Andyrews Progress Thread, 1/16/22 A Trip to The Red Barn - Lets fab a Firewall! Options

[Andyrew]

Alina update: Shes doing great!!! Learning so quickly! She loves reading books, dancing to music, running around chasing our dog, and grabbing my glasses off my face.

House update: I moved in January. My wife wanted a pool (Shes been in it 5 times... I've been in it 20..), I wanted a 3 car garage (minimum), and we both wanted more house, newer, and in a nice neighborhood. We looked 3 years ago and should have bought then, but you live you learn.


I spent a couple months decking out the garage and building some shelving and a bench and such till it was suitable for me to actually work. I have loads more to do but I've french cleated all the walls so everything is modular which is nice and my main bench I made is on locking casters so it rolls around pretty well. I still need another workbench but this and my collapsible 50's style sawhorses will work well.



On the car front I've done SOME stuff but not much. I drove it for the last time last weekend and said its time to put it down for a while. I have been facing a hot start issue for almost 2 years which has stopped by tuning as well as any real progress on the car or driving. The issue is the car will not start after its any bit warm (Im talking 1 minute started). I've thought it was a crank position sensor as it acts very funny and will start once every 20 cranks ish randomly when warm, but after replacing it multiple times this lead nowhere. At this point I think something is funky with the wiring.


So I've removed all the wiring on the car and I'll be consolidating, testing and cleaning it up as best I can (There are way to many wires in the harness right now). I have determined I will not be using ABS on this car or traction control from the AUDI computer.

Worst case scenario if I cannot figure out I'll do what I should have done from the start and go MS3-Pro EVO. This will give me a lot of cool features that I cant do with my current setup (E85 flex fuel, Traction control, Self tuning)

My current issues that need to be resolved before the car touches the road again.

1. Solve hot start issue.
2. Rewire car.
3. Replace transmission (Current one shifts very bad, Thought it was clutch engagement but after adjusting that it shifts no different).
4. Fix steering binding
5. Pull engine and find out why it leaks so damn much with all new seals. Reseal everything if necessary.



Things that I want to do.

1. Clean up engine bay fuel lines
2. Build better intercooler reservoir (Stainless)
3. Finish building firewall. Note targa top needs to still fit.
4. Clean up trans mounts a bit, paint.
5. Clean up shifter cable holders. (They keep popping out due to excess strain shifting).
6. Clean up the center tunnel. Possibly cut it open and replace it Its messy, sharp edges, and needs some attention.
7. Weld in roll bar and start working on full cage.
8. Figure out what I want to do with the seats so I can get the interior laid out better.
9. Figure out what I want to do with the dash and instruments (Depending on if I can get the Audi stuff to work properly)
10. Start the damn interior...

Pics and video's tomorrow during lunch. Gotta get some sleep now.

PS, I've written this post like 6 times over the past couple months..

[Mike Bellis]

I was having starting/dying problems with mine at first. I tracked it down to a loose wire at the temp sensor plug. This is a known issue on these donor cars. Remove the rubber boots from your connectors and tug on the wires. Pull hard. If they (wires) come loose, there's your problem.

[Andyrew]

I was having starting/dying problems with mine at first. I tracked it down to a loose wire at the temp sensor plug. This is a known issue on these donor cars. Remove the rubber boots from your connectors and tug on the wires. Pull hard. If they (wires) come loose, there's your problem.

Tried that, replaced the plug with no change. My coolant temp comes up like normal as well. Its all taken apart now ready for inspection/cleaning and continuity testing.


This is a video explaining the wiring. Note its a bit difficult to follow as it was about 12:30am and I was a bit tired.


https://www.youtube.com/watch?v=Q_oyBh3HwVU

[76-914]

Good to see that your "going back in", Andrew. That can be difficult sometimes. Looking forward to seeing you AND your 914 at some upcoming events. Also, looking forward to seeing some posts on your progress. :beer2

EDIT: Can't help but wonder if your ECU is locking out the Start circuit because it isn't receiving an OK from some system such as ABS sensor or Collision sensor system not functioning (IMG:style_emoticons/default/confused24.gif) .

[Andyrew]

House and Alina

[Mueller]

Alright, progress on the car!

She is too cute, everyone needs a spaghetti meal picture of their kid!


I think I know what the problem with your harness is:



https://www.youtube.com/watch?v=UOWquP1k6Oc

[Andyrew]

EDIT: Can't help but wonder if your ECU is locking out the Start circuit because it isn't receiving an OK from some system such as ABS sensor or Collision sensor system not functioning (IMG:style_emoticons/default/confused24.gif) .

Possibly, but it wasnt that way from the beginning, I had 6 months of starting 1st or 2nd crank rotation every damn time. This issue popped up as I was working on the cooling system and spilled a bunch of water near the crank position sensor, so I figured I had fried something there.


Its one of the reasons why my backup is just to go with a megasquirt system.

[oakdalecurtis]

Hey Andy, I don't see how you can work on your car at all when you're wrapped around Alina's fingers so tight! (IMG:style_emoticons/default/beerchug.gif)

[Andyrew]

Hey Andy, I don't see how you can work on your car at all when you're wrapped around Alina's fingers so tight! (IMG:style_emoticons/default/beerchug.gif)

Thats why getting this far has taken so long! (IMG:style_emoticons/default/wub.gif)

[76-914]

EDIT: Can't help but wonder if your ECU is locking out the Start circuit because it isn't receiving an OK from some system such as ABS sensor or Collision sensor system not functioning (IMG:style_emoticons/default/confused24.gif) .

Possibly, but it wasnt that way from the beginning, I had 6 months of starting 1st or 2nd crank rotation every damn time. This issue popped up as I was working on the cooling system and spilled a bunch of water near the crank position sensor, so I figured I had fried something there.


Its one of the reasons why my backup is just to go with a megasquirt system.

Ahh. We'll that's certainly logical. DNKT (IMG:style_emoticons/default/beerchug.gif)

[Andyrew]

Got some new tools and consumables. Not pictured is more heat shrink (3:1), and a new butane torch.

Last night I spent an hour stripping the wires of tape(thread remover works great if your slow to avoid crossed wires) and cutting a couple unused plugs out. Probably a pound of wire removed. I'll weigh it all when done. I've got to do this real slowly to not cut anything critical out.

[Mueller]

Got some new tools and consumables. Not pictured is a new 60watt soldering iron with orange case (IMG:style_emoticons/default/smile.gif) , flux, solder, heat shrink terminal kit, and on the way is more heat shrink (3:1), and a new butane torch.

Last night I spent an hour stripping the wires of tape(thread remover works great if your slow to avoid crossed wires) and cutting a couple unused plugs out. Probably a pound of wire removed. I'll weigh it all when done. I've got to do this real slowly to not cut anything critical out.

More tools...nice!

Things I don't see in the picture....safety glasses, a carbon filter exhaust fan and a "third hand" (IMG:style_emoticons/default/smile.gif)

[Andyrew]

Got some new tools and consumables. Not pictured is a new 60watt soldering iron with orange case (IMG:style_emoticons/default/smile.gif) , flux, solder, heat shrink terminal kit, and on the way is more heat shrink (3:1), and a new butane torch.

Last night I spent an hour stripping the wires of tape(thread remover works great if your slow to avoid crossed wires) and cutting a couple unused plugs out. Probably a pound of wire removed. I'll weigh it all when done. I've got to do this real slowly to not cut anything critical out.

More tools...nice!

Things I don't see in the picture....safety glasses, a carbon filter exhaust fan and a "third hand" (IMG:style_emoticons/default/smile.gif)

Safety glasses are directly above the table.

That big ass fan isnt big enough for you? And nope, I dont have a "third hand" yet. Im thinking of putting a "T" track in the front of my table and putting a third hand in it. Havent gotten around to soldering yet, just thinning out the harness still (And probably for another couple weeks if I work on it every other night).

[dan10101]

Finnegan's garage is giving away a $2500 worth of tools for wiring etc.
https://www.youtube.com/watch?v=DNwjFWv3iNs
All you have to do is comment something that catches his eye or his heart.

What you have looks good. Good tools are the key...

[76-914]

Something I found invaluable was the dual range heat gun from HF ($14.99) https://www.harborfreight.com/1500-watt-dua...1112-62340.html and the helping hands tool ($4.99) https://www.harborfreight.com/Helping-Hands-60501.html
The dual range heat gun is perfect for the Heat Shrink. Find the perfect temp setting for whichever style your using then set it and forget it. IIRC, 730F was perfect for melting the silicone in the Marine grade. The helping hands is that 3rd hand but doesn't let the wires move as we do by hand. Rather than twist the wires together I like to slide the exposed ends upon each other then push any stray wires back in before soldering. This way I don't end up with a knot or bulge after soldering. It's not important but looks a lot neater and I don't need the next larger size of heat shrink for it to slide over the hump. Does that make sense? I know that you know this but many guy's don't. A perfect resin core solder joint will shine when set. If the soldered object is allowed to cool too quickly
(eg by blowing on it) or moves before it is set then the joint will appear cloudy indicating an improper solder joint. Before sure that you have a Cold Beer each evening afterwards so you can relax. (IMG:style_emoticons/default/biggrin.gif)

[Mike Bellis]

Tried that, replaced the plug with no change. My coolant temp comes up like normal as well. Its all taken apart now ready for inspection/cleaning and continuity testing.


This is a video explaining the wiring. Note its a bit difficult to follow as it was about 12:30am and I was a bit tired.

My temp came up fine too. The water sensor is a dual element. One goes to the gauge and one to the ECU. It was the ECU wire that had an intermittent connection.

Check all the plugs for every system and try to pull out the wire from the metal terminal. Pull hard. Don't be afraid to yank on it. Like I said, failure at this type of connection point is a known point of failure and run problems. I've even seen some crimps where they crimp over the insulation. This works for a while and then wiggles out of contact.

[Mike Bellis]

What does you VCDS say the problem is? When was the last time you did a throttle body calibration?

[Andyrew]

What does you VCDS say the problem is? When was the last time you did a throttle body calibration?

I can no longer connect to the obd2. This happened about 3 months after the issue. Vcds showed bad crank position sensor, then it stopped showing an issue, then I could no longer connect to it. Another reason why I'm doing the wiring cleanup.

[Andyrew]

Tried that, replaced the plug with no change. My coolant temp comes up like normal as well. Its all taken apart now ready for inspection/cleaning and continuity testing.


This is a video explaining the wiring. Note its a bit difficult to follow as it was about 12:30am and I was a bit tired.

My temp came up fine too. The water sensor is a dual element. One goes to the gauge and one to the ECU. It was the ECU wire that had an intermittent connection.

Check all the plugs for every system and try to pull out the wire from the metal terminal. Pull hard. Don't be afraid to yank on it. Like I said, failure at this type of connection point is a known point of failure and run problems. I've even seen some crimps where they crimp over the insulation. This works for a while and then wiggles out of contact.

I changed the sensor 3 times then changed the wiring twice. Another item I'll be checking while doing the wiring again. All the junkyard connectors we're junk. I haven't found a source for the connector new or else I would do that.

[Andyrew]

Progress from tonight. More of the easy slow stuff. Removed about 10 connectors I don't need. Probably about 15 left to cut out throughout the harness, these were all in two simple clumps.

I am still leaving some wires to trim in case I find I make a mistake and need to solder one back. I'll power up the system and test it before I trim everything back and finish the looms.