Project 1995 ABY. Getting an S2 onto irish roads.

[newsh]

Incidentaly, if you're running Koni Sports, the good setting is 1/2 a turn from full soft at the back and 1 turn from full soft at the front. That's with stock springs though, if the HnRs are stiffer you might want to go 1 turn rear and 1.5t front..

[irishs2]

Thanks guys, yea , I am not sure how it passed last time either. It really shouldn't have. Oh and thanks to your photos I was able to clear the water channels and make sure no water got into the cabin by preemptive sealing the weak points you pointed out.
And I dont mind the wood trim, I would like carbon but I am not too pushed.


MOLD!!! I hate it, and I am kinda afraid of it to be honest. I would not like to breathing it in for sustained periods. So out with the leather and straight for disinfectant. (vinegar + water)


Yep, it hides everywhere.


I am leaving them overnight to soak in some leather treatment, hopefully it will soften them up a little.


I also took this oppertunity to replace the rear mid trims that had got chipped by over zealous powerwashing by some previous owner.


Chipped vs not chipped.



I also replaced this bit I had bodged 2 years ago. Time flies.



Careful of this bit, it can be hard to find.


New vs old. A new spring clip was used too. The ball was lubricated with a little red grease and refitted.

[irishs2]

Interior got more cleaning yesterday.


Before: I would prefer not to wonder what those stains are.



After: Not bad.



More cleaning.


Seats in.

This evening:

ABS was not working properly. I figured I did not push the sensors in far enough into the hub, and if I did I was not consistent with my air gap between cv and sensor.

So out with my vernier calipers and I did some measuring.


From surface of hub to top of the tooth on the cv joint was 35.8mm.


My sensor is exactly 60mm long at highest point.

If I push the sensor in all the way in to contact the tooth the sensor will protrude 24.2mm from the hub. Add the recommended [s]3mm[/s] 0.5-1.3mm air gap that I found in various places on the forum, giving [s]27.2mm[/s] 25.2mm of sensor protruding from the hub.
This calculation was done on the front hub, the rear hub turned out to be approx the same with 0.3mm difference. After clearing the ABS errors with VAGCOM, I took the car for a little spin. ABS problem seems to be gone.


But the car has developed a boost leak. Plenty of go up to 0.4bar and *cough* boost gone. Has to be releated to the boost gauge +homefried ecu I put in the last few days. Maybe I cracked one of those hard boost lines around the ecu.

Oh well. More on that tomorrow.

[djh]

looks brilliant in that picture above

[S2central.net]

Nice two post lift at home... and very good comedy on the boot stains !

[mcandmar]

Looks great in that last pic, but you need to lower the S2 badge so its in the middle, then it will be perfect

[irishs2]

Thanks Paul, I have HUGE respect for the guys who do this on axle stands. After working on mine that way I just got too scared to work under there with the underbody just inches from my face. Stuff of nightmares.

And yea, while looking at that stain, I keep thinking "Avants are to coffins, as coupes are to .... ?" Your homefires is just devine. Thank you for your work in that area. I wll need one done for the avant soon, I will contact you regarding that in near future.


Anyway first order of business was to correct the placement of the S2 badge




Damn ABS, what a nightmare to adjust properly. While making the sensors all equal did stop the juddering at slow down, the abs light kept coming on while at speed. A bit more research I found that the appropriate sensor ring gap is 0.5-1.3mm ... With the ABS sensors pushed in that little bit more all my ABS issues had gone. ... for now.


Boost leak: Due to the sheer awesomeness of homefries the boost hose to the throttle body popped off. A degrease clean and refit was all that was needed to restore the 'go faster now' mode.


I really like the stance now.






*Stone chips cannot be seen in photo



Done for now... NCT on Sunday.

[s2_wot]

Done for now... NCT on Sunday.

Spill the beans?

[irishs2]

It failed on headlight alignment but passed on everything else .. maybe because the back is lower compared to before?
I have to go back in 2 weeks and another 28euro retest fee. This morning was a bad morning for cars, 6 cars before me had all failed, and this was by 9am .

[mcandmar]

BTDT, to get mine to pass i had to get them set "professionally" in a garage, basically they were pointing at the ground so you could see about one car length on dipped beam. Its a complete joke.

If you makes you feel any better our S4 failed yesterday, Front Balljoint, ARB bushings, leaking exhaust, and an almost functioning handbrake. Downpipe join so far gone both flanges will need cut off and replaced, rear calipers are as good as seized so they need replaced too. Marvelous, S2 due in a few weeks too

[irishs2]

Oh dear. Thats quite a list. Fingers crossed for the S2

I know I had a leak mid way on my exhaust and the joint above the rear axle is on its last legs, (clamps are rotten, if you know of a replacement clamp I would be grateful), but that went unnoticed. My emissions were good @ engine temp at 79c. When I book it in for a headlight alignment I am going to give Automotif.ie a try, I am going to get the 4 wheels checked again, not too sure but my rear camber looks off (in too far at top of the wheels).

Oh I also bled the clutch yesterday, as I though it was biting a bit low. Thanks to your tip about removing the bit of gear linkage , it was easy enough to do. Much smoother and biting a bit higher now .

[s2_wot]

Headlight adjustment is such a fickle thing to fail on.

Otherwise it's a great result, nearly there eh?

[irishs2]

Yep, nearly there.

[irishs2]

Got some lovely floor mats...






*cough*

I found out about these mats from this thread:
http://www.s2forum.com/forum/showthread.php?p=318779 I missed out on the group buy, by about 3+ years but they were still able to do the mats.
Thanks to the advice in the thread, the better colour match was Anthracite with a grey border.

And luckly enough Sonic had a logo done here

http://www.s2forum.com/forum/showpost.php?p=318779&postcount=71

To be honest, I didn't think the logo would go through but it did

Next on the list is to remove the old Toad C4 alarm, and put in a Ai606.

[irishs2]

Still touching up the S2, now its got the full NCT

Headlights were way out but the adjusters were siezed


Adjusters were not only siezed but he adjusters were just spinning on the shaft


A good glean to remove rust and provide a key for liquid metal


Replaced my broken light body with a good one bought from the forum





Replaced the bulbs in the difflock switch


Refitted lights and freed up all the adjusters.




Replaced the lower door trim, with trim I bought from VRS over 2 years ago


Of course it never ends. Car cut out twice while driving.

Vagcom:


I checked the wiring around the camshaft and around the cover and back along the fuelinjector wiring, no really obvious wear, or chaffing.

Still trying to find where the issue is. I might have to replace the cps sensor.