WITW - Andrew's Irish Green

[MikkiJayne]

I prefer daily driving the Allroad to Big Red simply because of the gearbox. The auto ruins the 2.8 for me because it is so stupidly programmed. I'm not planning on taking a 5HP round Spa

Not much to report on the thread this evening. I put the oil back in the gearbox and put the gearbox back on the separating machine. Its going to spend overnight with two bellhousing bolts in and the valve body connector connected and make sure there are no more leaks before I reattach the converter and starter etc etc.

I pulled the power steering pipes off as they're pretty crusty. Hopefully I can get those off to the hydraulic shop tomorrow.

[MikkiJayne]

A good day today I put the engine and gearbox back on the subframe, but forgot to get any pics of that, then moved on to cleaning



First pass of APC



Sprayed with tar remover







Rinsed down after a second pass with APC



Nice and clean



The other side was much the same



Botang's hole needed attention, and since the interior is already out its pretty simple to take the electronics box out, and looking under here its a good job that I did! At some point in its life the water has got pretty high in here



Botang's hole just hiding there under the AC pipe



The source of the rust stains I've never seen one in this state, and tbh this is classified as 'nicht gerfingerpoken'. There are no more of these, and this is miraculously still working so I shall leave it alone. We can put it on the list for replacement when I reinvent this whole heater block



Hoovered out and there is an orange tide mark about 2" up



I attacked it with Bilt Hamber Auto-wheel, which is a first for me in this area! It immediately got to work on the iron and turned a deep purple.



Much better



The blower motor is getting replaced with a D3 version which is made considerably easier with the ecu box out as well



The D3 motor has a different connector



D2 connector spliced on to the D3 blower



Wrapped up

[HPsauce]

I've had some horrendous problems with the scuttle drains, the evidence is exposed above!
What exactly is the very rusty component that is "nicht gerfingerpoken" and is NLA but you're thinking of a solution to?
And what happens when it goes wrong?

D2 connector spliced on to the D3 blower

I like your thinking.

Presumably all a bit more comfortable to work on with no bonnet?

[MikkiJayne]

Very pleasant working with no bonnet That may become standard procedure.

The rusty lump is the water pump for the heater. Its built in to the side of the heater valve block and is supposed to push coolant through the two heater cores as the engine water pump doesn't have enough flow or pressure to get through the valve block. When the pump fails it just takes a while for the heater to heat up.

Good working valve blocks with good working motors are unobtanium now so I plan to redesign it using parts from the C7 A6 which has separate valves and pump. They're newer, cheaper and smaller. It's just going to need some creative plumbing to stick it in the space where the D2 valve block goes.

The drains are all clear now

[HPsauce]

Originally Posted by MikkiJayne

The rusty lump is the water pump for the heater. Its built in to the side of the heater valve block and is supposed to push coolant through the two heater cores as the engine water pump doesn't have enough flow or pressure to get through the valve block. When the pump fails it just takes a while for the heater to heat up.

So not the "Auxiliary coolant pump" that gets noisy as it ages? The one that kicks in when you use the "Rest" function.
If it is I've cut the wiring to it and taped it up as it got really noisy years ago (just like my original PF S8).

Heater still warms up fast enough for me.

[MikkiJayne]

Yes it's that. I guess thats why its not making a noise then

[HPsauce]

Good to know. If you have a rummage around you should find the cut wires taped up with Certoflex.

Looking at this was IIRC item 27 on my list from early March, I think you commented then about a future solution with A6 components, potential retrofit as definitely not ready in time.

[pete-p]

Originally Posted by MikkiJayne

The blower motor is getting replaced with a D3 version which is made considerably easier with the ecu box out as well

What's the benefit of using the D3 version? Is it that the D2 is nla or is the D3 version better and quieter?

[Ronin]

It's the same part with different connector that has reversed polarity. D2 part is NLA.

[johnny_quattro]

Originally Posted by Ronin

It's the same part with different connector that has reversed polarity. D2 part is NLA.

I learn something new every day on this forum and long may that continue.

John G