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Turbine
Turbine GRM+ Memberand Reader
11/18/21 9:36 a.m.

In reply to Turbine :

Remember how that 040 was going to fit in the stock basket? Ha. 

After pumping almost 10 gallons of old gas out of the tank, I was greeted with this. Someone replaced the 60mm pump and basket with a 43mm version from a urS car. So now I need an adapter. 

I also found some torn dust boots on my other 17z caliper, so the brake job is on hold AGAIN while a new seal kit is on the way. Guess I should've inspected it sooner. Ah well. 

Turbine
Turbine GRM+ Memberand Reader
11/18/21 9:39 a.m.

In better news, the 3B to AAN adapter harness and fuel pump relay harness are here, so I'll have something to work on while waiting for parts at least. I hate having this many projects going at once, but I want to keep things moving

de80q
de80q Reader
11/19/21 12:14 a.m.

The good thing is you don't have a brittle yellowed old pump basket!  That's nice to see!  

Turbine
Turbine GRM+ Memberand Reader
11/19/21 6:12 a.m.

In reply to de80q :

That's true! Thanks for the perspective lol 

Turbine
Turbine GRM+ Memberand Reader
12/1/21 5:34 a.m.

And we're back. Got the fuel pump adapter kit and installed it. 

And then took a break to help a friend replace strut mounts, rotors, and pads on his Alltrack. 

Pretty cool having two manual, AWD, turbocharged VAG products in my garage at once. Especially because of the extreme differences between the two. 
 

That was a few days ago. This morning, I couldn't sleep, so I snuck out to the garage to get some work done before my daughter woke up. 

Fuel pump basket's back in place 

And everything's back together in the trunk. I didn't take any pictures of it, but I also installed the fuel pump relay harness. 
 

Still waiting on the caliper rebuild kit. 

de80q
de80q Reader
12/1/21 6:46 a.m.

Are you rebuilding the front or rear calipers?  Sorry if you already mentioned it.  If it's the rear you will want a pair of These.  Also, make sure to pack the e'brale rod with high temp, waterproof grease.

Turbine
Turbine GRM+ Memberand Reader
12/1/21 7:38 a.m.

In reply to de80q :

No worries! It's the right front caliper. 2 of the 6 dust boots have small tears in them. No signs of leakage yet, but better safe than sorry. 
 

The rears were a little stiff when I tried to retract the pistons, but I was able to free them up. I should still look into a rebuild though. Was that link to a rebuild kit for them? I can't get it to work. 

de80q
de80q Reader
12/1/21 11:55 a.m.

For the rear kit, check out rockauto.  The centric kit for the rears is cheap, and fits perfectly.  

 

Here is the link to the snap ring pliers(again) you will need to do the job.

Pliers 

If that doesn't work this time, look up "master cylinder snap ring pliers" on Amazon.  They are a long 90° pliers to get the snap ring from the bottom of the bore.

 

 

 

Turbine
Turbine GRM+ Memberand Reader
12/1/21 12:17 p.m.

Awesome. Thanks! 

Turbine
Turbine GRM+ Memberand Reader
12/2/21 11:43 a.m.

I had another short stint in the garage this morning, so I tried to make progress on the ECU conversion. 
Step 1: Finding the grommet, which required cutting the passenger's side carpet and rolling it back. 

Step 2: Fish a coat hanger through the grommet to see where it exits in the engine bay. 

Under the steering rack. Cool. 
And finally, Step 3: Tape the harness to the hanger and pull it through the grommet. This went a lot easier than I anticipated. 
 

Afterward, I started pulling the ECU connector apart. I couldn't  quite pull the black piece back far enough to get good access to the pins, but I ran out of time before I could try too hard. Hopefully I don't have to de-pin the entire connector. Regardless, it'll be tight fitting 5 new wires through the black piece. It's already tight as is. 

Turbine
Turbine GRM+ Memberand Reader
12/5/21 11:56 a.m.

I played around with the ECU connector a little more yesterday. Access to the connector requires a bit of contortionism, but I've worked in far worse conditions at my day job lol

I got the power wires for the coils fed through the connector body, but unfortunately that's about where my progress stopped.

I haven't had any luck removing the pins from the ECU connector, and I'm starting to get worried about breaking the plastic. For reference, I'm using these

And they've worked without issue on some of the other connectors on the vehicle, but it seems like space is much more limited here. Any suggestions or recommendations for a good tool or set of tools?

Turbine
Turbine GRM+ Memberand Reader
12/30/21 1:57 p.m.

Life has been wild, and I've been neglecting this thread. But progress has been happening. Nothing too crazy, but it's something.

First, I figured out that I was doing it wrong trying to depin the ECU connector. I was able to make the correct tool out of a binder clip. Once I was able to get the pins to release, the rest of the job should have been easy, right? Nope. I ended up having to cut away part of the connector (the part I circled). It looks like a redundant locking device, so hopefully I didn't compromise the connector. The pins still feel secure in their housings, and the back piece of the housing still snaps into place, which should, in theory keep things together. Worst case, I'll put some clear RTV in the back of the holes or something. Also, if you're doing electrical work and don't have a set of hemostats, do yourself a favor and grab them. Best tool ever.

Second, I started rebuilding the shifter. There are a few bushings on the 016 that wear out and make it impossible to find a gear. The first is a ball/socket style bushing on the linkage that's NLA everywhere. 034 makes a poly version, but by all accounts it's awful and disintegrates within a few months. So I found an STL file for a 3D printed Nylon bushing and found a few people on the OT board that might be able to make something. Hopefully something comes of that, but if not, I'll try to figure something out. The second is the shifter assembly itself. The rod is plastic and prone to cracking, and the plastic ball and socket at the bottom of the arm is known to wear out occasionally. I bought an 034 shifter assembly on black friday started putting it together. Most of the original pieces seemed fine, but at least the billet rod looks cool, even though nobody will see it.

Third, my 17z seal/boot kit came in from the UK. Haven't had a chance to work on the caliper yet, but at least the end of this brake job is finally in sight. It's only been 3 months lol

Turbine
Turbine GRM+ Memberand Reader
12/30/21 2:05 p.m.

Oh! and a bonus update. The plastics on the car were complete and uncracked, which is pretty rare, but they were pretty faded, so I hit them with some Wurth Plast PT on the recommendation of a few VW guys. So far, so good! Of course, they haven't seen any sunlight or weather yet, so who knows how it'll hold up.

Before:

After:

de80q
de80q Reader
12/30/21 10:19 p.m.

If you look on theprojectpad.com you will find a guy who has those nylon bushings printed out and ready to go.  He's a good guy to deal with 

 

The mirrors looks great!  Hopefully they hold up.

Turbine
Turbine GRM+ Memberand Reader
12/31/21 4:15 p.m.

In reply to de80q :

Thanks! I'm hoping so too. Worst case, I've got plenty of the dye left lol
 

I saw his listings on The Project Pad and MG. Tried reaching out to him on both and didn't hear back. It is what it is 

Turbine
Turbine GRM+ Memberand Reader
1/16/22 5:55 p.m.

Thus ends the saga of the 3 month long brake job. Not super optimistic about how some of the dust boots fit, but I was able to get it to what I considered an acceptable point. 
So I moved onto the rear struts. Nothing too crazy there. Got into a bit of a disagreement with one of the strut nuts, but it was nothing a cutoff wheel couldn't solve. 

I also went to two Pull a Parts over the weekend to help a friend look for stuff for his Element. Didn't find anything for the Audi (which I expected), but I did see this

And came across a mk3 GTI VR6 with a seemingly complete engine. If I had more time, I would've tried pulling it just for the hell of it. Oh well. 

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