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

[76-914]

Your having entirely too much fun. (IMG:style_emoticons/default/biggrin.gif)

[mgp4591]

https://www.youtube.com/watch?v=Zoc0Mr5Kpkg



Figured out the wipers (I think)!

So you're controlling your wipers from the stalks on the column, right? Do you have the intermittent functions and still using the stock 914 wiper motor?

[Andyrew]

Yes, in the video I'm demonstrating me using the Audi wiper stall and controlling the 914 wipers with the 5 stages.

Off
Single sweep
Intermittent (delay variable)
Low speed
High speed

[Mike Bellis]

Where's your Audi wiper relay? That's what I used on mine.

[Andyrew]

It's the big brown(looked it up, and I can hear it clicking at the appropriate times) one with all the other relays. It's still there. The pink plug was to go to the chassis harness so there was no additional relay.

[Mike Bellis]

Then you should be fine. I though the wiper connection would be harder to figure out when I went through this process. Glad you got it so quickly.

[Andyrew]

Then you should be fine. I though the wiper connection would be harder to figure out when I went through this process. Glad you got it so quickly.

I had it labeled back from when I originally was tracing all the wire connections. Then I double checked it when I thinned down the dash harness.

[Andyrew]

3 1/2 months since the last update. Let me tell you all how much I've not progressed (IMG:style_emoticons/default/smile.gif)


Winter has been busy for me and family things, so I havent spent much time in the garage. The 944 developed an oil leak that is leaking onto the header so I cant drive it now like I want to. So i'll need to take it apart after I get the 914 back up and running (I can still drive it now, just smokey.. and I dont like oil fires..)



914 rewire progress.

I completed what I believe to be everything on the dash and engine side of the rewire.

I cut a new hole large enough for the new wiring harness to go through. I have decided I am going to use a small CV joint, cut it in half and glue it back together, then sandwich it with a cover plate to the firewall. I couldnt find a firewall grommet large enough to put my large engine harness through oddly enough. I needed about 3" x 2" Nothing was large enough and this seems like the best solution.

I put the engine harness and connected it all up, then placed my interior/dash harness inside the car and started mounting and hooking things up to test.


So far my tests resulted in the following.

1. Horn is stuck on (steering wheel wasnt even on the car). I found the horn wire to the steering column and unplugged it. Looks like my clock spring is broken so I'll get a new one of those.

2. Intercooler pump is on with just battery power no key. It should be on keyed power. I will need to rewire that.

3. Intercooler controller has no power. Either I have the wrong power source, a fuse is blown, or I wired it to the fuel pump wire (Entirely possible) and it wont turn on without the car being on. I'll swap the wire source to the keyed on and try again.

4. Brake likes non responsive. I traced this down to it being wired incorrectly. (I cut this connector off accidently and had to refind all my wires. But in the process of that I added some connectors on the engine bay side to be able to unplug the rear lights from the dash harness (Good choice IMHO).

5. Tail lights non responsive. Same as above.

6. Key ignition doesnt turn the car over. Suspect its because I have the wire from the starter disconnected (IMG:style_emoticons/default/biggrin.gif) I have the car battery in the interior as its the really small one and I was thinking of relocating it to save on the engine bay clutter.



What I do know that works/powers on correctly.

Headlights
High beams
Turn signals
Hazard
Wipers
AFR guage
Boost controller
Water pump controller


My wife (Six Sigma blackbelt..) asked me how much longer to complete the car for it to be ready for WCR 2019 (Planning on trailering it down) and I told her probably 200 hours to which she gave me this look (IMG:style_emoticons/default/blink.gif)

So then she's tasked me with making a list of the items that I need to do prior to WCR. So next post will be that list along with my anticipated timeframe for completing each line. Im thinking the 200 hours is going to go by very fast...

[mb911]

Six sigma will get you every time.. Good luck

[dan10101]

I'm only a Six Sigma Green Belt. She can kick my ass all over the Project Management World... (IMG:style_emoticons/default/ph34r.gif)

[Andyrew]

914 to do list

**Mandatory total: 121 hrs
Non mandatory total: 214hrs

Electrical: 32
**Fix tail light issue. 1
**Fix brake light issue 1
**Fix intercooler controller 2
**Fix intercooler pump 1
**Fix Horn 1
**Finalize testing of electrical components Test drive setup and heat cycle. 5
**Remove harnesses 2
**Finalize engine harness cleaning 3
**Finalize dash harness cleaning 6
**Reinstall harnesses 10

Steering: 40
**Mill down new steering shaft for steering component retry. 10
**Remove steering components 5
**Fabricate steering joint mounts 10
**Reweld system and test 5
**Adjust system 10

Suspension: 23
Fabricate front sway bar arms 20
Install and adjust 2
Test 1


Brakes:7
Bleed brakes 3
**Rebuild pedal cluster 4

Transmission: 16
**Replace transmission with spare 15
**Inspect clutch 1
**Check for rear main seal leak 0

Engine:29
**Drain fuel 2
**Replace fuel filters 3
Replumb fuel system for cleaner look 10
Clean engine of oil residue 2
Look for source of oil leak. 2
Fix oil leak 10


Body: 75
Fabricate trunk firewall 20
Fabricate and install roll cage 30
Fix targa top knicks 5
Repaint bumpers 5
Clean up front trunk for new paint 10
Clean up rear Trunk and paint 5

Interior:84
Design Dash Layout 3
Foam up dash layout 1
Finalize Dashboard 20
Fiberglass and prep dash for upholstery
Design and build rear firewall 20
Design and build center console 20
Design and build door cards 20



Send dash, Seats, Door cards, Center console, and Rear firewall to upholster for finalizing. (My tests revealed I don't have the skill to do this…)


Spares for WCR:
Trans
Axle
Clutch Disk
Serpentine belt
Shift Cables
Relays
Fuses
Fuel Pump filter
Fuel pump
Oil
Plugs
Coil packs



Items to purchase:
Spare trans $200
Spare clutch disk 200
Serpentine belt 20
Shift cables 150
Fuel pump filters 150
Fuel pump 75
Coil pack
Fiberglass door cards 200
Houndstooth cloth orange 3 yards 200
Upholstery work 2500
Roll cage material 150


I'll come up with a game plan over the next week (IMG:style_emoticons/default/smile.gif)

[dan10101]

(IMG:style_emoticons/default/sawzall-smiley.gif) (IMG:style_emoticons/default/welder.gif) (IMG:style_emoticons/default/aktion035.gif) (IMG:style_emoticons/default/smash.gif) (IMG:style_emoticons/default/welder.gif) (IMG:style_emoticons/default/ph34r.gif) (IMG:style_emoticons/default/driving.gif) (IMG:style_emoticons/default/MDB2.gif) (IMG:style_emoticons/default/signal914.jpg) (IMG:style_emoticons/default/tunez.gif)


(IMG:style_emoticons/default/cool_shades.gif) (IMG:style_emoticons/default/first.gif)

[Andyrew]

Well everything was going really well. I kept finding minor things and fixing them but I got to the point where I ran out of minor things to fix.

I fixed all the electrical issues noted earlier with the tail lights and the intercooler pump and controller.

Today I decided to forgo my notion of replacing the fuel (2 years old?) With some good fuel and try and start it.

First there was no crank, solved that with the signal wire to the starter.

Then there was no fire.

Pulled #1 plug, loads of fuel. Checked spark and there was spark.

So now we have timing and compression. Ecu could be programmed wrong for a start condition but it started 6 months ago . Same goes for compression.

After checking the codes I found the predominant ones were the following:
Crank sensor
Cam sensor
Temp sensor.

Any of those being bad could cause a no start issue.

Now I've changed the crank sensor a good 6 times trying to solve this as it's the most likely culprit and the coolant sensor at least 3. The cam sensor could he bad but I just doubt it.

So I decide that I need to check the wiring again. Check the pins from the ecu and power/ground to the connectors and every connector shows good oms for each pin.


At this point I see a couple options

1. bad cam sensor
2. Bad fuel
3. Bad crank sensor (who knows, I could just be that unlucky...)
4. Bad coolant sensor (I have a new spare I bought with my new connector I had installed)
5. Bad ecu (I have 2 spares that will start the car and neither work)
6. ???

I'm going to start with bad fuel and also order a new cam and crank sensor.

I currently have the engine harness out of the car again (getting good at that... Only took half an hour). I'll clean it up a hair with some tape and maybe some loom/zip ties and reinstall it.

My wife has been giving me good garage time but she's counting down the hours... I told her I'm in troubleshooting mode now and didn't account for there to be this much issues with getting the car restarted... She seems to be ignoring that... funny, so am I... (IMG:style_emoticons/default/beer3.gif)

[tygaboy]

Andrew - You have the patience of Job. Watching you with the wiring thing is giving me second thoughts about one of my latest hair-brained ideas.
If you'd like a break to bend some tubing, let me know!
Chris

[76-914]

Hang in there. I know what it's like chasing down Gremlins. When I started my conversion I had planned on doing what you are doing. Steering column. dash, ignition switch, etc. One day reality smacked me in the face and reminded me that at this stage in life I shouldn't be piddling around so I deleted that section of the conversion. After reading thru your trial and tribulations I'm glad that I didn't pursue that phase. (IMG:style_emoticons/default/beerchug.gif)

[Andyrew]

Andrew - You have the patience of Job. Watching you with the wiring thing is giving me second thoughts about one of my latest hair-brained ideas.
If you'd like a break to bend some tubing, let me know!
Chris

Chris,

Very much appreciate the compliment and offer. Next couple months I think would be a great time to come up and bend some tubing. I dont think I'll bring the car this time, yours is pretty much the same (IMG:style_emoticons/default/biggrin.gif)

The wiring part isnt bad, its the troubleshooting thats been the biggest headache and its probably all me doing it wrong...

[Chris H.]

Man that is such a pain in the ass. Similar thing happened to me when I tidied up the wiring.

Are you getting ANY ignition at all? Does it even cough? If it's the temp sensor it will usually fire after a lot of trying and then run like crap for a few minutes until it gets some heat in it. Had to hold the gas pedal to the floor for mine to start when the temp sensor went bad.

Off the wall thing to check...is you battery good and fully charged? Some ECUs require a minimum amount of voltage to fire the engine up. Probably fine but good thing to check.

[Andyrew]

Man that is such a pain in the ass. Similar thing happened to me when I tidied up the wiring.

Are you getting ANY ignition at all? Does it even cough? If it's the temp sensor it will usually fire after a lot of trying and then run like crap for a few minutes until it gets some heat in it. Had to hold the gas pedal to the floor for mine to start when the temp sensor went bad.

Off the wall thing to check...is you battery good and fully charged? Some ECUs require a minimum amount of voltage to fire the engine up. Probably fine but good thing to check.

Temp sensor is new, the Audi has a thing where it will shut off ignition after 5 seconds of cranking. I havent tried to touch the throttle with it cranking as it always lit at the first crank when it wanted to fire.

Battery just got a fresh charge.


It didn't cough or anything, which I found really odd since I have spark and fuel. I'm going to try my process and see if doing all that fixed the problem. If not I'm going to try starter fluid and then talk to my tuner about doing something with the start up tune to fix it.

[Chris H.]

Yeah that's weird that you got nothing at all. Good call on the starter fluid. It should do SOMETHING if you blast it with that.

I forgot to add the wire from the ECU to the + side of the starter initially which tells the ECU it's cranking..again unlikely to be your problem but something to check.

[914forme]

unless your cam timing is way off, you sure this thing has not jumped a tooth or two? Might want to run a compression check just to make sure you're not chasing your tail. If you already done that, then I am out of options.