Astro's RS Needs TLC

[Astrosquirrel]

Hi

Some years ago I posted my car viewtopic.php?f=2&t=110647&p=682808#p682618

She's aged and needs attention. Rather than posting infinite threads about it, I will condense it all here.

As of this week, this is the task list (excuse the writing).

Roof lining is already checked as it's been done. Here: viewtopic.php?f=2&t=142353

Interior trim was also replaced (and managed to offend Shop along the way ) Here: viewtopic.php?f=2&t=142539&p=964798#p964762

As I progress my intention is to keep you posted, along with sucesses and failures / difficulties.

[Astrosquirrel]

Starting off with the upper control arms. They're shot. The front axle rear upper control arm I broke it myself. It would not come off so I had the get forceful. The others just need replacing due to age I guess:

[Astrosquirrel]

While waiting for the replacement parts, I'm attacking the CPS. Interesting the differences I've found.

On my donor 2003 the cable goes from the sensor - cable tied - alongside the engine, then looping back to go up behind the engine with a heatshield wrapper:

Then halfway it meets the "extention cable" which is also wrapped in that heatshield material

On my 2004 RS, the sensor starts from the gear box towards the front of the engine - No heatshield, only one cable tie (probs was replaced already?) but also the Speed sensor (heatshielded) goes along the same way. Right behind the ac compressor there "extention cable" adapter is mounted on a bracket:

Here you can see how it loops back, meets the heat shielded Speed Sensor cable:

I guess I can count myself lucky as this looks like a much easier replacement job. (Then again, the one from the donor car outlasted it )


EDIT:
Yay the turbo outlet is in the way, can't remove the sensor... sigh... Any helpful tips? (other than remove the engine )

Re-EDIT:
Seems it's an oil cooler pipe that's really blocking it. If I remove the Driveshaft protection housing, I think I can get to the pipe and lower it.

[Astrosquirrel]

I battled the whole day, removed the oil pipe but unfortunately the turbo outlet is in the way. I can't get the CPS off... Slowly coming to th realization that I may have to remove the engine

[Shoppinit]

Are you trying to replace the CPS on the RS4?

[Astrosquirrel]

Are you trying to replace the CPS on the RS4?

The RS6 Plus

[Shoppinit]

I thought it could be changed without dropping the engine. Can't find much info on it.

https://audisrs.com/rs6-c5-crank-positi ... 94#p663576

[Astrosquirrel]

I thought it could be changed without dropping the engine. Can't find much info on it.

https://audisrs.com/rs6-c5-crank-positi ... 94#p663576

Yeah me neither. I will attempt the method described by that guy in that thread, though it sounds difficult. Missus is sick today so I didn't have time to work on the car

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[Astrosquirrel]

Now the mrs is better I had some hours to tinker. The method might just be doable, though it's difficult.

Looking at a spare assembly, the procedure calls for undoing these two, which I've managed to do:

Then proceed with these two, which I also did (actually far easier than the actuator ones):

And then undo the top ones, which I've not yet managed:

See the one on the right I believe I can reach from the top down through the engine bay, but the one on the left I don't have line of sight (or can reach it from the top) - and coming from below the banjo bolt and hose are on the way

From the top it'd be no issue

From below, forget it:

Once those are unfastened, the house should rotate like this, and there would be plenty of room to remove the sensor:

I'm done for today, doing this job on the floor does take a toll. I'm off to

[Astrosquirrel]

Alright, I managed to get the CPS out without removing the engine. I know it's not the most exciting bit in the world, but I'm chuffed. It really is one of the most difficult jobs I've done so far on this car.

Pics will be added later...

Edit: and here are the pics. Hopefully this helps someone who needs to know how to do this job.

Started with the Oil Return Line

Then unfastened (but didn't remove) the actuator bolts. The procedure called for lowering the actuator but there's no need. One bolt's easy, the one in the pic is difficult due to access.

I then moved on to the lower bolts (easy):

After that the top bolt accessible from below. The missus gave me a tip I should have thought about myself...just grind the wrench thin... . It went from impossible to an effing nightmare:

Finally the one accessible from the top.

First I'd to remove one of the breather pipes and the secondary air pump hose:

Then just easily reach down this path about 30cm. Who can spot the bolt?

And finally after rotating the housing a tiny bit to the left (from below), here's mr CPS chillin:

And this is the contraption that made it all possible ...

Alright, it's way past midnight, I'm hungry and tired. Hopefully this helps someone out in future. It is a b***h of a job, but as can be seen, doable

[Shoppinit]

Well done. I hate that kind of job. The one that has you crying with frustration as your improvised tool slips off the invisible bolt almost but not quite out of reach for the 70th time.

[Astrosquirrel]

Well done. I hate that kind of job. The one that has you crying with frustration as your improvised tool slips off the invisible bolt almost but not quite out of reach for the 70th time.

Thanks Ben. Yeah that and the fact that you can move the tool exactly 5 degrees but you need 6 in any direction else it won't bite on the bolt xD.

Gotta say the tip was pretty good. Cheers

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[Astrosquirrel]

Small update on my side.

New items added to the list, but the big one is ticked.




The CPS is replaced and everything that had to be removed/loosened up is now back in place.

I also added heat shielding to the new CPS, no idea why it didn't have any or even if it's supposed to. The other RS6 had it



Here's the routing




While removing one of the breather pipes, I looked at a vaccum line the wrong way and it snapped. So brittle.

Replaced with what the donor car had. Not OEM but the lines are nice and soft.





While at it I found this little fella just hanging there. No clue what it is, maybe you guys could help me identify it.





Cheers guys

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[Shoppinit]

Where was it hanging?

[Astrosquirrel]

Where was it hanging?

Just behind where the ac compressor would be. Same wiring loom as the CPS which goes towards the ecu




There's no part number or any indication as to what it might be. The "pin" in the middle rotates and it has some Heft to it, suggesting it's some sort of motor.

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