Expedition Allroad - It's alive! IT'S ALIVE!

by "Garrett Davis" (GarrettDavis)
Published 01/23/2017 at 10:43

Tags: expedition allroad ; audi allroad ; audi ; allroad ; offroad ; offroad allroad
STARS: 23

After bringing it home three months ago (almost to the day), the Expedition Allroad is moving under its own power, and it (mostly) does so quite well.

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After setting the engine in last weekend, we still needed to do quite a bit. We through on the new axles, both intercoolers, charge pipes, accessory belt and fan, hooked up all the coolant lines, the clutch line and bled the clutch, the Y-pipe up top, the airbox, routed all the vacuum lines as needed, added fluids, etc.

New axles in and looking nice and pertty:

Since we had to use the timing belt covers from the S4 engine (the Allroad ones broke apart when the timing belt shredded), the grommets and bolt holes for the charge pipes didn’t line up. They sit slightly lower on the S4 motor, so instead of forcing them down and potentially cut themselves up on the frame rails, we just let them sit how they wanted to. They’re pretty secure there, so I don’t foresee any issues.

You can see the tabs on the bottom of the charge pipes where they wanted to sit here:

This is what $100 in fluids looks like:

Once we got everything back together and ready to go, we left the ECU unhooked and cranked the motor over for about 10 seconds to get oil flowing everywhere that hasn’t received oil in a while, namely the turbos which have been out of a car for at least 8 years now (sitting oiled in a box). Then we hooked the ECU up and tried to fire it up.

After about 5 seconds of cranking, it fired right up, but quickly died. We figured we might have flooded it after cranking it without the ECU for so long, so we let it sit for about 15 minutes and cleaned up a bit. When we tried it again it fired up almost immediately, but again died out just as quick.

Here’s a quick video of that:

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So we went and checked, double checked, and then triple checked just about every connection we could think of and found nothing. We noticed a blinking light of a car with a little key, and figured that was the dreaded immobiliser light. I immediately thought this had something to do with the fact that I removed the cluster to work on it (never actually replaced the LCD), so we were googling around for solutions.

After reading through a few forum threads, I found one where a guy said he just replaced the battery in the key and it fired right up. We didn’t think it would work, but we decided to grab the spare key and try that. Sure enough, it fired right up and ran smooth.

It is making some sort of clicking noise from the very front, which we think is the mechanical fan, as it’s cracked in some places and visibly wobbly, but other than that it runs awesome. We took it around the neighborhood to test everything out, and it pulls as strong as 250hp should in a car that weighs just over two tons.

A few issues that need to be addressed:

That (possible) fan noise

The turn signal stalk has an issue that causes a very, very annoying noise (fairly common on these)

The tire rub is pretty bad on tight turns

The check engine light is on until I get a tune that will exclude the deleted SAI

Other than that, I’m just going to drive it for a while and get things sorted out before I even think of offroading it. I need to sort out the tire rub (probably some trimming and a larger spacer), and I NEED a good skid plate before doing anything off the pavement. The oil pan and filter are waaayy too vulnerable as they sit right now, completely unprotected.

More updates as they come...

Replies (23)

"Lumpy44, Proprietor Of Fine Gif" (lumpy44)
01/23/2017 at 10:50, STARS: 1

A true Oppo hero.

"Nibby" (nibby68)
01/23/2017 at 10:51, STARS: 1

The turn signal stalk has an issue that causes a very, very annoying noise (fairly common on these)

well, duh cause previous owner was probably a typical audi driver and never used them

"Garrett Davis" (GarrettDavis)
01/23/2017 at 10:52, STARS: 0

That’s the particularly annoying part, it only happens when the turn signal is not on. It must just be angry that it was never used so it bugs the shit out of the driver until you actually use them and then it goes back to normal, lol.

"functionoverfashion" (functionoverfashion)
01/23/2017 at 10:55, STARS: 5

Wow, congrats. That is no simple engine swap, color me impressed.

"Garrett Davis" (GarrettDavis)
01/23/2017 at 11:01, STARS: 0

Thanks! It’s been a crazy build so far, haha

"OPPOsaurus WRX" (opposaurus)
01/23/2017 at 11:03, STARS: 1

looking good. go for an electric drive fan. its a pretty easy install and take some of the parasitic loss out of the pulley system

"Garrett Davis" (GarrettDavis)
01/23/2017 at 11:04, STARS: 0

That’s the plan. I found a kit for about $200 that is plug and play. Nice and easy.

Thanks!

"Dave the car guy , still here" (a3dave)
01/23/2017 at 11:19, STARS: 0

Its a lot of work. He did a good job. How do I know... BTDT. The 2.8 is the same style block and many things shared. Not an easy job.

http://a3dave.kinja.com/garage-repairs-for-friends-1768760832

"Steve in Manhattan" (blogenfreude01)
01/23/2017 at 11:45, STARS: 0

Wow, great job!

"BobintheMtns" (bobinthemtns)
01/23/2017 at 12:52, STARS: 1

I transplanted a different motor into a motorcycle. It took some work to get everything to fit together. I cannot imagine what this build took.. NICE job.

"Garrett Davis" (GarrettDavis)
01/23/2017 at 12:56, STARS: 2

Thanks man! It has definitely been a challenging build, but not as bad as I think a lot of people would expect.

"RonnyPStiggs" (dyeg96)
01/24/2017 at 23:13, STARS: 0

Congratulations and good luck with the rest of the build! I’m a bit behind, are you using the stock suspension or did you replace it with something else?

"Garrett Davis" (GarrettDavis)
01/24/2017 at 23:23, STARS: 0

Thank you! Suspension components are all stock or stock replacement other than the ride height sensor arms that trick the air suspension into sitting higher and wheels spacers.

"RonnyPStiggs" (dyeg96)
01/24/2017 at 23:36, STARS: 0

Are there aftermarket suspension conversions for the Allroad?

"Garrett Davis" (GarrettDavis)
01/25/2017 at 00:28, STARS: 0

Not really. There are adjustable control arms (mostly for lowering) and replacement parts, but those sensor arms are really the only other thing available

"Herr Quattro - Has a 4-Motion" (spydermonkeywrench)
01/25/2017 at 02:11, STARS: 0

The turn stalk noise, how exactly would you describe it?

Is it the Blinker clicker blinking sporadically and for no goddamn reason?

Because I have that problem when it’s cold and it drives me effing insane.

And I have no idea how to fix it.

"Amoore100" (amoore100)
01/25/2017 at 02:43, STARS: 0

Holy Cow. Can you be my new hero? I can’t believe it was pretty much 100% mechanically sound on first startup, just the freaking German electronics screwing things up. Amazing work, great job to everyone involved. Working on these Audis must be a pain and a half and you made it come together beautifully.

"Garrett Davis" (GarrettDavis)
01/25/2017 at 08:52, STARS: 0

Yes, thats exactly it! It’s the relay in the hazard light switch that makes the noise, but from what I’m reading online, the problem stems from a worm out blinker switch making contact when it shouldn’t in the turn stalk — though sometimes it is actually the hazard switch/relay itself.

What year and model? Does it go away when you turn on your blinkers or hazards?

"Garrett Davis" (GarrettDavis)
01/25/2017 at 08:56, STARS: 1

Thank you! I know, I was surprised too, but luckily the engine we swapped in was a known good, low mileage, well taken care of motor.

This is definitely the most complicated car I’ve worked on, but it really isn’t as bad as I thought it would be. Most of the difficulty is clearance.

"Herr Quattro - Has a 4-Motion" (spydermonkeywrench)
01/29/2017 at 03:20, STARS: 0

I have a 2004 Passat Wagon.

Technically it stops the sporadic clicking once I hit the stalk, but once I turn it off it just randomly returns.

I have no idea how or why it does it.

It’s not temperature related as far as I can tell, because while it started when it got colder (and 90% of my cars issues come out only when it’s cold), and yet it stopped. But otherwise it hasn’t been triggered By hitting a bump or really anything.

I can drive for an hour just fine, and then signal, and then it just start randomly clicking for the next week and then stop for no apparent reason.

I’d fix it but I’m worried the moment I touch anything, the cars electrical systems will develop another 2 dozen gremlins.

If my only electrical gremlin is the blinker, and the parking horn sometimes not honking, I’ll take it haha.

"Garrett Davis" (GarrettDavis)
01/30/2017 at 08:39, STARS: 0

Just looked it up. It’s the exact same issue with your car. Unfortunately on RockAuto yours switch is much more expensive than mine was for some reason.

Without cruise control: http://www.rockauto.com/en/moreinfo.php?pk=3783558&cc=1427183&jnid=403&jpid=0

With cruise control: http://www.rockauto.com/en/moreinfo.php?pk=935592&cc=1427183&jnid=403&jpid=2

On the Audi’s the installation doesn’t look too bad, I figure they can’t be any worse on the VW. Just make sure to disconnect the battery haha

"Herr Quattro - Has a 4-Motion" (spydermonkeywrench)
01/30/2017 at 20:24, STARS: 0

Since when has “common man” VW parts been more expensive then the luxury Audi?

It’s annoying but its not doing it right now so haha. Thanks for letting me know!

"Garrett Davis" (GarrettDavis)
01/31/2017 at 00:56, STARS: 0

Haha, I know right? Even more ridiculous is just how freaking cheap mine was: http://www.rockauto.com/en/moreinfo.php?pk=2994897&cc=1383038&jsn=365

$18!! And it’s surprisingly OEM quality. If I didn’t know better, I’d say it was a genuine Audi part.