95 S2 Limo Replica

[sjw185]

Boot lid wiring
Reverse lights were not working due to no switch connection from the ABY loom to the V6 loom.
Found the switch wire and connected to V6 loom but the reverse lights were still not working?
Ended up the boot lid loom was broken in parts so replaced the loom section with some new cable and fitted a new grommet in the body as the old one had disintegrated.
Number plate lights were giving me some bother but just corrosion on the holders.
Fitted a extra bracket to support battery tray.


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Brakes
Ordered new disk and pads and got them fitted, had a problem with rear offside caliper.
Got new seal kit from VW but was still leaking caused by the piston.
Looked into getting a recon exchange but local motor factor couldn’t help and same with local dealer.
After speaking to a forum member about a set of calipers he suggested brake parts international for spares.
Very good service and got a piston and seal kit next day which did the job.


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Front wings are pretty poor with RH wing holed in the arch, couldn't get wings from TPS and second hand were thin on the ground so got some pattern parts to try.

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Had to remove and rivet bracket from old wing and drill indicator hole, refitting went pretty good for first time doing a wing.


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After fitting new track rods and finishing up backbox brackets I got it booked in for MOT
Unfortunately the garage couldn't do the alignment right now but it passed its MOT and was road legal again for the first time in ten years



Before and after Limo.JPG

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[sjw185]

Wiring
Removed power cables from engine bay and rerouted main 16mm to right hand side.
Drilled hole into the chassis leg using photos and my coupe for reference.


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Drilled the hole required to route the cable down to the starter motor with good protection.

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Found aby starter solenoid and oil temperature cables unused in the wing, after tracing the other ends under the glove box mess got them connected to the V6 wiring and operational.

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Trying to work out how the fuel pump was hooked up as it was coming on with Ignition and if you pulled the relay it was still running? Pulled fuel pump fuse and it stopped so the feed was in the correct place.
Checked fuel pump for any wiring mods and couldn’t locate any splices near the fuse box?
After looking over schematics for 80V6 and S2, I pulled the fuse S27 and the pump stopped so after some tracing found a ignition feed under the glove box feeding into V6 N80 wiring.
After some further investigation and wire swaps I found the relay coil wire for the fuel pump relay and got it tested so all working through fuel pump relay.

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A lot of nights checking and testing got all the main engine wires connected and re-crimped from the old mess.
Relocated the fuses from the passenger floor to the fuse box in the correct order.
Got the Injectors fed from correct fuse, sorted ignition circuits and all sensors working.
Only stuff left is the autocheck wiring but car only has minicheck so will need looking into.


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[sjw185]

No updates for a few months but the work on the cars has never stopped.
After timing belt reassembly I noticed the timing belt was sitting really close to the back of the cam wheel.
The penny dropped that’s why the rear timing cover was cut up with belt marks I needed the diamond washer.
Ordered one from ebay packaging was worse than amazon

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Before and after washer fitted.


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Next I removed the old oil cooler which was held on to the towing eye rod with a bit of flatbar.
the hoses were pretty juicy and connectors were welded on to adaptors.

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Made up some brackets to mount up a 13 row I had on the shelf with some MG hoses.

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Steering
got a electric power steering pump to try it out as was interested to see how it would be on the track car.
If it works good was thinking to swap single stage pump from track car on limo later.
Made up a rough bracket and used the original flow and return hoses so very easy to rig up.
Used original V6 loom wiring for signal and put a 50amp fuse at the bulkhead for heavy 12v supply.
Wired it through a switch so it can work with engine off.
An old hazard switch with a bit of insulation tape and a sharpy for now

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Cooling
Started looking at the fan wiring. Have the two speed wiring at the chassis leg from the v6.
Couldn’t get a hold of ABY fan speed resistor so used a cabriolet one 8A0959493
it doesn't have the correct resistance for turbo after run pump but as my after run wiring and relay has been chopped from my loom it’s not a problem for the moment.
Got a hold of replacement radiator, ABY fan and cowlings so thanks to various forum members I now have an almost original cooling set up.


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[sjw185]

Update.

Limo been neglected and outside in the cold the last while.
Back in the garage for a check over, very dry inside under mats and in the boot.

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Fitted rear trims and and seat belts I never replaced after rear screen fitted.

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Swapped BBS wheels to track car and fitted 17inch Avus on for the first time since refurbed.

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Been trying to clay and cut the paint to see if I can remove the years of damage from being covered up.
looking better but poor close up.

Started stripping down for timing belt today.
Pulled radiator as it has a wee leak and have replacement and ABY fan setup to install.
Started cleaning off years of rust and treating parts.

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As usual growing arms and legs, timing belt change turns into cleaning, treating and repairing job.
The wiring is a real worry.
Main power is fed from the rear to a pudding joint next to radiator, the oil temp sensor and solenoid start wire are not used.
Want to fit OEM wiring system with starter motor supplied through chassis leg,
2 x 6mm cables from alternator to fuse box
1 x 6mm cable from battery to fuse box.
Change wiring to get ABY loom starter solenoid and oil temp working.
Repair auxiliary loom
Reverse light switch plug and wiring seems to be missing.


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Krust treatment on parts and do some more tomorrow time for a beer

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[sjw185]

You can fit the protective cover from the inside to keep the dust out if you like.

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[_ShurikeN]

Not sure there is any chance for tandem booster protecting sleeve there if you push it through the bulkhead.

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[Prosac]

Not sure what you mean by adjustment of the brake booster?
It is fitted to the bulkhead with an adapter, still has factory front to rear bias valve and adjust pedal with threaded rod although there is still a lot of pedal travel before brakes work?
Need to investigate that but not had a chance to get near it yet.

Thank you. I have one more question. What is the outer diameter of the gray protective sleeve? I have the brake booster from the Audi A6 4F 3.0 Tdi (4F0612105G) and the piston rod with the protective sleeve does not fit through the bulkhead because the diameter (approx. 55-60mm) is too big.

[sjw185]

How did you adjust the vacuum brake booster?

Not sure what you mean by adjustment of the brake booster?
It is fitted to the bulkhead with an adapter, still has factory front to rear bias valve and adjust pedal with threaded rod although there is still a lot of pedal travel before brakes work?
Need to investigate that but not had a chance to get near it yet.

[Prosac]

How did you adjust the vacuum brake booster?

[sjw185]

how long is a piece of string
Wanted to have it MOTed for end of year but plan and budget have slipped.

[add]

Ok no bother

Thanks all the same...so when's the beast going to hit the roads is the big question,you have an obligation to the saloon crew

[sjw185]

It'll be fine no doubt,just know from experience that the non teflon line permeates fuel vapour,at least the stuff i bought did.
What used to be the glove box is now the ecu's living quarters

Ok no bother

[add]

Thanks for the heads up, looked up spec its not teflon lined but says a synthetic nitrile inner tube suppose to handle fuels including ethanol so hope it all good.
Yea was checking out your saloon, let me know if you want a non AC glove box I found one in the loft yesterday

It'll be fine no doubt,just know from experience that the non teflon line permeates fuel vapour,at least the stuff i bought did.
What used to be the glove box is now the ecu's living quarters

[sjw185]

Is the fuel line rubber or teflon lined?
Just as a heads up you might get some fuel smell if its the rubber lined hose unlike teflon,either way good call.
I went -6 an from rail to tank myself,good to see another saloon getting the treatment!

Thanks for the heads up, looked up spec its not teflon lined but says a synthetic nitrile inner tube suppose to handle fuels including ethanol so hope it all good.
Yea was checking out your saloon, let me know if you want a non AC glove box I found one in the loft yesterday

[add]

Is the fuel line rubber or teflon lined?
Just as a heads up you might get some fuel smell if its the rubber lined hose unlike teflon,either way good call.
I went -6 an from rail to tank myself,good to see another saloon getting the treatment!