Heli-Coil Install

[Don Muirhead <dmr@kwic.com>]

August 4th

8:00 AM - Call my trusty wrench at the Dealer to find out if Heli-Coils are 
ok in the I5's - he said no problem have fun.

8:30 AM - Called Emhart Technologies to find closest supplier.  Gave me 1/2 
dozen names.

9:00 AM - Closest Heli-Coil supplier (60 km) with inventory.  Inserts $4.00 
a piece, handy-dandy insert tool $69.00.  So for under $100.00 (incl. tax), 
I'm in business.  Back by 11:00 AM (stopped for breakfast) and drove the S6 
(wife's).

Brief digression - I gotta drive the S6 more often before we trade it this 
fall.  I think I've only driven it maybe a dozen times and only around town 
since last year - was a nice change.

1:00 PM - Head is on the drill press.  About 45 min. to set-up (checked, 
checked, and re-checked) to verify angles.  Drill out threads (30 min.). 
 Tap takes about 45 minutes.  Clean out debris and use the special insert 
tool to install (20 min.) removed tangs.  Check for debris one more time. 
 Took a Molson break.

4:00 PM - Decide to do a couple of "might as well" housekeeping items. 
 Checked cam, caps, lifters, timing belt, etc...cleaned injectors. 
 Installed old plugs to check thread, then replaced with new set.

6:30 PM - Head is back in place.  Engine starts after 4-5 cranks.  Clears 
its throat (a few puffs of smoke) and a chatters for about a minute - 
running a little rough so when the engine comes up to temp. I check and 
adjust timing - all's ok.  I get out instant smoke to see if there are any 
leaks (btw - dumb idea with engine running), turn off engine grab a bite 
and another cold one.  Check plugs and the Heli inserts after engines 
cooled down.  Turn key - it starts instantly and purrs like a 13 year old 
kitten with asthma.  In other words its back to normal.

Note:
Could have done this job in a couple of hours, if I wasn't over-cautious 
(over-kill) with the set-up, drilling and tapping and left the head on the 
block - but since I decided to do all 5 I think this was the safest route 
for a Heli newbie.

Last digression (sentimental reminiscing):
The engine is no doubt getting tired.  Manifold is getting thin and the 
head and block are starting to show their miles even though compression is 
within 15% average of factory spec's.  From a longevity and durability 
perspective this has been the finest engine and tranny I have ever owned. 
 It has outlived 5 other Audi's since 1986 including a 5,000, 90, 200 and 
2-S4's.  It's retirement as my daily driver will be imminent once I hit the 
1,000,000th mark which should happen around X-Mas 1999.  Notice of 
Retirement Party to follow.

Don Muirhead
'99 A4
'96 S6
'86 CGT x 2