I’ve been working on the serpentine belt routing so I can hook up the alternator. I cut down one of the original engine brackets and relocated the idler pulley. The new pulley location should allow me to install a serpentine belt for just the alternator while utilizing the original belt tensioner. I ordered a new 250 amp high output alternator but it turns out that Audi used two alternator styles in the early 2000’s (Bosch style and Valeo style) and the HO alternator uses the larger Bosch style housing that won’t clear the frame. I was able to get a … Continue reading Update 8/3/21

Installed replacement valve covers in crackle red finish with new gaskets, hardware, grommets and sealant. Installed newer style Audi/VW pencil coils and adapters. The newer coils are supposed to be more reliable, better spark and replacements are less expensive. The engine looks like new inside with no varnish or sludge even though it’s supposed to have 43k miles. According to LKQ, this engine came from a Euro spec car that was used in one of the Transformers movies. After filming, the car couldn’t be registered on the street so it was sold to a parts yard where I bought the … Continue reading Update 7/18/21

I replaced all the hydraulic lines (brake and clutch) with nickel/copper lines. I had been using flex lines throughout the car due to problems making good flares on steel hard lines. I bought a new flaring tool that makes really nice inverted flares. With the new tool and the copper line, I had no leaks on the first try. I installed Kevlar flex lines at each wheel. I installed C6 Corvette parking brake shoes in the rear so when the car breaks down I can secure it from rolling. Due to mounting constraints, the brake lever is on the left … Continue reading Update 7/16/21

The new idle valve is working. After adjustments to the fuel injection software the car starts and idles without having to touch the pedal. I fixed several coolant leaks. There is an oil leak from the righthand valve cover which is dripping on the exhaust manifold and making some smoke. The catch can is also venting vapor. I tried out the auto tune feature of TunerStudio which makes on the fly adjustments to the VE table. The feature doesn’t really work without the wideband O2 sensors unless the mixture is already very close. Without any load on the engine I … Continue reading Update 6/9/21

After all the changes and rewiring, the engine runs again. I’ve got a few leaks to fix and the engine is producing some smoke as it burns off surface residue. The silicone exhaust wrap spray is curing which is causing most of the smoke in the video. I warmed up the engine to about 160 degrees before shutting it off. I think it’s still running very rich. There is a strange whistle coming from the intake that varies by rpm. It might be coming from air passing through the idle valve which is currently disconnected while I check timing and … Continue reading Update 5/24/21

Replaced starter with a remanufactured unit.Did more clean up of MS3-Pro fuel injection wiring.Installed 80mm throttle body.With new cold air intake, I removed the MAF sensor housing and converted fuel injection to Speed Density.Replaced external fuel pump with in-tank unit.Replaced all fuel hoses, reducing # of connections by 50%.Wired up O2 sensor heaters for quicker transition to Closed Loop.Hooked up vacuum brake booster. The changeover flap diaphragms and hoses are torn and need replacement. New parts on order. I found a set of valve covers that were professionally coated with a red crackle finish. I’m keeping those aside for when … Continue reading Update 5/10/21

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