20V CQ Tidy Up

[Error404]

I finished fabricating the bracket for the gearbox hall sensor today, so I'll be testing mine out over the next few days

[andy10v]

Is it an adjustable bracket or bolt in exact fit?

[irishs2]

What plating kit did you get?

[Vorsprung durch Technik]

By the way Eric i got the one you gave me the link for cheers

[Error404]

I think it will be similar to the one you got Eric, off eBay came in a bucket! Not looked at it yet, only arrived yesterday
Andy bracket has a slotted hole to allow the gap to be set right
I'll post some pics soon

[Error404]

Time to sort out the PAS pump - 2nd to last job

As I've converted to vacuum brake servo, I needed to sort out a single stage PAS pump.

It’s possible to turn the stock S2 tandem pump into a single stage by removing one or both of the pistons for the brake assist circuit. In my opinion the tandem pumps are a pain in the butt and rebuilt ones don’t seem to last long. As far as I know you can no longer get the genuine ZF seal kits for them which I’m sure has a lot to do with that.

So a better solution IMHO is to use the single stage pump from a vacuum servo’d car. Without the brake assist stage in the pump, they run a much larger diameter shaft, so the bearing faces in the pump are much more substantial and I’m sure this also contributes to less wear meaning they are less likely to leak like a sieve.

An issue with that is the B3/B4 single stage pumps don’t fit the stock pump bracket. I’d previously made an ally spacer to adapt it to fit the ABY bracket, then I noticed browsing the bay that the single stage pumps off the C4 A6 had a different pump casing with two mounting bosses on the front part which were missing off the B3/B4 platform pumps. They looked like they might just bolt onto the ABY bracket, so I took a punt and bought a couple of C4 A6 pumps to play with (cheers James & Andy )

Guess what? They do – perfect straight fit!

The C4 pump is rated at 120bar vs the 100bar of the B3/B4 pump, so not suitable for a straight swap. I stripped them down to use the front part of the A6 pump casing with the rear casing and working parts from the B3/B4 pump keeping the 100 bar rating. Of course I had to clean them up and fit a new genuine ZF seal kit in the process

A6 pump, alongside the front part of the B3/B4 casing:




Parts stripped down, cleaned & casings painted:




Pump assembled:




Pulley & bracket fitted – like they were meant to be together...




Fitted on the car, new fluid, bled. Dry as a bone







Should be a big day tomorrow, will be back on its wheels and might even make it outsde for the first time in over a year

[irishs2]

Wow nice work, timing on this is perfect thank you.

[re2500]

Good job alex, looks much neater and more oem than the spacer bracket i made for the pump on my coupe.

[pixsaudisex2]

Nice but. ze pulley bracket takes seconds to look

[Error404]

What you smokin Neil?

[K Simmonds]

Hmm, I really like that solution to the pump, seriously tempted to convert mine to vacuum brake's while it's apart to change the rack.

Nicely worked out.

[pixsaudisex2]

What you smokin Neil?

You last year or so ago.....

garnard me passenger still talks about it as do i...

[Error404]

All I remember is the sniffer dog suspended from the helicopter

[andy10v]

That is a really nice solution.

How are you cleaning alloy parts, and what are you painting them with?

[pixsaudisex2]

All I remember is the sniffer dog suspended from the helicopter

Tis true,,,,,,