'01 Silver - The daily commute smile machine! (Turbo build)

[jvanzyl]

Progress update:
All 4 subframe bolts torqued up.
Rear engine mount all on and torqued up. So that's all 4 on! YAY!
Next up will be the driveshafts with their brackets I guess... Then it's onto sorting out the gear cables (will have to sand down one of the shift bearings) and checking all the electrics... Oh and making sure I do the slave thingy for the clutch...... THEN the plumbing...

Feeling a bit of pressure to get this done so that I can sort out the Audi... But I'm of the position that it'll all work out in the end, no sense in getting upset or stressed about it ( saying that you should have seen me driving to work- I was a proper stress ball).

My wife is out tomorrow night so hopefully I'll get a few more hours in...

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[jvanzyl]

This evening's progress:
Drive shafts all in!
Gear cables in!
Clutch slave cylinder in!
Wiring loom pulled through into cabin and I think I have everything plugged in- there are a few cables which I'll put in my next post trying to identify what goes where...

Finally the throttle body intake pipe is on along with the battery tray.

Next up will be the air box heatshield, (might need help figuring out how those bits of metal go back together...) And the exhaust manifold etc..
All in all a fantastic evening :-)

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[jvanzyl]

Further to the above post I could do with some help with what goes where for the wiring...

I have 4 plugs that all look like they go into the O2 sensors... So one of them just be lying.

I've got two on the right side and two on the left... Any ideas?

Then I've got what I'm guessing it's a ground wire? Which is attached to the negative battery terminal... Where does that one attach to?

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[Carolyn]

Top pic - connector at top, air-con pump if you have one.  Otherwise redundant.  Connector below - O2 sensor on manifold.

Middle pic - O2 sensor on main cat.

Bottom pic - to top of gearbox via short 12 mm headed bolt.  Take your battery tray back out to get at it.

[jvanzyl]

Top pic - connector at top, air-con pump if you have one.  Otherwise redundant.  Connector below - O2 sensor on manifold.

Middle pic - O2 sensor on main cat.

Bottom pic - to top of gearbox via short 12 mm headed bolt.  Take your battery tray back out to get at it.

Thank you! :-)

Just to check that middle pic for the main Cat O2 sensor, you're referring to the one in my hand?



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[Carolyn]

Top pic - connector at top, air-con pump if you have one.  Otherwise redundant.  Connector below - O2 sensor on manifold.

Middle pic - O2 sensor on main cat.

Bottom pic - to top of gearbox via short 12 mm headed bolt.  Take your battery tray back out to get at it.

Thank you! :-)

Just to check that middle pic for the main Cat O2 sensor, you're referring to the one in my hand?



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yep

[jvanzyl]

So as things progress, I must admit that I'm getting more and more nervous.
I really want this thing to work when it's all back together!

Anyway, tonight's update is as follows:

I connected the ground to the gear box after Carolyn's direction (thanks!). It took me a while to find it, then I looked under the label I'd made entitled "gearbox ground".... Doh.

Then I set about trying to reaassemble the airbox heatshield - fortunately I find a pic on Spyderchat showing just enough to help me get it done! My pic below is for anyone else getting stuck at that point.

Then I attached the abs sensor plugs, got the airbox back on and swapped my TRD filter for a normal paper one. The TRD one appears to be a dry filter.... Anyone know how to clean it??

I then put the ground back in the fuse box and put the battery in its place- still need to put the bracket on though..

Finally I put the new oil filter on.

Next time it's going to getting the exhaust and cat back into place, and putting the manifold on. Would be helpful if the zero arrived in time! But then I guess I don't have the extended O2 sensors yet... Still have to figure out where to get those!

THEN it'll be onto fluids and running the engine over without the sparks in! Eeek!

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[Carolyn]

Good progress John.

You can extend the sensors you've got.  Just some wire and a soldering iron.

That 'earth' in the fuse box is a 'live'

Getting there!!!

[jvanzyl]

HAHA... Shows the "depth" of my knowledge!

Cheers :-)

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[tomaky]

Big breaker and a lump should do the trick, they often need abit of a shock.

[jvanzyl]

Eh??

Big breaker and a lump should do the trick, they often need abit of a shock.

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[Carolyn]

Just a note of caution:

Double check the cam timing and chain tensioner before you fire her up.

I always do.

Just to be on the safe side!!!

[jvanzyl]

Just a note of caution:

Double check the cam timing and chain tensioner before you fire her up.

I always do.

Just to be on the safe side!!!

Thanks. I've just checked the "how to" on cam timing... I'm going to have to read around a LOT before I'm able to understand what I'm doing...  I'm likely going to have to risk it.

I should hopefully be able to do the chain tensioner though...

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[Carolyn]

It's only a check!  You almost certainly won't have to do anything tricky.

Cam cover off.  Plugs out. (makes it easier to turn the engine).

Postion engine to TDC (in the 'how to') .  check the timing marks of the cam sprockets.

Do this with the tensioner in place.

You could be on cylinder 4 or cylinder 1 for timing.  If you can't see the marks on the sprockets, take the engine round again to TDC.

Then they should all be lined up.

I'm sure they will be!! 

[tomaky]

Eh??

Big breaker and a lump should do the trick, they often need abit of a shock.

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doh forgot to click page 21 i responded to caliper bolts issues on page 1 haha

[jvanzyl]

It's only a check!  You almost certainly won't have to do anything tricky.

Cam cover off.  Plugs out. (makes it easier to turn the engine).

Position engine to TDC (in the 'how to') .  check the timing marks of the cam sprockets.

Do this with the tensioner in place.

You could be on cylinder 4 or cylinder 1 for timing.  If you can't see the marks on the sprockets, take the engine round again to TDC.

Then they should all be lined up.

I'm sure they will be!!

Thanks Carolyn- I appreciate it's a check, however I lack a lot of technical knowledge and that prevents me from understanding even your summary.... I don't actually know what I'm looking for in order to ensure things are correct.
I could follow all your instructions ( well, mostly) but when you say things like "check the timing marks" or "they should all be lined up" I honestly couldn't do this because I don't have the knowledge as to what it all means.

The fact is that it'll take me more than a week to read up and actually do this (if I can), and I'm weighing this up against my memory of the time when I can remember you doing the timing and explaining an awful lot and me trying to understand and keep my brain from shorting out from the overload...

I definitely remember you doing the timing, there was a little bit of yellow paint on the chain which you pointed out, and then gave a technical explanation as to what it was for. Bright colours stick with me.... Complex technical knowledge... Not so much...

I shall absolutely recheck the chain tensioner- I reckon I can do that.


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[jvanzyl]

I think what I'll do is get the cam cover off and then go nuts with the photos... Then use those to try and wrap my head around (with your help) what I'm actually looking at ..

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[jvanzyl]

https://youtu.be/99pc88tsP5A

Ok I'll try and find some time to watch this..

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[Carolyn]

Fair enough.

Ignore the marks on the chain, just check that the dots on the sprockets line up (second pic in the 'how to')

But, judging by your recollection, we were pretty thorough on that one, then!!

Been a while!

You'll probably be fine skipping that one!

Forget the vids -they are all bloody awful.

I'm sure we got it right. 

[Gaz mr-s]

Ok I'll try and find some time to watch this..

Presented by Mika Hakkinen's Grandad...... 

[jvanzyl]

Ok so... Here come the pics..
I'll try and do the chain tensioner now..

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[Call the midlife!]

Eh??

Big breaker and a lump should do the trick, they often need abit of a shock.

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doh forgot to click page 21 i responded to caliper bolts issues on page 1 haha

I thought you were telling him how to clean the filter [emoji23]


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[jvanzyl]

Ok so the quick sharp jerk the crankshaft is not resulting in a click... It's really hard to turn to be honest, should I put the oil in first??

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[jvanzyl]

Ok I'm going to stop this business...I'm going to carry on as before, put the oil in and THEN try and turn the crankshaft... No idea about the timing. Trust it's fine.

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[Call the midlife!]

Ok so the quick sharp jerk the crankshaft is not resulting in a click... It's really hard to turn to be honest, should I put the oil in first??

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In gear?


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