superkarls overhaul

Started my car the other day and low coolant warning came on, turned out my reservoir was dry as a bone.
Found the leak anyway:
52f63852cac8db3bd85ed52177a49596.jpg

The banjo for the coolant line is all rusty, other one is clean shiny stainless.
So I'm going to get a new line made with a more permanent solution to a hose jubilee clipped onto a barbed banjo fitting.

Also checked the plugs just because, all seem ok if a little dark:
0a652f4e32fc6bee4db993ab594cbea2.jpg


Plenty of things to do on it yet
 
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Changed haldex controller, oil and filter the other day, and gave it a wash, huge thanks to my dad as he basically did the job at his garage.
4e2f6cc3be9f2aa9086bb457fcdc0d0d.jpg


I've been occasionally getting a lateral acceleration sensor fault, it's either 'no adjustment' or 'electrical circuit failure' or something along those lines. It's annoying because sometime it will read this:
b1b8e402943b75fcee073fd74aaf8bdc.jpg

And then even during the same scanning session it will go and read this:
8e6cc164b268dc48020a4857fdc1fb28.jpg


Those accel values should lie between +/-1.5ms^2.

So what I'm going to do is swap the lat and long sensors (they are the same part) and see where and if the fault moves.

Oh I've also done a tad over 1000miles now. Car is at 154106

Happy motoring
 
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Nice stuff! Adolf is looking clean! Change to the blue controller?
 
Gops said:
Nice stuff! Adolf is looking clean! Change to the blue controller?
Click to expand...
I assure you it's far from clean and looks exactly how a 2yr stood car looks like lol.

I fitted a standard one that I painted blue, so in a way yes lol.

I'd had some intermittent comms error, and had a spare controller I bought probably 4 years ago now.
 
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Goubo1 said:
Not long now..it will all be good ...bet you can't wait...what figures you hoping for ?
Click to expand...
I'm fully aware that my setup isn't optimal for the turbo I have, so I know that 400hp is going to be hard pushed, but anything close to that il be happy.
Ultimately I just want it to make me smile after the difficult journey it's been, and I'm sure I will.
 
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superkarl said:
I'm fully aware that my setup isn't optimal for the turbo I have, so I know that 400hp is going to be hard pushed, but anything close to that il be happy.
Ultimately I just want it to make me smile after the difficult journey it's been, and I'm sure I will.
Click to expand...


That's all that matters really isn't it the grin factor
 
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Fixed the lat sensor issue.
They're so sensitive, slightest touch and values change, its position must be vital.
Just a slight pull on the mounting bracket and the values were within tolerance.
3e9f6c7787510dd5492f3b7169772d16.jpg


Also found my clutch sensor like this:
a336a6c82ef5012acfe9acb10a2a64b0.jpg

The end of it should be rounded lol.
Worn against the clutch pedal from when it was welded up and reinforced.
 
So I'm having some trouble, had this code since it was built up and running:

16725/P0341/000833 - Camshaft Position Sensor (G40): Implausible Signal

Possible Symptoms
Malfunction Indicator Light (MIL) active
Possible Causes
Wiring from/to Camshaft Position Sensor (G40) faulty
Camshaft Position Sensor (G40) faulty
Timing misaligned
Possible Solutions
Check Wiring from/to Camshaft Position Sensor (G40)
Check Camshaft Position Sensor (G40)
Check Timing

I've put up with the trouble starting for long enough now.
First I checked the sensor was getting the correct voltage, which it is, 5v.
Then I checked my cam timing, which I'm sure is correct, 16 links cam to cam.
Yesterday I replaced the sensor which changed nothing. So now I'm not sure what to do.

As I understand (thanks to Ben) it struggles to start due to mixed signals between crank and cam, not knowing what part of the cycle it is in, and so reverts to a default firing based purely off the crank sensor.

I thought that if timing was wrong between crank and cams I would get a correlation code that seems typical? Not this one?

Some online reading, which is frustrating and tends to lead nowhere, people suggest issues with the Ecu itself, I don't know if this is possible?

What I'm going to do is check the timing, crank to cam and cam to cam, AGAIN. Other than that, I really am stuck, and a little over 2 weeks till mapping.

Any help is appreciated

Cheers
 
Checked the wiring all the way back? Might be a dodgey wire.. Or try wiring it back to the ECU and see if that still happens.

Did you change the cams at all?
 
Gops said:
Checked the wiring all the way back? Might be a dodgey wire.. Or try wiring it back to the ECU and see if that still happens.

Did you change the cams at all?
Click to expand...
Not checked it all the way back no.
But I checked all the pins with a multimeter and they are exactly as they should be.
Standard cams.

I'm thinking timing might be wrong. Why are these engines so ****** difficult to time up!
 
i am impressed..i wish I had the patience...do you have an air compressor???did you get sore arms next day trying to undone some bolts/?
 
oldcar said:
i am impressed..i wish I had the patience...do you have an air compressor???did you get sore arms next day trying to undone some bolts/?
Click to expand...

You've seen his avatar and user name? the man of steel doesn't need air tools and never gets sore arms!...

<tuffty/>
 
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limbo118118 said:
Might be worth trying another cam postition sensor. Mine was showing on vagcom an it wasnt until the 3rd one from the shops that worked fine.
Click to expand...
That's interesting, il try another.

I hope I don't end up in the same boat as adam p, who has had the same issue for months and has tried everything.
 
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audi upgrades
fwiw, I have noticed when fitting the cam belt, with the crank at TDC and the exhaust cam markings lined up. The exh cam starts to move backwards one tooth, I assume its from the spring pressure pushing on a cam lobe.
So I hold the cam bolt with a spanner and keep tension on the cam, while I fit the belt to the pulley.
After fitting the belt, I use a thin Stanley blade to check if the cam pulley marking is spot on with the valve cover marking (sharp side away from the belt - duh)
It may just be my old age kicking in but sometimes the markings look lined up when looking at it from the top of the engine, but when you get a side view from the cam pulley end, you can see its slightly off.
 
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Scullies said:
fwiw, I have noticed when fitting the cam belt, with the crank at TDC and the exhaust cam markings lined up. The exh cam starts to move backwards one tooth, I assume its from the spring pressure pushing on a cam lobe.
So I hold the cam bolt with a spanner and keep tension on the cam, while I fit the belt to the pulley.
After fitting the belt, I use a thin Stanley blade to check if the cam pulley marking is spot on with the valve cover marking (sharp side away from the belt - duh)
It may just be my old age kicking in but sometimes the markings look lined up when looking at it from the top of the engine, but when you get a side view from the cam pulley end, you can see its slightly off.
Click to expand...
I was aware of this when first building it, so I like to think I've done that right at least.
I think my problem lies with the cam to cam timing. Il have an update some time this week when I look into it
 
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So I've not even had time to check the cam to cam timing yet as the car has been rendered useless by a leaking turbo oil drain, and when I say leaking, I mean *******.

At first I thought the AN fitting wasn't seating properly on the turbo fitting, but it was leaking from the hose that goes into the fitting.
Took it off anyway, it's not easy getting a 26mm spanner in there btw
fd7ec69440ad2e4b0c3ef285eadd50e5.jpg

It was leaking from under the tape.
Notice how kinked it is too. It's also subject to quite a lot of heat, about 4 inches away from the exhaust.

Not content with any sort of DIY bodge or hose of my own, I did what I should've done in the first place and went to a hydraulics specialist, pirtek.

aede9bb0cb894b1b05d532eff6ce3113.jpg

Coolant feed, drain.
Oil drain.
Hose is obv very high pressure, with temp rating of 200 degrees, added to that will be the fire retardant sleeve I have which is rated at 1000degrees.

Oil drain went on fairly easy, no pics of that, but had to fit the turbo end, thread the hose between the transfer box and block, and secure it to the sump with a push on fitting and mikalor clamp.

Coolant feed fitted
0f0c5419062481718b7af17145f320f7.jpg


Unfortunately the coolant drain was made too short:
a7b44fb43a92f2651324a5a7085f033e.jpg

So they made it longer this morning
3033000d59ede5d217f65a1407e58f91.jpg

That will be fitted tonight, which is a fiddly one and will require bending and twisting.
The hose may seem very stiff but it doe bend nicely, and does so without any kinking whatsoever no matter how sharp and hard you bend it


Then il move onto the cam timing, hopefully Friday evening.
Then I'm just left with the most annoying exhaust leak in the world. I cannot find it for the life of me, on the ramp, several people under the car, it cannot be seen or found.
It only occurs when the car is stone cold, and disappears completely when the car is warmed up.
I've emailed Rick my concerns about this as I don't want it to cause him problems, so il see what he has to say.

5 days till D day
Over and out
 
You'll do it mate.

Few evenings of hard work and it'll all be worth it when it's mapped!
 
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'should' be ok but I ran gasketless on mine as they tend not to last very long...

You have a 2 bolt flange further down? silicon works well in situations like this... even use it on v-bands as cold they never seal 100% and always sound a little tinny and farty until warmed up

<tuffty/>
 
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<tuffty/> said:
'should' be ok but I ran gasketless on mine as they tend not to last very long...

You have a 2 bolt flange further down? silicon works well in situations like this... even use it on v-bands as cold they never seal 100% and always sound a little tinny and farty until warmed up

<tuffty/>
Click to expand...
No 2 bolt flange no, a v-band, which feels good and is tight as I dare take it, I shall try some silicon on it.
That's exactly as it sounds tho.
 
In other news I fitted the final coolant line for the turbo. I say I, my dad did all of it while I ate a ham sandwich.

And here's the oil drain which started this episode.
a899eccaee50b5dd1f7e100573feef12.jpg

3483de57f8e53d20aeea7b0984c84586.jpg


Then on the way home I ran out of fuel in the middle of town. I had 20 miles range apparently, but I'm also doing 35mpg lol. Now I know not to believe it till the mpg/trip computer is sorted for the injectors. I heard the fuel pump struggling too right before it conked out. Anyway I took the opportunity to take some snaps whilst I was waiting for rescue
ed1be25f31ce062b5af4032428b5e52d.jpg
cccc946fb8b1b3dfeb8d8abdc1309c8b.jpg
a42e46656df21ac42db37b503cafc858.jpg
 
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So I finally got to the bottom of my cam sensor issue.....cam timing.

Got the car on he ramps and stripped in no time to check the timing
2872090e68cfd46400496373798efe29.jpg


And a before and after shot of the timing. Before I had 15 links, now the required 16.
This effectively meant the inlet was retarded half a tooth, and explains how it drove
ddaee21390a274502e2413a8ab4715a7.jpg
d1364a3b9e61d3b4d7d8ca30ea10ab0b.jpg

Quite the difference

It's a fiddly job to do, tensioner tool on, tensioner and inlet cam out, and there isn't a great deal of space or slack in the chain to change it but I got there in the end.
Cam caps all torqued back up to 10nm which I thought was incredibly loose.

Now the car starts first time, and it has COMPLETELY transformed the way it drives!
It is no longer flat and sluggish off boost, it's responsive and pulls from 2500rpm.
I don't have to rev it to 4k+ and boost it to make progress.
Full boost has improved by about 700rpm, hitting at 3500rpm now. It is so smooth and even sounds different. I was so happy I went for a long drive yesterday grinning like a Cheshire Cat. If this can be improved on with mapping, and it will, I'm not sure how happy il be

Good day to you all
 
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Good work i had a nightmare trying to line everything up when my tensioner died
 
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You just need to practice getting the timing right, a lot of practice :tearsofjoy::tearsofjoy:
 
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Awesome!

When is mapping? Tuesday? Does Rick have a dyno now?

Good luck mate :) it'll all be worth it!
 
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