A Polo that won't rust :)

On your behalf had a look this afternoon on the correct route of the knock sensor cable on my project FSI. No need to thank me, as I have said before I have a full depth pit and staring up at the bottom of the engine drinking tea was no hardship (I have lots of time being retired) and besides it was quite interesting to look at this FSI engine from a new viewpoint.

Once I got my inspection lights in a good place I found my knock sensor!

SAM_3894.JPG


Wish I hadn't because I found the outer protective cable cover to the knock sensor connector broken and something I should really fix.

SAM_3899.JPG


And now the news you do not want, yes, it goes on the cabin side of the death pipe. Apologies for the quality of the next pic but I was holding my camera rammed up high threaded between obstacles taking blind picture at random angles until I got something.

SAM_3915.JPG


And a better picture.

SAM_3900.JPG


Some other thoughts.

The cable in the pictures is much smaller than the thicker cable that runs over the two coolant pipes discussed earlier. I can only assume this larger cable divides higher up, one part being the smaller knock sensor cable, but I cannot see the fork.

Why your cable is 2" short is a mystery. Is it possible by moving the engine forward the knock sensor cable has been sucked back into the larger looms it joins and simply needs pulling out again? I agree a bit daft but I am clutching at straws.

Andy
 
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Thanks for the pics, I’m going to have to either extend the cable or just keep poking at things until the reason it’s short becomes apparent. Has to be routing but still no idea why. There’s a big look comes in from the cabin on a massive flexible passage, so there should be plenty of slack, even pulling the engine forward.

Today I got lots cleaned up and I’m now geared up to have a go at carbon blasting myself with crushed walnut shells. Strangely I’m looking forward to this!
 
So here’s a mystery solved I think. This happy longer fellow was going to the thermostat I believe, while the shorter cable was the mystery cable :mad:

Also of concern is the photos above seem to show a kind of support mount... which I’m missing! :mad:

The kinds of mechanics that are left with a pile of bits after they put together a motor are the kind to avoid.

5E638ABC-6535-4C80-AD09-980362152D4F.jpeg
 
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The mystery of your unconnected "short" cable unravels, not quite Agatha Christie!

To clarify I have interpreted your last post correct you are saying you have a hypothesis that the actual knock sensor cable was connected to the thermostat (temperature sensor) and the actual thermostat cable was left disconnected. No wonder the engine ran rough and if I was the ecu I think I would have had a mental breakdown.

Next the support bracket I mentioned that you seem to be missing. To clarify when I said cranked support earlier with hindsight it might have been better described as obtuse angled. In the earlier picture when I said you could just see the top of it I was referring to this

SAM_3846.with arrow.jpg


In fact my next picture from lower down it appears again, namely

SAM_3869.with arrow.jpg


When I looked a few days ago to take these pictures I was more concerned with the cable route and not what appeared to me to be a cable support. I will look again tomorrow and report back. I have looked on 7zap for this cable support and failed - I have no idea in which parts diagram it would appear, it is not in electrical which simply shows the knock sensor at one end of a cable with connector at the other end.

Andy
 
BFD948A5-4892-4ABA-9C78-5E6DABCEB3F6.jpeg

The support I was talking about was the triangle affair in the foreground of this picture which seems to support the bottom of the inlet manifold. I don’t have anything like it!
 
Also spent a lot of time messing around with the timing today and when I found out where the actual point of TDC for the engine is vs where it ended up after I removed the timing belt, it looks like it was 1 tooth out! I went as far as to measure the height of piston 1 with a dowel in the spark plug hole, and it matches where the notched tooth and marking on the casting is. It either moved when the belt was removed or something along those lines. Anyway, it’s right now!
 
B4Andra said:
View attachment 38898

The support I was talking about was the triangle affair in the foreground of this picture which seems to support the bottom of the inlet manifold. I don’t have anything like it!
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More serious than a simple cable support !!!!(my wrong interpretation). From memory a big chunk of steel that does indeed support the big upper inlet manifold at each end!!!! I am thinking part 32 in

https://audi.7zap.com/en/rdw/audi+a2/a2/2003-248/1/133-133005/

I will look tomorrow.

Andy
 
Just had a look at the support bracket you are missing. Bottom two bolts secure bracket to block and top two support the upper inlet manifold, about 8" diagonal in size.

Viewed from just below

SAM_3927.JPG


This view is roughly level and I have included because you can read the part number.

SAM_3928.JPG


Lacking this support you can certainly understand why the manifold dropped off when you removed the upper bolts!

Bracket seems to be used in other VAG models and one available new on ebay from Latvia for ~£23.
It would not surprise me if one of the main recyclers on here have one to hand, I would ask.

Andy
 
Oh I have already enquiried. I did buy parts for this car from Lithuania, which took 3 week to arrive. I’d rather avoid ordering things from further afield than say Germany....
 
B4Andra said:
Oh I have already enquiried. I did buy parts for this car from Lithuania, which took 3 week to arrive. I’d rather avoid ordering things from further afield than say Germany....
Click to expand...

Yes sorry I’ve had a right day of it will check 1st thing and let you know... my apologies !
 
Worth checking bracket price with Tom at Crewe Audi as it could be slightly cheaper than the one from Latvia

Cheers Spike
 
Vorsprung durch Technik said:
Great write up and watching this thread like a hawk. Seeing the pic of your V6 Cabriolet and timing belt tool the penny dropped from your pic on fb yesterday, nice one Andy!
Click to expand...

The cabrio is my loooong term project, it’s one of these cars that will be finished.... One day! Needs priority to get it back on the road just now, because summer... If only I hadn’t been so lazy and did it during winter when it was parked up in the garage!

I’ll get back to the A2 when my injectors re-appear......

6960A1DD-7E9D-4DFE-ACC6-CE8D0A8B724F.jpeg
 
spike said:
Worth checking bracket price with Tom at Crewe Audi as it could be slightly cheaper than the one from Latvia

Cheers Spike
Click to expand...
What’s the deal with Tom? He just happen to be a guy who’s into his motors who also happens to be a parts guy? Does he post the parts to people far, far away like me?
 
Tom works in the parts dept at Crewe Audi and has been very helpful in offering new parts at discount prices. I do believe he may well post parts to Glasgow so if you send him a PM he may be able to help.

Cheers
Dave.
 
B4Andra said:
The cabrio is my loooong term project, it’s one of these cars that will be finished.... One day! Needs priority to get it back on the road just now, because summer... If only I hadn’t been so lazy and did it during winter when it was parked up in the garage!

I’ll get back to the A2 when my injectors re-appear......

View attachment 38930
Click to expand...

Great pic of Cabriolet looks stunning! :cool:



index.php
 
spike said:
Dave summed it up nicely but in addition, it's worth checking the price as the bracket may be cheaper than you think from Audi.

I've had a few bits mail order from Tom and they usually work out to be more convenient and cheaper than buying from my nearest Audi dealer when I factor in the 50 mile round trip I'd need to make to pick them up.

https://www.a2oc.net/community/index.php?threads/hi-from-crewe-audi-discussion.34984/post-306770

Cheers Spike
Click to expand...
Apparently I don’t have permission to view that page or perform that action!
 
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