What have you done to your Audi A4 B7 today?

[northpole]

It passed its mot on Thursday with halogen bulbs in my tester is friendly but the same will fail for led headlights.
My headlight units have h7/D1S on them if that makes any difference?

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the only mod that allows you to put in a LED is to put in a LED projector instead of the HID one you got... the Driving light can be LED but not the one in the reflector in your case the daylight driving lightbulb... just so you know. I was going to replace my halogen dipped beam to a retrofit source LED projector setup but didn't in the end... don't want that layout of money just for the regulators to make them illegal.

 

[Charlie Farley]

I've made a last-minute decision over breakfast and put the current work on hold for a couple of weeks.
As I still require a few bits that i'd overlooked and taking into account the MOT due 3 months time , I'm going to get it in for an MOT this week if possible but I expect the following week will be more likely and see what occurs.

That gives me a bit more time to get all the parts to cover everything I'm planning , covers any unexpected problems that may occur in the MOT and once done a least I will have a full 12 months before i need to deal with swapping over the decat pipe for the MOT .

Just make sense to do it all sooner than later and doubling up on things.

 

[norad97]

Hi Rob, When I bought my car it had a decat pipe fitted, but I removed it as I did not like the vibration and droning at higher speeds.
I fitted an 034 cat in its place, but we all no how that turned out.

 

[Charlie Farley]

I replaced my 034 hfc with a decat pipe a few years go before going to the factory cat until now, I cant say I noticed any difference between the 034 and decat to be honest only that both were way better than the OEM cat.
Maybe it is more noticeable on yours as you have a non-res miltek, I've opted for a res version so will report on things once fitted and tried.

 

[Charlie Farley]

Finally decided to go with these tips, the same guys that supplied my current ones but these are a bit better shape and size wise, they will supply me with custom-made reducers for the miltek outlets which is a bonus.
They should fit on perfectly.

 

[northpole]

uhm might just upgrade the dipped beam reflector for an upgrade halogen projector prices should have come down on those... and it'll look like the oem hid lights but with one difference it'll still rock the halogen bulbs.

 

[Jamsmoo]

Breezed through


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[Charlie Farley]

Breezed through


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Great stuff James.

 

[Charlie Farley]

We have lift off...

All change again , my local MOT guys are booked solid until the end of January so with that in mind I've just thrown caution to the wind and started the work.

Started out well for the first 5 mins then all ground to a halt with a pesky driver-side wiper arm issue.
Solid on the wiper motor splined shaft and wasn't coming off, heat, puller, penetrating fluid, I've tried it all but it won't budge, so will leave that until last, the center arm came off no probs, but then I've had issues with the driver's side arm being stuck on in the past but would come off with the puller.
next issue, off with the wheels and i noticed grease on the inside of the driver-side front wheel again, After closer inspection and sure enough, the cv boot is loose on the hub end and grease is being pushed out, another warranty claim, at least they are not split this time around.
The intercooler had a friend living in front of it...lol
then more concerning there a large, well that looks to ba a large oil leak in the turbo area, hard to see exactly where but maybe from above, wont know until the lumps out, glad I started now to be honest before they get worse.

 

[northpole]

well at least you got a nice dry place to work in... mine decided to blow the headgasket... lovely just ordered a full headgasket kit including the head bolts and all the other gaskets and rings that need to be replaced... I can use that job like a hole in the head. And no if this would be done by a garage or mobile mechanic they'll charge me an arm and a leg... simply because of the sheer amount of stuff that needs to be removed to get to the parts to replace them... don't worry timingbelt kit with waterpump is also ordered... now just waiting for the parts to be delivered so i can start the job... i might just drain the fluids already as there is coolant in the oil. lovely really wanted to do this job... NOT!!! summertime i don;t care but in this cold???? yeah f-no!

 

[Charlie Farley]

Its like we allways say, there is always something.

I'm on day two, dropped off the leaking drive shaft this ,morning and pickup the warranty replacement tomorrow.
Finally got that pesky wiper arm off with a different , but modified puller from amazon this morning , so that is another problem off the problem list.
draining the power steering fluid now , all coolant drained and about to remove the rad panel assembly.
Cat is off along with intercoolers and filter box etc, basically its just all about removing bolts next.
I'm not rushing at it to be honest, that's when mistakes happen , just doing as much as i want to do in a day given i have other stuff todo anyway.

 

[Charlie Farley]

I do believe I'm making headway now, a few awkward ones but nothing major thus far.
just having some nose bag then going outside to carry on for a couple more hours.

 

[Charlie Farley]

I had to get my angle grinder on the downpipe to mid-section coupling , nuts were rusted beyond normal removal so cut the off.
On closer inspection whilst laying under the old bus the original exhaust is really showing its age now, a few very thin spots around the silencers and a couple of very iffy welds, glad I opted to replace it sooner than later.
Hoping all being well and no last minute glitches to get the engine/gearbox out in a one go tomorrow morning.

 

[Charlie Farley]

A few more bits disconnected and removed, all ready engine wise , just need to disconnect the loom at the ECU then a few bits on the gearbox and its coming out

And the person who designed the right-hand engine mount needs talking too, access to that top nut under the turbo is a nightmare, even with the air box, cat etc removed it's just stupid access wise.
On a side note both my engine mount top fixing nuts were loose, nearside was only just finger tight and the drivers side as very loose to the point some of the threads were damaged so the nut wouldn't spin off by hand , had to spanner it a fair bit, maybe the cause of my vibration problems too.
the engine must have been moving around a fair bit.

 

[Matt275]

That could very well be the source of the vibrations. Making massive progress there Rob

 

[Charlie Farley]

Day 3 and a few setbacks today.
Yesterday's optimism that today would be an engine /gearbox out day has been dashed.
Nothing major just silly things that have a habit of causing delays to be honest.
Ecu box lid screws were a pain and two snapped so had to fix that , then had a trip to the vets with our new friend so an hour went there.
The electrical plug connector on the starter , what a pain that is to get off..
Then getting access to and detaching parts on the gearbox took a while, the limitations of working from the floor on axle stands etc really becomes apparent.
some of those linkages are really awkward placed on the top of the gearbox but I got there with some patience.
So spent a while getting the old bus a lot higher front and back which really worked out well and just made the difference, along with the gearbox jack which works great.

As of now its ready to come out , everything that needs to be unbolted , disconnected, drained and un-plugged has been.

first thing in the morning its coming out, whether it likes it or not ..lol
Am I regretting starting this project, not really ,it was never going to be a text book job but I enjoy a challenge and all the benefits it will result in for the old bus.
hopefully wont be as cold but I'm just dreaming this week.

 

[Charlie Farley]

I like to bag up and label nuts and bolts etc as they come off , that way there wont be any lost, mislaid or just mixed up.
Raided the wifes kitchen cupboard for 25 zip close freezer bags, hopefully she wont miss them, and no way they can be used for freezing now...lol

 

[Charlie Farley]

Well its out......yea

Had some nose bag and then just decided , sod the cold I'm going to pull this lump today one way or another.

came out a treat and i think the time spent prior on checking everything etc paid off.

I have a motto with anything mechanical, " Fail to prepare prepare to fail" works for me

Now on the floor ready to split the gearbox then put on the engine stand and commence stage 2.

I'm off for a nice cuppa now and a choccy biscuit.

 

[northpole]

Wished mine was just an engine out job.... mine looks like your pictures from yesterday after spending a good old 6 hours with hand tools taking most of the parts off... than when I called it a day, had to build half backup because it's outside in the parking lot.
I will continue tomorrow to get both the intake and the exhaust manifold off... so I can pull the head off.

No pictures taken as I don't have time to mess about. I need to finish this job asap.

 

[M22ust]

Not too sure if i should ask in here or else where but today I have been head unit shopping and then remembered I have the bose sound system/amplifier so what options do i have? This is my current head unit

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[Charlie Farley]

Lots of options but price range maybe more of a factor and what do you want from the head unit.

 

[M22ust]

Lots of options but price range maybe more of a factor and what do you want from the head unit.

Bluetooth connectivity, maybe a sat nav/google maps and maybe have carista on it so android based something like this

For Audi A4 S4 RS4 7" Head Unit Car Stereo Radio DAB+EQ GPS Sat Nav Android 12.0 | eBay

Compatible Vehicle ModelFor S4 RS4 8E 8F B9 B7 RNS-E. Compatible Vehicle ModelFor AUDI A4(2002-2007). Head Unit FunctionalityCar Radio. Junsun has earned itself a solid reputation for quality, reliability and professionalism in this field.

www.ebay.co.uk

I do have something similar to this but got lost with wiring adapters/harness

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[B7Tourer]

Well its out......yea

Absolutely fab work, Rob well done

Well, airbag recall done; very pleasant experience - no emissions remap on the 2.0TDI neither. They gave me the most basic courtesy car they could; figures, since the old trooper was the oldest, least valuable car there that day. But they said they see quite a few, were complimentary about mine, and how much better they were made then! It was quite nice for a 5 speed S-Line A1; but a bit tinny and gutless feeling compared to the B7.

 

[B7Tourer]

Not too sure if i should ask in here or else where but today I have been head unit shopping and then remembered I have the bose sound system/amplifier so what options do i have? This is my

If you want to keep an OEM look then you will have to look at the Android based Head Units; like mine...

Mine was made by a company called Xtrons and has been rock solid for over 6 years; their current equivalent is this - https://xtrons.co.uk/audi-seat-vari...-ram-64gb-rom-global-4g-lte-solution-px74a4al . Otherwise generic or branded 7" HUs, like Pioneer, Alpine etc. are very good and well made; but usually a lot more expensive.

 

[Charlie Farley]

Just realised I’d forgotten a new clutch pilot bearing, , my local Audi dealers have one so a trip out later for it.

 

[northpole]

Broke dipstick tube, one coolant pipe ripped because it's 19 years old, still fighting with removing the exhaust manifold... other than that need to access 2 more bolts and the head can come off once I pulled the head bolts... getting there slowly...

 

[Charlie Farley]

Any progress is a plus point chap, stick with it.

 

[Charlie Farley]

Not had much time to allocate on the old bus today but just got an hour on it this afternoon.
Gearbox separated and ready for a good clean and service.
A closer look at the original clutch , its totally shot, flapping around all over the place, as is the release bearing, I'm surprised it has last until now, on its last legs without doubt.

will get it off this evening along with the DMF then give the engine a good degrease and clean down before stripping it down more.

 

[northpole]

Audi sucks b*lls! Why did they put headbutts with a hex head instead of the normal multispline found in all the other VAG engines?

So they stopped me from pulling the head today and that really p#£%Ed me the f- off! Running around from shop to shop to find a hex m8 one 1/2 inch socket adapter that os long enough to pull the bolts out....

Seriously not impressed with this left field choice of headbolts.... still didn't find the socket adapter I need so am stuck to order the darn thing online and wait a whole 24 hours for delivery.... it just pi$$es me off!

 

[Charlie Farley]

Yep, the clutch has definitely passed it's best before date.

Fricton prettywell on the rivets and dmf has more free play both rotational and lateral than you can shake a stick at.
look like I'll be needed 6 new pressure plate bolts to when visiting my local audi parts dept tomorrow.

 

[northpole]

Yep, the clutch has definitely passed it's best before date.

Fricton prettywell on the rivets and dmf has more free play both rotational and lateral than you can shake a stick at.
look like I'll be needed 6 new pressure plate bolts to when visiting my local audi parts dept tomorrow.
View attachment 279586View attachment 279587

You can buy new ones but they can be used if you block the flywheel from rotating... in that case you can save some pennies. But tbt officially you should replace them.

 

[northpole]

Well after a long search I found the tool to remove the headbolts... needless to say I pulled the head yesterday, cleaned the top of the cylinder block, cleaned the head, skimmed it, replaced all the needed gaskets, and put the head back on top of the bottom block and torqued it up to factory spec.

Still waiting for some replacement parts but all are external so can reassemble the engine completely.

 

[Matt275]

Well after a long search I found the tool to remove the headbolts... needless to say I pulled the head yesterday, cleaned the top of the cylinder block, cleaned the head, skimmed it, replaced all the needed gaskets, and put the head back on top of the bottom block and torqued it up to factory spec.

Still waiting for some replacement parts but all are external so can reassemble the engine completely.

How did you skim the head?

 

[northpole]

How did you skim the head?

With a tool that connects to a drill on a set height on a workmate (foldable workbench) than slide the head surface under it. And let the drill do it's job. Skimmed 0.01mm of both sides more than enough.

 

[Charlie Farley]

Off to pickup pressure plate bolts and pilot bearing this morning also order a new starter motor wire plug.

The inlet manifold is being a tad stubborn and refusing to come off , I suspect it is stuck on the injectors, a more gentle approach is required at this point as i suspect injectors will com off with it when it does decide to detach itself.
crankshaft rear seal has been leaking too, all to be expected .

 

[northpole]

That might have aided in the clutchslip if it's leaking g bad enough... I checked mine both.the front and rear seal are I. Very good condition and look like they have been replaced. Same as my timing belt, waterpump and tensioner... I will replace them anyway but will keep them as spares. They have no sign of ware at all.

That all said, the leak was deffo the headgasket, efficency 1st cylinder was covered in oil and coolant mixture and the 4 head bolts closed to that cylinder where covered in oil...

All clean and ready for a fresh oil but I forgot ro buy a new oil filter... so I'll be off to pick one up soon... that. Go back and brave the cold and continue building the car up.

Ps @Charlie Farley the injectors can be stubborn to pull mine put up a good fight but came out after some evely applied pressure leverage (both sides of the fuelrail) injector seals came off intact too. But got new ones so they'll be replaced.

 

[Charlie Farley]

Yes , I’d all ready factored in new injector seals etc.
I gave my hand a right whack on the inlet underside pulling out the dipstick .
Had to find a massive plaster to stop the blood flow, not normally a problem but with blood thinners it takes for ever to clot now, that’s life.

 

[Charlie Farley]

That might have aided in the clutchslip if it's leaking g bad enough... I checked mine both.the front and rear seal are I. Very good condition and look like they have been replaced. Same as my timing belt, waterpump and tensioner... I will replace them anyway but will keep them as spares. They have no sign of ware at all.

That all said, the leak was deffo the headgasket, efficency 1st cylinder was covered in oil and coolant mixture and the 4 head bolts closed to that cylinder where covered in oil...

All clean and ready for a fresh oil but I forgot ro buy a new oil filter... so I'll be off to pick one up soon... that. Go back and brave the cold and continue building the car up.

Ps @Charlie Farley the injectors can be stubborn to pull mine put up a good fight but came out after some evely applied pressure leverage (both sides of the fuelrail) injector seals came off intact too. But got new ones so they'll be replaced.

Did you perform a decoke on the inlets too?
I’m expecting mine to be really choked up when I eventually get the manifold off.

 

[Charlie Farley]

Allways something….lol

 

[northpole]

Did you perform a decoke on the inlets too?
I’m expecting mine to be really choked up when I eventually get the manifold off.

Inlets are clean as a qhistle on mine the exhaust side had some coverage nothing that couldn't be removed with a wire brush drill attachment. Even the exhaust valve stems where that clean a simple spray with brake cleaner brought them back to new looking.

If it wasn't for rhe headgasket failure I wouldn't have taken the engine apart. As it only bellowed white smoke when driving... that actually got worse once I welded the hole in the rear exhaust box. Long story short, the engine is and was in very good condition apart from having 2 very brittle hard plastic bits that crumbled when moved a bit further than they liked.

Waiting for thise parts to show up but I can rebuild the rest of the engine now. I got my oil filter so nothing stopping me to continue doing the hardest part...(exhaust manifold) the rest is easy. And it's only hard because 5 bolts have to be put on blind with the cat being in the way took me 3 hours to get them off. Will probably take the same time for me to put it back, big hands don't help in this case even worse with me wearing thick gloves because it's cold outside.