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My 1991 S2

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  • My 1991 S2

    I have owned the car for around 8 years now. But, and your going to beat me for this. I had a fire under the bonnet 5 years ago approaching a set of traffic lights. I bumped up the kerb to get off the road, switched the engine off and lifted the bonnet to see the wiring loom going up, a bloke in a van asked what was up and I asked for some pliers, I couldnt believe it when he pulled some from the glove box. So I disconnected the battery and the smoldering stopped. I opened the doors and the tail gate to stop the smoke settling and Im sure that stopped the car smelling to date. I must admit at the time I debated letting it burn and doing the insurance but had a rush of sense thinking there can't be that many of these around anymore hence the pliers. As I was moving house at the time I didnt get round to doing anything with it, I did put the car in the workshop where its been ever since. I have pushed it out from time to time and washed it but until recently has remained untouched.
    I have pulled the front off and got to a point where Im thinking the motor may have to come out to do the job.
    I have found the fault that caused the short. A wire from the water circulating pump had been rubbing on the dip stick tube. Some nobber had cable tied the pump to a hydraulic hose and the wires rubbed.
    The car has now been off the road for far to long and I want to enjoy driving it again.
    Has anyone got any tips on how to change the loom before I go mad and pull the car to pieces needlessly?
    Many thanks for any tips.

  • #2
    it's not a nice job on a 3b because of the battery box but i would start by removing the engine harness which unfortunately means removing the dash. Once the loom is out on the floor you will be able to trace the melted wire through the loom and make the repair. However from past experience the plastic coating burns into other surrounding wires. So it may be easier and quicker to just swap the engine loom.
    Audi Nut!!!

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    • #3
      Your right its a nightmare job with the battery tray in the way. I have some pix of the strip down so far so will try and post them.
      Looks like the loom is burnt beyond the to sockets near the coil pack and along under the battery tray, Im guessing it dissapears behind the dash, does this all have to come out.
      Every time I go in the work shop my heart sinks at the thought of it never going back on the road, but Im trying for this year.

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      • #4
        don't get disheartened it's a good day's work to swap the engine loom. Grit your teeth and get stuck in. Take the rad out it will assist with feeding the loom through the bulkhead.
        Audi Nut!!!

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        • #5
          i would suggest you swap the heater matrix too while it's out. It will save a future job and it's surprising just how much more efficient a new one is.
          Audi Nut!!!

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          • #6
            agree with tonks its well worth it. Makes a change to see one being saved rather than stripped. Look forward to hearing progress and seeing pics


            Sapphire cos running custom 2.8litre conversion,es cos rims,raven black leather interior and 500+ with the gas turned off.

            Audi s2 cooking on gas

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            • #7
              This is my S2 when I first had it, obviously before the loom started to smoulder.
              I really miss the experiance of driving it.
              Attached Files

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              • #8
                Really sorry to hear this one, but it confirms something I found when studying 3B schematics in the past. I added the concern to my website some time ago...

                NOW is the time for anyone with a 3B engined S2 to get this sorted. I'll be happy to help where I can with info on how to retrofit a suitable fuse into the offending circuit.

                http://www.s2central.net/cooling02.html
                Paul Nugent
                Webmaster http://S2central.net
                Administrator http://S2forum.com

                1994 S2 Coupe ABY - aka Project Lazarus
                2001 A6 allroad 2.5TDi - family tank
                2003 S4 Avant 4.2 V8 - daily burble

                Purveyor of HomeFries and Exclusive agent for Samco hose kits (S2/RS2)

                There are only 10 kinds of people that understand binary - those that do, and those that don't

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                • #9
                  For anyone that understands Audi schematics...

                  The 1991 3B engine schematic is at http://www.s2central.net/S2_Schematics/A/A17.PDF - see track 61 on sheet A17/5 where you can see the unfused red (ro) wire that connects to track 66 on sheet 6 for the afterrun pump - the root cause of this fire.

                  But look at MY92 3B where fuse S21 is used to protect the 12V feed into the afterrun pump on track 102 - http://www.s2central.net/S2_Schematics/D/D34-09.pdf


                  My suggestion for a fix here on 1991 3B motors is as follows --->

                  1 - working underneath the main fusebox, find the red wire from the afterrun pump that connects to one of the big 'L30' terminals - buzz it out to isolate it properly, but should be easily found as S27 hangs off the same L30 pin.

                  2 - cut this red wire and splice it neatly into the red/black wire on terminal 'M30ac' in the fusebox. This is on the safe side of fuse S21... this is reflected on track 50 (sheet 4) of the A17 schematic - it is also used to protect 12V supply to black OBD plug.

                  Making this a sticky for obvious reasons !
                  Paul Nugent
                  Webmaster http://S2central.net
                  Administrator http://S2forum.com

                  1994 S2 Coupe ABY - aka Project Lazarus
                  2001 A6 allroad 2.5TDi - family tank
                  2003 S4 Avant 4.2 V8 - daily burble

                  Purveyor of HomeFries and Exclusive agent for Samco hose kits (S2/RS2)

                  There are only 10 kinds of people that understand binary - those that do, and those that don't

                  Comment


                  • #10
                    hold on a minute, on the 3B the loom for the afterrun pump and other sensors various is connected by the two multi-pin connectors by the strut brace, no need to remove the dash or the engine if this is the part of the loom thats melted - you might remove some skin from your hands and arms changing it though - but you should be able to do it with the rad out
                    Panthero Coupé quattro 20vt
                    Indigo ABY coupé
                    Imola B6 S4 Avant

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                    • #11
                      YeH but that circular connector tracks back to fusebox on the main loom... The main loom could be well frazzled - such is the pain from having such a fundamental flaw as omitting a fuse from a permanent feed.

                      Paul
                      Paul Nugent
                      Webmaster http://S2central.net
                      Administrator http://S2forum.com

                      1994 S2 Coupe ABY - aka Project Lazarus
                      2001 A6 allroad 2.5TDi - family tank
                      2003 S4 Avant 4.2 V8 - daily burble

                      Purveyor of HomeFries and Exclusive agent for Samco hose kits (S2/RS2)

                      There are only 10 kinds of people that understand binary - those that do, and those that don't

                      Comment


                      • #12
                        That's what has happened. I can see the loom is burn from the connector plugs and running under the battery tray. I'm not sure weather to put the pump back on and remove the wiring. But with the fuse in circuit it should be safe(r). Thanks for the info on this. I'm working blind on it really as wiring is not my strong point.

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                        • #13
                          You should be fine, if you have unburnt wires take pics as a running guide to look back on. Just remember melted/burnt wire casing is carciagenic so wear gloves!
                          Was a '93 3B, Dont ask now tho......

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