905593 repairs

[bethridg]

Creating this thread to document my progress.

I've spent a lot of time researching, cross referencing parts and searching for them. Another thanks to Bigglezworth for pointing me in the direction of Shokan. I've had VERY good luck with them. Pics below!

As it was delivered to me from the body shop. Minus the hood which I took off before I remembered to start taking photos.

http://i.imgur.com/wyFSfBgl.jpg

http://i.imgur.com/7Aq7T60l.jpg http://i.imgur.com/hW24VIEl.jpg

http://i.imgur.com/r2qxDcEl.jpg http://i.imgur.com/yLgB50cl.jpg

Bumper removed. You can start to see the passenger fender support needs a little massaging.

http://i.imgur.com/DGKyXPGl.jpg http://i.imgur.com/yydmHbol.jpg

http://i.imgur.com/fVcJG73l.jpg http://i.imgur.com/xwllQ3Ul.jpg

Test fitting the replacement core support, radiator and headlights. Fender support is close but still needs a little adjustment.

http://i.imgur.com/jQMJYkkl.jpg http://i.imgur.com/0huVMdpl.jpg

http://i.imgur.com/lFyqbyRl.jpg http://i.imgur.com/lcIFOMPl.jpg


Still need to source some body panels (hood & fenders). Got a quote from genuineaudiparts that I feel is reasonable. I'm positive I can repair the cracks in the bumper cover; already have it disassembled. Then will have everything re-shot in Avus (not sure what that will run yet).

If anyone has a spare trans cooler air duct (4B3117339) or A/C condenser (4B3260403H) sitting around please let me know.

Also note the passenger side intercooler. Is caked oil/grime a sign of a leaky intercooler? I know for a fact I have a boost leak somewhere in the system that was confirmed shortly before the accident. Because of this I've been kicking around the idea of Wagner's.

More updates to come. :addict:

[LIRS6]

passenger side intercoolers seem prone to leaking .. i had to replace mine (driver's side was fine)

[P1054]

Check with ECS Tuning for the body parts. They are less expensive than genuineaudi when I checked, but get the parts directly from Audi. I just ordered a new bumper and fender from them at a substantial savings, and the parts I received were brand new genuine Audi parts. Shipping was also very reasonable, at $150 flat for both shipped anywhere in the US. Just my .02.

I also have both my stock intercoolers laying around, along with all of the auxiliary radiator parts and the secondary air injection parts if you're interested in any of those.

[bethridg]

I double checked ECS Tuning for the body panels. Surprisingly they are a few dollars cheaper but I need to email them to get a shipping estimate.

Core support is all back together and ready to install. I mounted the damaged A/C condenser temporarily since it's not a huge priority at the moment. I realized after I took the pics below that I had the trans cooler brackets in the wrong place. Then placed it back on the car to do a hardware check so that I can order whatever is missing.

Deciding on where to order the timing belt, valve cover gasket and transmission filter kits from now. Also need to collect the specialty tools for those jobs.

Quick question, while checking the replacement headlights I noticed the dash is still showing what I believe is the "dipped headlight" warning. Do you think the code is still stored in the computer from the broken lights and just needs to be cleared? A VAG-COM cable is on my shopping list; just haven't made it that far.

So far so good considering I haven't taken the time to order a Bentley manual yet...

http://i.imgur.com/MB9EoUkl.jpg http://i.imgur.com/jGxrUpdl.jpg

http://i.imgur.com/Og544l6l.jpg http://i.imgur.com/0y7sIJFl.jpg

[P1054]

As far as ECS goes, I forgot to mention it in my post above but you'll want to call them to place the order. They'll get you MUCH cheaper shipping than what comes up on the website. Or at least that was my experience.

Looks like your project is going pretty well! I hope it all works out for you.

[bethridg]

A new grille arrived today. Lucky find on ebay.

Hood and fenders have also been ordered from ECS. Ended up saving $100 from what I initially estimated including shipping. However, there is a caveat on the hood. They said the system showed low stock (< 5 in the US). Will get confirmation tomorrow on availability. Fingers crossed!

http://i.imgur.com/WeNI9Lpl.jpg

[P1054]

Congrats on the grille!

Regarding limited availability, when I spoke to Audi about my new bumper cover, they told me there were exactly 2 left in the US. I ended up buying it through ECS, but they got it from Audi, so I would imagine there is now only 1 left in the system in the US! And all of the used-bumper places I checked that recondition bumpers said they have no RS6 bumpers in stock and none coming in the foreseeable future. Who knew parts were so rare..

[bethridg]

Do you happen to have a part number for the bumper cover? Just in case.


Congrats on the grille!

Regarding limited availability, when I spoke to Audi about my new bumper cover, they told me there were exactly 2 left in the US. I ended up buying it through ECS, but they got it from Audi, so I would imagine there is now only 1 left in the system in the US! And all of the used-bumper places I checked that recondition bumpers said they have no RS6 bumpers in stock and none coming in the foreseeable future. Who knew parts were so rare..

[P1054]

Absolutely. The VAG part number is 4B3 807 105 B GRU (the GRU suffix just means it's pre-primed). The ECS part number is ES#372153 if you're interested, and shipping was $150 flat to anywhere in the US. Hopefully you can get yours back in usable condition, but if not this should help!

[Other_Erik]

Since you've already got it off, and I don't have access to ETKA to get part numbers, can you see if there's a part number on the silver surround of the center lower grill in the front bumper cover? Not sure when/where mine went missing, but the new one is going to be plasti-welded into place :|

If not, I'm going to get reamed for a full center grill with surround, probably to the tune of $400+ knowing how RS6 parts pricing works...

Thanks
O_E

[P1054]

Erik, if bethridg doesn't get to it by tonight, I'll take a look at mine and see if I can get you the part number.

[Brav]

Since you've already got it off, and I don't have access to ETKA to get part numbers, can you see if there's a part number on the silver surround of the center lower grill in the front bumper cover? Not sure when/where mine went missing, but the new one is going to be plasti-welded into place :|

If not, I'm going to get reamed for a full center grill with surround, probably to the tune of $400+ knowing how RS6 parts pricing works...

Thanks
O_E

From what I see, ETKA only has the whole grill, not just the surround. 4B3 807 647 F. Then below, it gives a date and code 1L1 for matt-alluminum

[bethridg]

No part number printed on the trim ring it's self. Grille portion has 4B3807647F printed on it. I use jimellisaudiparts.com a lot to look up parts and came up with 4B3807647F 1L1 for the entire assembly.

They do show 4B3807174E 1L1 and 4B3807173E 1L1 as separate part numbers. When I look them up on ECS they are described as TRIM. Your guess is as good as mine as to which is silver or black.

Ebay also has a couple of auctions for the entire assembly. Claiming to be genuine OEM Audi.

Good luck, that's actually one thing I don't have to buy. Haha.




Since you've already got it off, and I don't have access to ETKA to get part numbers, can you see if there's a part number on the silver surround of the center lower grill in the front bumper cover? Not sure when/where mine went missing, but the new one is going to be plasti-welded into place :|

If not, I'm going to get reamed for a full center grill with surround, probably to the tune of $400+ knowing how RS6 parts pricing works...

Thanks
O_E

[P1054]

Yeah, I'm not seeing a part number on the trim piece. I'd say bethridg's response about sums it up.

bethridg, I'm planning to reinstall my bumper tonight but I'm not sure where the headlight sprayer "t" valve attaches to the bumper/frame. It has a little screw tab on it so I assume it attaches somewhere. Do you know where? Or anyone?

[bethridg]

Mine was broken but there is a bracket next to the drivers side sprayer opening. The valve is riveted to that bracket and the bracket has two screws attaching to the bumper cover.

http://i.imgur.com/V16Mifzl.jpg http://i.imgur.com/i5V2rlpl.jpg

[P1054]

Thanks, that makes sense. I appreciate the pix!

[Other_Erik]

No part number printed on the trim ring it's self. Grille portion has 4B3807647F printed on it. I use jimellisaudiparts.com a lot to look up parts and came up with 4B3807647F 1L1 for the entire assembly.
They do show 4B3807174E 1L1 and 4B3807173E 1L1 as separate part numbers. When I look them up on ECS they are described as TRIM. Your guess is as good as mine as to which is silver or black.
Ebay also has a couple of auctions for the entire assembly. Claiming to be genuine OEM Audi.
Good luck, that's actually one thing I don't have to buy. Haha.


Yeah, I'm not seeing a part number on the trim piece. I'd say bethridg's response about sums it up.

Thanks, confirmed with local stealership, the 4B3807647F1L1 is the correct part, it's the entire Grille and costs $375. Not happening any time soon. Genuineaudiparts has it for $275, still not happening until at least a month after I pay the tax man...

4B3807174E and 4B3807173E are the codes for left and right grilles, with 1L1 and 5PV being aluminum trim ring and black trim ring attached respectively

[bethridg]

Decided to prep for the timing belt replacement today. So I removed everything to gain access and noticed the timing belt is VERY loose on the top end. There is a good inch of play and the water pump pulley can be spun freely. Is this normal or is the belt stretched? Teeth look good. Need to get that kit ordered asap!

Order with ECS for the body panels is now in a "Holding" state. I think it's because they entered my shipping address as Kansas instead of Missouri. Gawd! Otherwise, everything looks to be ready to ship.

[P1054]

I can tell you that when I changed mine (just a couple of weeks ago) it was very snug all around. Sounds like yours is either stretched (unlikely I would think), or the tensioner is failing or failed..? Or possibly the eccentric pulley came loose somehow? Either way though, all of those items will be replaced if you order the complete kit.

[bethridg]

More parts arrived today! I screwed up and put two small dents in the hood. Ugh, freakin wind. The body shop can deal with that later...

http://i.imgur.com/Bl5yLY5l.jpg http://i.imgur.com/CuoJ9Qll.jpg

[LIRS6]

More parts arrived today! I screwed up and put two small dents in the hood. Ugh, freakin wind. The body shop can deal with that later...

Nah - just cut some air vents into the hood!

http://www.rs6.com/showthread.php/17474-Hood-Vent-Template-and-instructions?highlight=hood+vents

[bethridg]

Another quick update. Timing Belt, water pump, etc have been changed (the old belt was stretched a bit). Replaced the valve cover gaskets. Passenger side cover was a bastard. Also swapped out all the vacuum hoses with silicone while I was at it. Finished buttoning up the front end today. Body panels all line up nicely. Just need to fill/top off all fluids before she's fired up again.

Next on the list is replace the trans filter/fluid and repair the bumper cover. Already have all the materials needed for the bumper cover but need to find the time.

Making progress fellas, making progress.

[4.2Crew]

Passenger side cover was a bastard.

Congrats on the progress!... Regarding the passenger-side valve cover gasket, were you able to loosen and remove the 2 bolts on the coolant pipe to gain enough clearance?

[bethridg]

Yeah, I removed one bolt for the coolant pipe and pulled it away but the real issue I had was clearance at the EGR valve on the back of the head. After lots of wiggling it finally came off.

[bethridg]

Received the VAG-COM cable today. Below is the first scan done on the car since I purchased it. I've had my suspicions about the throttle body since the accident. It's been making a high pitch alarm sound when the ignition is turned on. Anyway, most appear to be intermittent codes. Any hints/pointers as to the cause so I can clear these up?


Wednesday,07,May,2014,15:25:35:07800VCDS -- Windows Based VAG/VAS Emulator
VCDS Version: 12.12.2.0 (x64)
Data version: 20140212




VIN: 905593 License Plate:
Mileage: 89792 Repair Order:






--------------------------------------------------------------------------------
--------------------------------------------------------------------------------




Chassis Type: 4B (4B - Audi A6 C5 (1998 > 2006))
Scan: 01 02 03 06 08 15 16 17 18 22 34 35 36 37 45 55 56 57 65 67
75 76 77

VIN: 905593
-------------------------------------------------------------------------------
Address 01: Engine Labels: 077-907-558-BCY.lbl
Part No: 4D1 907 558 D
Component: 4.2l V8/5VT G 0003
Coding: 0006752
Shop #: WSC 02195 785 00200
VCID: 2F6D039EBD03346632D-5142


6 Faults Found:
16825 - EVAP Emission Control Sys
P0441 - 002 - Incorrect Flow - Intermittent
17580 - Angle Sensor 2 for Throttle Actuator (G188) Signal too Low
P1172 - 002 - - Intermittent
17976 - Throttle Actuator (J338)
P1568 - 001 - Mechanical Failure - Intermittent
17987 - Throttle Actuator (J338)
P1579 - 001 - Adaptation Not Started - Intermittent
17951 - Angle Sensor 1 for Throttle Actuator (G187)
P1543 - 002 - Signal too Small - Intermittent
16622 - Manifold Pressure / Boost Sensor (G31)
P0238 - 001 - Signal too High - Intermittent
Readiness: 0000 0000


-------------------------------------------------------------------------------
Address 02: Auto Trans Labels: 01L-927-156.lbl
Part No: 4B0 927 156 FL
Component: AG5 01L 4.2l5VT USA 0305
Coding: 0000002
Shop #: WSC 02195 785 00200
VCID: 76E3F6FA02D945AEB1B-5142


No fault code found.


-------------------------------------------------------------------------------
Address 03: ABS Brakes Labels: 4B0-614-517.lbl
Part No: 4B0 614 517 AD
Component: ESP 5.7 RS 6 2310
Coding: 06697
Shop #: WSC 02195
VCID: 63C5BFAEF14BC006E65-5142


2 Faults Found:
01119 - Gear Recognition Signal
35-10 - - - Intermittent
18256 - Please check DTC Memory of Engine Controller
P1848 - 35-10 - - Intermittent


-------------------------------------------------------------------------------
Address 06: Seat Mem. Pass Labels: None
Part No: 4B0 959 760 C
Component: Sitzmemory R1 BF 0205
Coding: 00003
Shop #: WSC 00000
VCID: 2D511996E70F4676001-4B02


2 Faults Found:
00668 - Supply Voltage Terminal 30
07-00 - Signal too Low
00668 - Supply Voltage Terminal 30
06-00 - Signal too High


-------------------------------------------------------------------------------
Address 08: Auto HVAC Labels: 4B0-820-043-MY2.lbl
Part No: 4B0 820 043 AR
Component: A6-Klimavollautomat 0208
Coding: 00010
Shop #: WSC 02195
VCID: 6ADBD28A1661914E253-2580


2 Faults Found:
00779 - Outside Air Temp Sensor (G17)
30-10 - Open or Short to Plus - Intermittent
00819 - High Pressure Sensor (G65)
30-10 - Open or Short to Plus - Intermittent


-------------------------------------------------------------------------------
Address 15: Airbags Labels: 4B0-959-655-AI84.lbl
Part No: 4B0 959 655 Q
Component: Airbag 8.4EP 3001
Coding: 0000707
Shop #: WSC 02195 785 00200
VCID: 3E732EDA6A69CDEEA9B-5142


No fault code found.


-------------------------------------------------------------------------------
Address 17: Instruments Labels: 4B0-920-xxx-17.lbl
Part No: 4B0 920 983 D
Component: KOMBI+WEGFAHRS. VDO D14
Coding: 03284
Shop #: WSC 24102
VCID: 2959ED86D3E75A56EC9-5142
905593 AUZ7Z0C2472790


No fault code found.


-------------------------------------------------------------------------------
Address 35: Centr. Locks Labels: 4B0-962-258.lbl
Part No: 4B0 962 258 M
Component: Central Lock/Alarm D38
Coding: 15885
Shop #: WSC 02195
VCID: 33650FEE012B1086565-4EB2


1 Fault Found:
01369 - Alarm triggered by Hood Switch
35-00 - -


-------------------------------------------------------------------------------
Address 36: Seat Mem. Drvr Labels: None
Part No: 4B0 959 760 B
Component: Sitzmemory R1 F 0204
Coding: 00001
Shop #: WSC 00000
VCID: 2C571492DC154F7E17F-4B02


2 Faults Found:
00668 - Supply Voltage Terminal 30
07-00 - Signal too Low
00668 - Supply Voltage Terminal 30
06-00 - Signal too High


-------------------------------------------------------------------------------
Address 55: Xenon Range Labels: 4Z7-907-357.lbl
Part No: 4Z7 907 357
Component: dynamische LWR D09
Coding: 00050
Shop #: WSC 02195
VCID: 04079C321405673EBFF-4B1A


3 Faults Found:
01535 - Control Circuit for Right Headlight Range Adjusting Motor (V49)
30-00 - Open or Short to Plus
01534 - Control Circuit for Left Headlight Range Adjusting Motor (V48)
30-00 - Open or Short to Plus
00532 - Supply Voltage B+
07-10 - Signal too Low - Intermittent


-------------------------------------------------------------------------------
Address 56: Radio Labels: 8E0-035-1xx-56.lbl
Part No: 4B0 035 195 N
Component: symphony II NP2 0410
Coding: 00221
Shop #: WSC 24102
VCID: 2B55178ED91B48461E5-5092


No fault code found.


-------------------------------------------------------------------------------
Address 75: Telematics Labels: None
Part No SW: 8E0 035 616 A HW: 8E0 035 616 A
Component: Telematik USA1
Coding: 0002003
Shop #: WSC 24102 444 00992
VCID: 2345FFAEE1CB8006A65-5142


1 Fault Found:
01531 - Emergency Battery
002 - Lower Limit Exceeded - MIL ON


-------------------------------------------------------------------------------
Address 76: Park Assist Labels: 8Z0-919-283.lbl
Part No: 8Z0 919 283
Component: Parkingsyst. A6 RDW D08
Coding: 01116
Shop #: WSC 02195
VCID: 020B9A2A0E11690E8D3-5142


No fault code found.


End ---------------------------------------------------------------------

[Bigglezworth]

I've had my suspicions about the throttle body since the accident. It's been making a high pitch alarm sound when the ignition is turned on.The throttle body will self calibrate when the ignition is turned to the accessory slot. It does it for the first few seconds and while it's doing it you will hear a high pitched noise.

[bethridg]

The throttle body will self calibrate when the ignition is turned to the accessory slot. It does it for the first few seconds and while it's doing it you will hear a high pitched noise.

Okay, I guess I never noticed it having only had the car a few months prior to playing chicken with the deer. I'm still curious about those codes.

I just filled her with coolant and topped off all the other fluids. The Beast Lives!!!

I'll do the trans filter/fluid this weekend then get started on that bumper cover. I'm in love again. :rs6kiss:

[DHall1]

This is a great thread!

The beast lives

[MaxRS6]

^+1- Great story to keep one alive and growling

[bethridg]

I was just running some numbers from my spreadsheet. So far I've spent $3584.67 towards repairs (excl paint) and $1569.20 in maintenance. Far shy of the $15k quoted by insurance just for repairs. But the car is completely paid off now which leaves a lot of room for upgrades, tires and fuel. Suppose I'll finish pre-funding for that almost inevitable transmission rebuild; even with the later VIN. Mwahahaha!

[SteveKen]

Most of your codes (hood switch, ambient temp, high pressure) are related to the harness that comes from the core support. I'm guessing it's not plugged in?

Also, did you get headlights without the leveling adjusters?

[bethridg]

It's very likely that I turned the ignition on when I had the core support removed. High pressure code is because the A/C system hasn't been recharged.

Headlights are original RS6 units (used). Once I get it back on the ground and level I'll run thru the alignment procedure.

Should I just clear all the codes to see what comes back over time?

[bethridg]

First time out of the garage since March 12th. Finished trans filter/fluid change late last night.

She needs a bath baaaaaad.

http://i.imgur.com/GlyDhs1l.jpg http://i.imgur.com/hcT6swel.jpg

http://i.imgur.com/AtcZLyQl.jpg http://i.imgur.com/8tA8uX9l.jpg

http://i.imgur.com/bYUc7gel.jpg http://i.imgur.com/OpWb4cgl.jpg

http://i.imgur.com/rRua3qdl.jpg

[RAUDI]

Awesome work. Very cool to have it paid off and back together for so little money. Congratulations.

[mik15]

it looks great man, glad you didn't ditch it and took the challenge to put it back together, well done! Getting a full respray? Where did you buy the headlights from and how much were they? they seem to be new, am i right?

[bethridg]

Getting a full respray? Where did you buy the headlights from and how much were they? they seem to be new, am i right?

Not sure on a full respray yet. Headlights are used from Shokan $295/ea.

[bethridg]

It's been a long few months but here she is just back from paint. The sprayer cover had just been cleared when I picked the car up so it's going on later. The shop did some magic on the bumper cover. Can't thank them enough. RS6 grille emblem will be the last thing to go on. I'm calling this project a complete success! Check out the full gallery (http://imgur.com/a/JS40B).

http://i.imgur.com/bg5yjmUl.jpg http://i.imgur.com/8pFZq4ml.jpg
http://i.imgur.com/OaFqi6Rl.jpg http://i.imgur.com/fdigs26l.jpg

[Dmb408]

I'm so jealous of all your strong work.

[lswing]

Glad to hear it!

[nistah]

Sweet, excellent work!

[DHall1]

Warm and fuzzy knowing my #1 was just a few units behind this one on the assembly line. She lives to fight another day