Engine refresh – day 9

Passenger side turbo is off… and took much longer than expected (which I should start to expect).

Don’t try this at home

One more thing I surely would have found crazy frustrating if the engine wasn’t out of the car. In order to take the passenger turbo completely out there are a number of fluid lines which need to be disconnected. For some of the bolts it’s impossible to get normal-sized tools in to reach them (and I only have normal-sized tools). To get the turbo loose I cheated by loosening the housing and rotating it to gain better access. I wouldn’t recommend this, however, if you’re not planning on replacing or rebuilding your turbos as you could damage them.

Accessories going back on

I also started putting the accessories back on the front of the engine. I need a new idler wheel for the accessory belt, so am not completely done with that part of the refresh.

Time invested: 6 hours

Engine refresh – Day 8

Valve covers went back on today.

A little gasket maker into the corners.

All the seals are done, so it’s time for the valve covers to go back on. After double-checking the torque on all the bolts I applied gasket sealer to the recommended corners, put on fresh gaskets and then put the valve covers back on.

Timing belt waiting for crank bolt.

Moving from the top of the engine to the front I put on the new timing belt tensioner and idler roller. I’ll confess, getting the timing belt back on was much more of a chore than expected. There is not much space around the shroud, so the belt has to slide in perfectly straight or it binds up. There is no slack in a new belt so it was a struggle to get in. I’m not sure I would have been able to do this with the engine in the car.

Stretchy (new bolt is on left)

Along with putting in the timing belt I replaced the crank bolt. I found it fascinating that the bolt actually stretches from the torque applied to it during it’s time in the engine.

If you are doing your own timing belt, I found the ECS guide was an excellent reference. Print it out and have it on hand to supplement whatever manual you are using.

To close out the day turned my attention to the passenger side turbo and loosened the exhaust manifold.

Time invested: 4 hours.

 

Preparing for new brakes – Day 7

I took a day off working on the engine today and focused on brakes (sort of).

It could be argued that the brakes on the B6 A4 are undersized for normal duties. They will stop the car, no problem, but warping is common. For my upgrade I will be going with a set of Brembo 6 piston calipers which require more wheel clearance than the stock setup. To make room I’ll need to order some wheel spacers and I want to get the spacing correct. I used some cheap spacers to test fit the wheels and make sure they would stay inside the fenders.

At the same time I put in some temporary hub adapters to scale down the bore of the B8 wheels to match my B6 hub. It was totally worth the $20 I spent on the set, it cured the vibration I was getting on the highway (see Day 6).

Time invested, a couple hours of jacking the car up, putting it down and then jacking it up again to add spacers.