drifter_hex
drifter_hex New Reader
10/17/14 7:50 p.m.

So after much deliberation, and many, many hours of reading of the builds, I have come to terms with needing to vent and explain my situation. I am the PROUD owner, and I use this term lightly, of a 1999 Audi A4 Quattro. This car had 218,000 miles on the supposedly stock 1.8 turbo and tiptronic transmission upon purchase a month ago. Now, I know the question is going to come up, but the reason I bought the car is it was cheap and I needed a new DD, but again this story goes into many details that will hopefully come up at some point.
Background
My original DD found its way into a concrete barrier, on a very slippery when wet bridge, with 75% treadlife tires, and FWD. Remarkably the car was still driveable, sort of. The car was a 2004 Scion xB 5 speed, fun to drive, even more fun to show off. Insurance company did a total write-off on it and handed me a check that day, awesome. Now to find that perfect car, I always liked the AWD cars and this little black gem just happened to show up in my price range. Test drove the car and paid cash money for it On the drive home the car decides its not quite ready to make it to its new home yet and promptly lets me know by shredding the tread off the passenger side tire. Fine, it wins round 1, Round 2, my wife who has been following me all the way, helps me look for the jack and tools to take the tire off. Round 2 goes to the car, No jack, No tools. Luckily my wife's Corolla has a jack, but no lug wrench... oh the irony here. Seeing as how it is 12 am and there wasn't a car in site we called AAA, had an agent on his way and BAM, a good Samaritan shows up with a 4-way. Tire comes off, Space saver goes on, I get caught by little sharp strands hanging off of what is left of the tire, and we are back on our way home.
Check engine light comes on at this point, I don't care, I'm a mile from home and bed sounds good since I have to work a couple hours on a Saturday. My wife goes and gets a tire put on the rim and gets it remounted while I am at work. 2 hours later and I am on my way to figure out the CEL. I stop and grab a new OBD2 scanner and find out the code is actually 3 codes. Fix all the issues as best I can with what I got with the car and no more codes.
Issues
So far I have had only a few issues.
Issue 1: Mass Air Flow sensor failure, fix: plug it in, cleared all CEL codes.
Issue 2: Low boost to intake, Vacuum leaks are not this cars friend. On top of that, the turbo to intercooler hose has a beautiful split in the seam, that can't be good for boost pressures.
Issue 3: Exhaust leak, work in progress. Apparently, a PO had attempted to repair this once, All of the nuts holding the manifold on were finger tight, and the 3 bolts holding the turbo on were completely loose allowing the turbo to move around and destroy the threads on one bolt, and heat a second bolt to such temperatures that it just snapped as soon as I touched it with a wrench.
Issue 4: Cracked Exhaust Manifold, replacement part in hand cleaned, prepped, coated and ready to install.
Issue 5: Broken bolts in turbo housing, gotta love a good machine shop.
Issue 6: Filter Box Melted. OK, this one sucked all the fun out of the work on this car. Factory Air box had not been properly positioned or bolted in. It had been rubbing against the turbo. Luckily for me eBay had a new listing, a factory air intake system out of a VW Passat. This should also fix Issue 2.
Issue 7: Headlights cracked, easy fix right? Wrong, entire bumper cover had to come off to replace them.
Issue 8: Factory head unit missing, electrical work, good deal, the single DIN DVD player from the Scion fit perfectly into that hole.
Issue 9: Factory muffler has a hole in it, needless to say for $65, I promptly cut the factory muffler off and replaced it with a high flow glasspack and dual tip. It still looks factory from the rear but sounds so much better considering a previous owner had a cheater pipe made to replace the catalytic converter. I love living in an area where we don't have to worry about emissions testing, yet.
Issue 10: Rear brakes, easy fix until the pilot bushing for one of the calipers gets stuck, Autozone had the bracket but no guides. Pull-a-Part to the rescue. Thankfully, VW was kind enough to use interchangable parts on alot of their cars.
Issue 11: Oil Leak, found a leak on the valve cover that I had not noticed proir to purchase and teardown of the exhaust, really noticed it when cleaning the head for the new manifold gasket to be installed. Added to my list of must do soon.

turboswede
turboswede UltimaDork
10/17/14 11:36 p.m.

Wow. I wish you luck. You're going to need it!

mndsm
mndsm MegaDork
10/18/14 12:20 a.m.

You are a brave man. I shall follow this thoroughly and enjoy it.

drifter_hex
drifter_hex New Reader
10/18/14 9:23 a.m.

Brave, not so much, a glutton for punishment though? I will say yes.

drifter_hex
drifter_hex New Reader
10/18/14 9:24 a.m.

I will be at the shop this afternoon, if I can remember to do it, I will get some pics of the car before I put it all back together and after.

Harvey
Harvey Reader
10/18/14 9:32 a.m.

How does it fool the OBDII into thinking the after cat O2 sensor is still getting good readings?

drifter_hex
drifter_hex New Reader
10/18/14 9:34 a.m.

Still searching for that answer since the second bung was never welded in.

1kris06
1kris06 Reader
10/18/14 10:18 a.m.

RE: #7, I feel your pain. All this to change bulbs, admittedly I don't "need" to take the bumper off, but I'm not going to berkeley up $50 bulbs for 5 minutes of work.

Mr_Clutch42
Mr_Clutch42 Dork
10/18/14 12:22 p.m.

Wow, that's a long list of maintenance to do.

drifter_hex
drifter_hex New Reader
10/18/14 10:51 p.m.

Finally done. All put back together and running.
Before


Broken headlight that I just replaced. I hate living in an apartment complex that houses the entire Roane State Community College Baseball Team during the terms:

Found the other O2 sensor. They did a spacer/reducer on it to trick the computer:





Might not be able to see them but there are cracks in this header: Time to get to work:
Finally off the lift and back outside



Harvey
Harvey Reader
10/20/14 8:55 a.m.

Hows it run now that everything is back together?

edizzle89
edizzle89 Reader
10/20/14 9:23 a.m.
drifter_hex wrote: Found the other O2 sensor. They did a spacer/reducer on it to trick the computer:

i did this same trick after my cat melted and i went with a test pipe on my a4, all it is is a spark plug non-fouler with the end drilled out, the theory is that it pulls the 02 sensor out of the exhaust flow so that it can still see exhaust gas but doesnt see the same rich/lean readings the front 02 sensor sees, kinda of more neutral exhaust reading.

it worked for ~7000 miles for me with out one CEL

drifter_hex
drifter_hex New Reader
10/20/14 9:43 a.m.

Got a good run in on I-40 yesterday. Car ran like a champ for a total of 111 miles round trip, just need to figure out the fuel consumption.

drifter_hex
drifter_hex New Reader
10/20/14 3:36 p.m.

The next project is going to be putting in the triple gauge pod a pillar. This will be a cut and fit project that will involve some plastic work and fiberglass. Time to learn a new skill.

drifter_hex
drifter_hex New Reader
10/27/14 4:47 p.m.

Got an alignment done today and afterwards decided to do some internet digging for specs on this car. Found lots of useful information and some not so useful tidbits that weren't relevant to my particular car. Next up on the list of work to complete is New Guage pod, Second battery for audio install, fixing an oil leak or leaks, replacing outer tie rod ends.
Anyway onto the good stuff that has been siphoned through to get what I need:
1999 Audi A4 Quattro 1.8T 20V 4 Door Sedan

Vin Structure:
WAUCB-8D-XA-------- - 4 Door Sedan, Full time AWD w/ TCD & EDL Traction Control, 1.8 Turbo, A5 Transmission
WAU - Audi
CB -
8D - Body Style
XA -

General Specs:
102.6" wheel base
60.2" track front
58.1" track rear
178" length
68.2" width
55.7" height
1.71 wheelbase ratio
2767 lb. kerb weight
15.6 US gallons 91 Octane
8.8 second 0-60 MPH
6.3 qt. Engine Oil Capacity

Suspension:
Sport Suspension - 1BE
4-link design with upper and lower control arms, stabilizer bar with coil springs/shock absorbers (gas charged)
Double control arms (upper and lower), stabilizer bar, coil springs/shock absorbers (gas charged)

Front: Camber: -40’ ±25’ Toe: +10’ ±2’
Rear: Camber: -40’ ±30’ Toe: +8’ ±5’
Maximum allowable difference in camber between two sides (front & rear) – 30’

Brakes: Dual Diagonal system w/ ABS, VPA, Ventilated front disc, solid rear disc, EBPP
10.9" front Brakes
9.6" rear Brakes

Wheels Tires & Steering:
7J x 16 Cast Alloy 10 Spoke Wheels
205/55 R16 H rated
R&P steering, VPA
36.4 ft Turning Radius

Body Style:
8D2515
8D251Z

Engine:
150hp @ 5700 RPM
155ft.lbs. @ 1750 RPM

Code: AEB
Compression: 9.5:1
Wrist Pin: 20MM
Turbo: K03
Injectors:
VVT: No
Bore: 3.19"
Stroke: 3.40"
107 cu.in.
Cast iron Block
Forged Crank
Aluminum Alloy Head
Belt Driven DOHC w/ Hydraulic Lifters
Firing Order: 1-3-4-2
Dual Knock Sensors
Hot Film MAF
Direct Solid state Ignition
Fully Adaptive Controls

Transmission:
Torsen Center Differential
5-speed Tiptronic® automatic with Dynamic Shift Programming (DSP)

Features:
3-spoke leather covered Sport steering wheel (Tiptronic controls included on automatic transmission models)
Leather wrapped shift knob and hand brake lever
Manually adjustable tilt-and-telescopic steering column
Interior lights in front and rear headliner with fade-in and fade-out feature, time delay and automatic activation when key is withdrawn from ignition
Illuminated glove box, trunk, lighter and ashtray
Ambient lighting in headliner for dash and center console
Fully automatic climate control system with sun sensors
Power windows with power retention, "one touch up" for front windows, "one touch down" and "pinch protection" for all windows
Electronic cruise control with coast, resume and acceleration features
Electrical rear window defogger with automatic timed shut-off feature
Radio frequency remote locking system with selective unlock, panic function, interior lights and alarm system activation (control integrated in folding ignition key)
Retained accessory power after key is removed from ignition
60/40 split-fold rear seat
Cloth or perforated leatherette seat upholstery
Full-length center console with forward storage area, cup holders and adjustable rear passenger air vents
Folding front center armrest with adjustable height and retractable storage area for cellular telephone
Retractable assist handles in headliner
Tool kit located in left rear storage compartment in luggage area
Seating capacity-5 passengers
White and red illuminated backlit instrument cluster with automatic brightness control, including tachometer, electronic speedometer, voltmeter, digital clock with date, service interval indicator, fuel, coolant and oil temperature gauges
Anti-theft alarm system with blinking theft deterrent light and interior monitoring sensors
Windshield wipers with 4-position adjustable intermittent interval rate
Anti-lock brake system (ABS 5.3) with vacuum power assist and electronic rear brake pressure regulation
Next generation driver and front passenger airbag supplemental restraints
Driver and front passenger seat mounted chest side airbag supplemental restraints

Front 3-point safety belts with automatic pre-tensioning, height adjustastable upper mounts and force limiters
2 rear 3-point safety belts with automatic pre-tensioning
Front passenger and rear safety belts with Automatic Locking Retractors (ALR)
Central locking system with safety unlock feature (if airbag deploys)
Emergency warning triangle located in trunk
First Aid kit located in rear center armrest
Child safety rear door locks
Active reflectors in rear of all doors
Locking head restraints for front seats
Rear child seat tether anchors
Glass sunroof with pre-select function, sunshade and pinch protection

*Airbags are supplemental restraints only. Always use safety belts and seat children only in the rear, using restraint systems appropriate for their size and age.

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