Daily Tdi avant project

[philj]

I was pretty lucky to find mine. FK highsport dampers aren't up to much, wouldn't recommend them, konigsports are better with the Koni adjustable dampers. The Gaz would be about £700, and they can be specc'd to be as high or low as you want.

Too much agg I thought to fit the ABY cooler. If I wasn't stuck for time, I would have seen it out. 3B could be a better bet, but if the outlet is the same as the aby (unlike my 3b) it'll be the same agg.

[macspring]

Great thread man ! keep it going

Agree, looking forward to seeing how you get on.

Keep up the good work. It is a good reference for everyone with a tdi daily driver / non S2 B4.

Best wishes.

[anthonys2]

Loved reading through this project starting to look a real gem mate!!! You've certainly put a lot of time and effort into her looking forward to seeing the end product

[philj]

Cheers, has felt like Christine a few times recently though.

Shot of some nice new bushes...



Well having one good S/H CV joint left, I did some more research on CV joints, really didn't want to have to wait for GKN till the car could be on the road. Gave euros a number I found on here which wasn't listed to fit the 80 (along with a few others) and found a winner....



That's the number if anyone is after one, and although being forced into using Q-drive parts again, I got them cheap, and hopefully the GKNs will arrive soonish. In the meantime, my challenge is to break them, and it meant I could get it back together.

Got some VW CV boots (more £ than the Q drive joints!) Fitted the new joint, then fitted the S/H one, grabbed it to put it in the hub and noticed the abs ring spun a bit, closer inspection revealed a crack, so I pulled it off and waited another day for another q drive joint.

Got it all on and torqued up now anyway



Went for EBC Yellows, might regret that, hopefully not.



Next issue was brake pipes, luckily had a bunch lying around from other projects.

Sacked off the metal section, joined 2 that had the right taper up.



Went to undo the old brake pipes and they've all been rounded previously, great fun. Fortunately the drivers side was ok, still had to hack off the old hoses from the brackets...



Made a new hose bracket but there was no thread on the coilover for the bolt so had to use a self tapper. Tied a bit of silicone round it out of precaution (will tidy that tomorrow) quick lock test and one side is done...



So I just have to knock up a new brake line from the abs to the inner wing, quick bleed then wait for the sound of CV ball bearings hitting the floor.

[philj]

Brakes done and bled...





School boy error in forgetting Audi bolts are M14, couldn't get it on the floor, so changed the pollen filter.



The alarm has shat itself too. Plugged the battery back on, C/L now doesn't work, and you can't open the car door without the alarm going off, but you can get in and start the car, with the alarm going off. Anyone got any ideas on that?

[philj]

Decided to do the cambelt - usual can of worms. Got sent the wrong timing tools to start, went ahead anyway, wasn't too bad to do. Aux belt tensioner shaft was seized in its housing, tensioner was knackered also, both a pain to remove. Euro wrong parts struck yet again - faulty aux tensioner, another days wait.

Been a long sweaty day, but it looks like a car again...

















Next issue is the brakes need a pump before working properly?

[Sleeper_Avant]

air in circuit or pads not sitting propperly on the disk

Cool project!

[targus]

any update?

[philj]

Well I've been driving it, few issues. The travel was just needing a pressure bleed. Front calipers were binding, replaced those and the discs were wearing on the outside only, had to replace the guide bushes. Fixed that.

Then the turbo was passing oil, changed that for an older T2 for the moment as a mate had a spare. Did pick up a GT18v, but its electronic actuator, will need converting to vacuum.

Fitted an S2 rear bumper.

Was still getting air in the fuel. Changed all the leak off pipes and some better hose clips rather than jubilee type has improved it no end. Pump timing was miles out after the belt change, so set that up.

Ruined the top mounts within a hundred miles or so. Quite alot of play on there now, pretty irritating. Before that though it did handle very well for a barge. Went for 1 and a third of camber parallel toe.

Was getting huge lag and what seemed like no fuel off boost. Already changed all the vacuum pipes in the front of the engine. Left a mate to change the one inside the ecu for silicone while I was doing something else. Good improvement, but he didn't do the one to the ecu case from the plastic pipe. Changed that over the weekend and got another improvement.

Then whilst giving it some stick on the way home yesterday the throttle pedal came off it's arm and suddenly it got a fair bit quicker. Reminded me of something Pete told me - there's some adjustment on the pedal, another one I forgot to do. The other tdi almost has a button at the end of its travel that tells the ecu it got full throttle and goes a bit better. This one never did that but hopefully will now after an adjustment.

Picked up a PD150 inlet, going to get the end TIG'd, inside cleaned and whack it on.

Hopefully heated seats, electric windows and a pc to go in next

[AndyP]

Use 'Mr Muscle' oven cleaner on the inlet manifold. I've just done mine this afternoon, took a full can and 3 or 4 applications , but it's come up like new

[Acidburn]

Stick with it, well worth it in the end just for the fuel saving alone and being able to drive the car without worrying about the fuel gauge.

Yup there is a 13mm nut on the pedal box to take up any slack in the pedal so its quicker response.

[JMLAudi]

Air in fuel lines

Hi

Great project..............well inpressed
Just thinking.........the fuel filter cap(with all fuel lines on it)........the brass pipes come loose or crack causing air to be sucked into the fuel lines.

I canverted my fuel filter set up to the A4 set up..................great improvement

Hope this helps

cheers
john

[Christi.Cohoes]

I would also like to add when you do not currently have an insurance policy otherwise you do not take part in any group insurance, you may well reap the benefits of seeking the assistance of a health agent. Self-employed or individuals with medical conditions generally seek the help of any health insurance specialist. Thanks for your article. best wishes

[Christophski]

Another Spam

[Dobby84]

Great to see that your pressing on with your vaggon. Its looking good to me.

Im still running around in your old blue avant which is doing okay although still needs a new fuel pump but I managed to get it to drive okay but just hunts on idle which I can deal with. Oh its no longer blue either! lol

Like others Im interested in how you get on with that intercooler set up.