cylinder. Out again and into the turbo? Pass right through without doing any harm?

I did install new seals and, perhaps foolishly started it up to see if they made a difference. I hoped it was safe based on how aged the area where the tip had been looked. It still didn't idle and I don't think it made any strange noises.

Next step?

team illuminata

So I had another look at the odd injector over the weekend and it turns out to have the same part number as the other four: 0 437 502 041. All the pictures I find of it show an end cap (air shroud) so now I think I must have one floating around in my intake or stuck at the end of the inject insert. I don't think it's in the insert as that one injector has quite a lot of lateral play when inserted so is at least not locating in the cap.

So now I feel I should take the intake manifold off or the head or even the engine out. I f I take the engine out I could also fix a lot of leaks, replace engine mounts, clutch etc. Maybe I can even get it to idle again!

What do you think?

team illuminata

Back from Europe and inspired to get the Quattro running again.

Before I went away I had my Friend Werner look over the engine and we agreed the best course of action was to totally refurbish the CIS system as it has been messed with over the years, is not as Audi intended and looks to have some very dodgy vacuum lines. We thought the best approach was to remove the engine to do this as I also want to take the head off to find the bits of missing injector and replace the clutch. But first, and today I did a compressions test:

1525704_4545269966338_8221214129329366875_n by Team Illuminata Motorsport, on Flickr


At least I now know the head is coming off. Hopefully the problem is with the valves on #1 as I have a refurbished head already. Just over 100,000 miles on the block so that should be OK.

I found specs online that suggest stock compression should be from 100-130psi so the rest of the cylinders look pretty good.

So here we go with the next big project. Hopefully it wont take too long as I'd like to drive the car this season. Here is the scope and issues I hope to resolve in the process:

*starting and idling issues
*Injector holder
*Coolant leak
*Boost issue
*Shifter link
*Alignment
*Tune up
*cat joint leak
*engine mounts
*Drive line shunt
*clutch
*Belts
*Check timing
*Timing belt cover missing
*Cracked exhaust manifold?
*Oil Leaks
*Hot starting
*Plastic pipe broken engine bay
*spark plug wires wrong
*Fuel pipe orientation wrong

Wish me luck.

team illuminata

And so it begins. Spent the afternoon draining fluids, removing the radiator and disconnecting about a thousand wires and vacuum hoses. Tomorrow I'll start disconnecting the same around the transmission.

Engine and transmission could be out Tuesday!

10364116_4554323072660_2557119417139114435_n by Team Illuminata Motorsport, on Flickr


I don't know what it is about this car but I'm already missing two nuts, a bolt and the accelerator cable clip. When you drop Audi fasteners on the floor they make one sound then evaporate!

team illuminata

OK, well I didn't exactly promise it would be out Tuesday did I?

Due to wheels sales keeping me busy and the ridiculous complexity of detaching everything necessary to drop the engine and gearbox they are still in the car. The hardest component was the clutch slave cylinder. It took me over an hour just to find it. Then I still couldn't see it. I was supposed to remove it to keep the lines sealed but it is held in in such a ridiculous fashion that I finally gave up and detached the line. Hopefully I can bleed it later, in situ and blind!

Some pictures of progress so far:









So, If I have found everything only the subframe is holding it all in. I'm going to try to drop the engine, transmission, subframe and front suspension in one go. Just have to figure out what to drop it on and how. Maybe today. No promises though.

team illuminata

Here goes......

10537027_4559768488792_7023689556499875354_n by Team Illuminata Motorsport, on Flickr


and it's out.

10525769_4559768648796_3436364074631754398_n by Team Illuminata Motorsport, on Flickr

10273555_4559768808800_2927780594547535467_n by Team Illuminata Motorsport, on Flickr

10570345_4559769088807_2045425313343828880_n by Team Illuminata Motorsport, on Flickr


That was tight. Going to be fun getting it back in. Wish I'd known this was still attached. Would have been a whole lot easier. DOH!

10271619_4561174603944_6404720823281949131_n by Team Illuminata Motorsport, on Flickr


Right side engine mount fell apart.

10557334_4559769568819_7866817184123284223_n by Team Illuminata Motorsport, on Flickr



SO next is remove sub-frame, split engine and box, Asses all the leaks, clean, remove head. That will be next week as I'm busy over the weekend.

team illuminata

Some progress today . I removed the subframe and dragged it to one side of the shop:

10524017_4575068911293_2835192701529782284_n by Team Illuminata Motorsport, on Flickr

10341657_4575069071297_2067181424762820864_n by Team Illuminata Motorsport, on Flickr

Was going to split the block and transmission next but was thwarted by one wastegate bracket nut so decided to remove the intake and exhaust plumbing first.

10544375_4575071071347_6268382722877742546_n by Team Illuminata Motorsport, on Flickr

10537857_4575071591360_7914573473282991438_n by Team Illuminata Motorsport, on Flickr

10570379_4575072671387_4706849729211369977_n by Team Illuminata Motorsport, on Flickr


Discovered a few issues of course. One is that almost every fastener I have removed so far seemed very loose. Is this normal? Also these:

1888565_4575072151374_7997902474220793907_n by Team Illuminata Motorsport, on Flickr

10517573_4575071951369_2461782827130574865_n by Team Illuminata Motorsport, on Flickr

10522443_4575071351354_5903759323579562841_n by Team Illuminata Motorsport, on Flickr


What's this?

10577146_4575069471307_143061650747588010_n by Team Illuminata Motorsport, on Flickr


Broken connector on the diff lock actuator:

10511258_4575069231301_2627185516530486987_n by Team Illuminata Motorsport, on Flickr


If I get time tomorrow I'll split the block and trans

team illuminata

They're under starter's orders......

10563051_4578800844589_4357570291975784638_n by Team Illuminata Motorsport, on Flickr




Ready............

10348197_4578800924591_6945617564837517176_n by Team Illuminata Motorsport, on Flickr


Go!

10532457_4578800964592_8254263941989033535_n by Team Illuminata Motorsport, on Flickr


YUK!

10583874_4578802044619_352056740911211585_n by Team Illuminata Motorsport, on Flickr


Not too bad

10584042_4578802124621_6559099247938415985_n by Team Illuminata Motorsport, on Flickr


Clutch slave cylinder off. Replace?

10407643_4578800804588_239428268717640863_n by Team Illuminata Motorsport, on Flickr

Borrowed this to test fit. Will it fit?

936074_4578800884590_2425092070513567589_n by Team Illuminata Motorsport, on Flickr


Today I might get to power-wash everything and take off the clutch.

team illuminata

Quite a bit of progress these past few days. I think this is the furthest this car has been from being drivable since before it was made!

Got the clutch off. What do you think?

10464175_4587383059139_1167876015888859853_n by Team Illuminata Motorsport, on Flickr

10537422_4587383099140_6436809930110731002_n by Team Illuminata Motorsport, on Flickr

10550899_4587383139141_6451263723936078947_n by Team Illuminata Motorsport, on Flickr


Doesn't look that worn.

10346608_4587384099165_6604347482977378353_n by Team Illuminata Motorsport, on Flickr


Bought some supplies and cleaned the sub-frame and box.

10505307_4587383179142_2773421405140676986_n by Team Illuminata Motorsport, on Flickr

10429388_4587383019138_1530739605946241536_n by Team Illuminata Motorsport, on Flickr

10569071_4587384059164_5875101408040911686_n by Team Illuminata Motorsport, on Flickr


Got the flywheel off and mounted it on the engine stand.

10557339_4589847400746_6839155576890702400_n by Team Illuminata Motorsport, on Flickr

10527667_4589847600751_6259119635779507748_n by Team Illuminata Motorsport, on Flickr


Next, off with it's head!