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Today is a momentous occasion for me as its the day i got my avant on the road and legally imported with an Irish reg plate. It’s alive 
I've been slowly working away on this project since i bought the car at the start of the year so i thought it was about time i posted some info and pics of the work to date. When i bought it i knew there was a few problems, noisy gearbox, bodged fuel lines, rusty exhaust, no handbrake, leaking PAS pump, no power assisted brakes and the bushings were all due for replacement. To top it all off within a few days the clutch packed in with the pedal stuck to the floor.
Cosmetically it is in great shape as the car had been resprayed a few years back so it wasn’t all bad news.
Stage 1: Gearbox and clutch.
The first big job to tackle was the gearbox, fuel lines, and clutch. After a little pondering of the best approach to get at them i opted to pull the engine/gearbox out and strip the engine bay back to the body work and pressure hose it all clean. I used my spare 6speed box that was intended for the coupe project so that solved the first problem.
Looking at the receipts that came with the car a new Dual Mass Flywheel and clutch had been fitted the year before. Just to be sure i pulled the pressure plate off and sure enough it was all nice and fresh looking with a sachs/luk clutch. Slave cyl was a cheap aftermarket unit which looked like it was leaking, the master cyl also showed signs of leakage so i replaced them both with original Audi parts i sourced from vagparts ages ago for my coupe project. I also replaced the release bearing with the metal version from 034.
The fuel lines were a mess, it was routed the wrong side of the master cyl so it was wedged up against the intake pipe, and along the strut brace it was all mangled and out of shape. Thanks to the forum a solution was quickly found, with a few wade connectors, copper pipe and some patience i made my own. As the engine had a fresh timing belt, water pump, and acc belts i didn’t need to do much to it. All i did was give it a quick pressure hose, replaced a few vacuum lines, new WGFV, BOV, spark plugs w/rubber boots, oil and filter. Good for another 115k miles. The rest went together fairly easy, fitted a new bomb, MarkH mod, and PAS pump to finish the job.
Stage 1 complete, car started first time, no strange noises and no leaks. And the idle was as smooth as butter, really does run like a peach! Good news is the clutch is light and smooth and works perfectly. Big thanks to Baltiboy for the PAS pump and other misc bits i needed along the way
I've been slowly working away on this project since i bought the car at the start of the year so i thought it was about time i posted some info and pics of the work to date. When i bought it i knew there was a few problems, noisy gearbox, bodged fuel lines, rusty exhaust, no handbrake, leaking PAS pump, no power assisted brakes and the bushings were all due for replacement. To top it all off within a few days the clutch packed in with the pedal stuck to the floor.
Cosmetically it is in great shape as the car had been resprayed a few years back so it wasn’t all bad news.
Stage 1: Gearbox and clutch.
The first big job to tackle was the gearbox, fuel lines, and clutch. After a little pondering of the best approach to get at them i opted to pull the engine/gearbox out and strip the engine bay back to the body work and pressure hose it all clean. I used my spare 6speed box that was intended for the coupe project so that solved the first problem.
Looking at the receipts that came with the car a new Dual Mass Flywheel and clutch had been fitted the year before. Just to be sure i pulled the pressure plate off and sure enough it was all nice and fresh looking with a sachs/luk clutch. Slave cyl was a cheap aftermarket unit which looked like it was leaking, the master cyl also showed signs of leakage so i replaced them both with original Audi parts i sourced from vagparts ages ago for my coupe project. I also replaced the release bearing with the metal version from 034.
The fuel lines were a mess, it was routed the wrong side of the master cyl so it was wedged up against the intake pipe, and along the strut brace it was all mangled and out of shape. Thanks to the forum a solution was quickly found, with a few wade connectors, copper pipe and some patience i made my own. As the engine had a fresh timing belt, water pump, and acc belts i didn’t need to do much to it. All i did was give it a quick pressure hose, replaced a few vacuum lines, new WGFV, BOV, spark plugs w/rubber boots, oil and filter. Good for another 115k miles. The rest went together fairly easy, fitted a new bomb, MarkH mod, and PAS pump to finish the job.
Stage 1 complete, car started first time, no strange noises and no leaks. And the idle was as smooth as butter, really does run like a peach! Good news is the clutch is light and smooth and works perfectly. Big thanks to Baltiboy for the PAS pump and other misc bits i needed along the way
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