My S2 coupe bit of a rebuild and repair thread.

[LHD_Kid]

Well...... how was the screen job?

Breath is baited.....

[B5NUT]

It went 97% well.

First minor issue was the top rubber trim does not go all the way to the edge on the drivers side
1-trim.jpg
The side trim on the drivers side is not seated correctly, they are coming back out to sort that
2-trim.jpg
Finally also on the drivers side the interior trim is also not fitted correctly which I will sort out

The glass fitted was manufactured by Pilkington as figured. I guess all the Audi branded glass (make by Pilkington) went long ago.


While I'm on about glass the sunroof glass was bonded to the frame this afternoon, it's not the nicest stuff to work with and it goes off quickly. Also I wish I have another 4 clamps. but hopefully I won't have to do it again unless the other roof can be repaired but I think it past saving. I'll take that one apart once that panel is back in the car.
3-roof.jpg

[newsh]

You’ve done well to save the glass roof, they’re a rarity now, mine had one but it was rotten and the glass was flapping about and I chucked the whole thing and fitted a tin one, then another tin one! Lol

[B5NUT]

Thanks. I want to try and save the one on the car even if it does require some welding and new metal. The glass is in one piece so I hope the frame can be saved.

[B5NUT]

Fitted the replacement sunroof panel today, as it stopped snowing for while.
1-panel.jpg

With the old panel removed, I separated the glass from the frame. It's not in the best of condition but I think it could be saved with a bit of work.
2-frame.jpg

Glass is in good condition, but the rust has scrapped away some of the coating that will need to be repaired. No idea what sort of coating that is, so will will have to talk with some glass companies.
3-glass.jpg

[sidrick]

You're a braver man than I

[B5NUT]

The body of the frame is OK, it's just the edges that have corded away. It's metal after all so it should be repairable. If not then the frame goes in the bin and I'll keep hold of the glass.

[B5NUT]

Few job done over the the weekend.

First off find a good position of the microphone. Found a nice little place in the interior light cover. The microphone is clamped in place using a trim clip from an A6 and and used an iron to melt the top section in a couple of places so it would not work it's self lose.
1-mic.jpg

Also cut a small section from that area so I could fix the right hand side spring clip which had been snapped off at some point!
2-clip.jpg

Also re-tensioned the alternator belt, was getting a bit of squealing from the belt. It was fine for the first few days, just started to happen over the last couple of days and was getting worse.


Next job was to fix another issue caused by the screen fitters. The lower water deflectors no longer fitted properly, and were rubbing against the wipers. Once removed the issue was found. Massive about of screen adhesive stuck to them.

4-water.jpg

This was the excess adhesive removed from the trims, it was about the size of a golf ball.

5-glue.jpg

Gave a area clean up. Also before I removed the wipers I marked up the position on the screen using the masking tape.
4-fix.jpg

Also fitted new wiper blades as the old ones where hard has hell. Just fitted standard Bosch wiper blades front & rear.

Have a question for anyone still running standard brakes. I've fitted Brembo all round (Front disks are zimmermann as Brembo is NLA for the discs) So after a week of driving the car around, and to be fair I'm still taking it very easy the front wheels were covered in dust. Now this could be the coating zimmermann apply to there discs but it's very black dust so don't think it is.

This is the first time I've used Brembo pads, and was not expecting this much brake dust. Is this normal for Brembo pads?
6-wheel.jpg
Inside of the wheel is thick with dust
7-wheel.jpg

If this is the amount of dust I need to remove from the wheels every week I will be looking for better pads. This reminds me of the Pagid pads which were awful for giving off dust. I thought Brembo would be better that this.

Also I got the dreaded Brake Bomb light and beep on the car this evening! Brakes and steering felt OK, there was no loss of brakes or steering, and I did not have to press the brakes any harder. So after a fair bit of reading I filled up the PAS reservoir to the max and the light went out. Are these sensor caps a know failure?

[Tractor Dave]

The brake bomb is half filled with nitrogen with a diaphragm between the gas and oil. The gas slowly discharges over a long period of time, then can't maintain pressure when the car is unused for a few hours. I sent my bomb to a Citroen specialist who 're charge the gas. Came back like new.

[Tractor Dave]

Copied from another thread here
My bomb has been successfully repaired by these guys.
Pleiades Garage, Unit 12A, Brookside Ind Estate, Sawtry, Huntingdon. PE28 5SB. Tel 01487831239
Ask for Phil.
Total cost with postage was £96.
They drill into the bomb, fit a valve and 're charge it to the correct pressure with nitrogen.

[B5NUT]

The question is the bomb faulty, or is the PAS reservoir sensor faulty? It's very strange that I top up the fluid level to the maximum and the light goes out. It was just below 1/2 way. Just been out for another quick drive and again no light on and no beeps.

[Tractor Dave]

If the light comes on after the car has been left overnight then it's the bomb. I think there is a test you can perform by pumping brake a number of times. Someone will know.

[B5NUT]

The light came on after a quick test drive. I just had the wheels balanced, so wanted to check the difference. About a minute into the drive the light comes on along with the beeps.

[Tractor Dave]

That's not the bomb then. Pressure switch or pump.

[newsh]

Could be a dirty contact on the PS Fluid level switch.