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DD & Winter Beast - 91 200 20VTQAvant (3B)

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  • #76
    Did a few things on the 200 over the past couple days...

    1.)Ran vacuum lines to the rear and center diff so now they can both be locked.
    I just Td off the lines that were meant for the rear. I'm thinking about adding some kind of remote valve ( if such a thing exists) to be able to work the two separately. The diff lock signal wire was cut off at some point so I still need to get that so I can have the full function of the button.

    2.)Dropped the cats and "cleaned" them out.
    They were both shot and not doing any good so cleaned them out. Car seems to have a bit more pep to it

    3.)Fixed my rear defroster and windshield wiper
    Driving around with neither working fro the back window is not good in Utah. Put in a new rear defroster switch and exchanged my rear windshield wiper for a good working unit

    4.)Stole the ABS cancel switch from my coupe for the time being, as the one in the 200 was shot. Much better without stupid ABS when your driving on ice or snow.

    So basically what I'm saying is I'm ready for what the rest of this winter has to bring. Bring it on mother nature!





    Discovered one of my front outer cv joint boots has torn and slung grease all over. Seems like ill be replacing both front outer boots and cleaning the joints next. Oh Joy!
    Justin
    1990 Audi Coupe Quattro= http://www.s2forum.com/forum/showthread.php?t=46309
    1991 Audi 200 20VTQA= http://www.s2forum.com/forum/showthread.php?t=54410
    1987 Audi Coupe GT

    Comment


    • #77
      Welp the Audi Gods were not happy with me for some reason....

      The 200 was down for a few months for repairs, I opened a can of worms as I dug in.

      My front left outer CV boot had torn some time back and sprung grease all over. I put off fixing it for a while but as it warmed up I knew I had to fix it, CV grease + brake dust = good times cleaning :wtf: ...


      So I jumped in and made some dumb assumptions, mainly that it must be just like my coupe where you thread the axle bolt back in and it pops the CV off. Well to my surprise the is a captive circlip that must be spread to remove the CV. Not realizing this i proceeded with catastrophic results of a cracked CV....


      [img]http://imageshack.us/a/img822/6608/eg0x.jpg[img]


      So I sourced a replacement CV and boot. The CV was in good condition but needed a good cleaning..


      So once I had that I pulled the entire axled to get a better angle to spread the circlip so I could get the innards of the CV off the axle. Welp the first time I went to spread the ears on of them snapped off and flew across the room :frustrated: FML....



      So I had to just throw it down and come back another day because I was enraged at this point. So I came back another day with a clear head and tried to figure out how to get his thing off. Nothing I tried worked. Finally I realized the only way to get it off was to cut it off. So I broke out the angle grinder and very carefully, making sure not to cut into the axle, cut it off. A couple wacks with a 5 lbs hammer after the cuts took care of the rest. Success!


      So with that off I was able to re-grease and reboot. Looking good as new....


      As a reminder to not make assumptions, double check, and ask questions this now resides over where I keep my tools....


      So with the axle back together I put it back on the car and while messing about under there I realized both my front brake lines have disintegrated rubber exposing the nylon inside. Doesn't exactly leave you with that warm and fuzzy feeling so I decided to order some stainless steel lines. I also ordered some new brake wear sensors as the ones on the car were shot and the brake pad dash light was on all the time...


      So i take the calipers and old lines out as I figured while I'm waiting on the lines I may as well clean up the calipers and paint them. So I go to remove the short lines from the soft lines to the caliper and they strip out on both front calipers. This was using the proper flare wrench so I tried vice grips. nothing. So I had to cut the lines and use extractor socket to pull the ends out of the calipers...



      Except the piece in the drivers side caliper breaks off flush in the caliper when using the extractor (half in the extractor, half in caliper) so I had to carefully drill it out slowly pulling pieces out making sure not to scar the area where the brake line mates to the caliper to make a seal. Success! So I went to NAPA and bought some 8 inch pre-flared lines and bend them up. Also painted the calipers and fitted the stainless brake lines, eventually will go for a BBK but for now looks much better/safer...



      So I get all the caliper on and and start to bleed the lines with a power bleeder and when I get to the rear passenger there is fluid on the ground. Closer inspection its not coming from the break lines fitting but from the piston. So I pull the caliper figuring it must be the seals, and even though they look fine I replace them with some new piston seals. Fit the caliper and the same thing, leaking from the piston, not the brake line or the e brake mechanism seal. So I pull the caliper again and inspect only to find nothing seemingly wrong. But I take the piston out again and clean everything, check the seals, and swap in a different piston all good. Fit on the caliper again and the freakin piston continues to leak. At this point Ive had it, my car has been down for a month and a half which all started with a torn CV boot and all I want to do is drive the car again, not spend more time diagnosing why this caliper is leaking and waiting more time for parts. So I order a refurbished rear drivers side caliper. While I'm waiting for it to come I did a leak test and fit a Forge bypass valve...




      Pressurizing the intake track reveals two leaks, one at the intake tube to throttle body hose. The clamp had run out of thread to fully tighten down. Felt tight but needed a few more turns to really seal it. Also the oil dipstick had lost all the rubber o rings. A trip the hardware store produces a new properly sized screw clamp and some 5/15" o rings that fit the dip stick perfectly...




      So I finally get the caliper and wanting it to match the other painted calipers i paint it. Come back to it the next day and realize they had shipped me the wrong freakin caliper, a rear passenger aka right side caliper grrr. Contact the company (Partsgeek) and they claim it is the correct one and I'm crazy and if I want the correct one I need to order the correct one. I wont go into too much depth as I will make an entire thread on that whole experience but they refused to man up on mis-listing the caliper. You be the judge (rear calipers, check the pic versus the description, I didn't realize at the time and went off the description) ....
      http://www.partsgeek.com/catalog/199...e_caliper.html

      So here I am still stuck with my car down after over 2 months and functional caliper, the last piece to getting the car back on the road. So I did what I should have done in the first place and ordered a replacement caliper from a reputable vendor, Germanautoparts.com. Wait a week and get the correct caliper, paint it , fit it. Go to bleed the brakes and get to the rear left only to find more brake fluid on the ground. Seriously WTF! check closer and its seeping from the brake screw. go to tighten it but its fully tightened. hmmm grab a few extra bleed screw I have laying around and try each of them. same thing fluid seeping from the screw. tighten each to nearly the point of stripping them but not dice just keep leaking. Welp the area where the caliper meets the end of the brake line was dis-formed or something. Write Germanautoparts.com on Sunday afternoon, Monday morning I get a call from them saying they will overnight a replacement to me so I can get the car back on the road. Tuesday I had a replacement on my doorstep when i got home from work. Painted it and fitted it Wednesday and what do you know....it doesn't leak! The car was in the garage for so long that it had a thick layer of dust on it, so i gave here a good cleaning. Needless to say I'm happy too have the car back on the road again after nearly 3 months of BS 8) ....
      Last edited by Kliminati456; 3 July 2013, 03:48.
      Justin
      1990 Audi Coupe Quattro= http://www.s2forum.com/forum/showthread.php?t=46309
      1991 Audi 200 20VTQA= http://www.s2forum.com/forum/showthread.php?t=54410
      1987 Audi Coupe GT

      Comment


      • #78
        The audi gods werent happy with you that day, you must have put a bit of effort in to crack your CV like that! Good news its back up and working once again though
        Greg

        S2Forum.com Administrator & Webmaster

        '93 Coupe with a few tweeks

        Comment


        • #79
          and 40 days later there's a box from Germany on my doorstep...
          Justin
          1990 Audi Coupe Quattro= http://www.s2forum.com/forum/showthread.php?t=46309
          1991 Audi 200 20VTQA= http://www.s2forum.com/forum/showthread.php?t=54410
          1987 Audi Coupe GT

          Comment


          • #80
            I've never seen o-rings on the dipstick, should they be there?

            Comment


            • #81
              New tailights mounted



              No "egg yolk" here. Chrome orange bulbs> clear/invisible when not lit, bright legal orange when lit


              Justin
              1990 Audi Coupe Quattro= http://www.s2forum.com/forum/showthread.php?t=46309
              1991 Audi 200 20VTQA= http://www.s2forum.com/forum/showthread.php?t=54410
              1987 Audi Coupe GT

              Comment


              • #82
                Originally posted by quattrostyle View Post
                I've never seen o-rings on the dipstick, should they be there?
                No I don't think they are necessary but I was tracking down air leaks and air was seeping out there so I sealed em up!
                Justin
                1990 Audi Coupe Quattro= http://www.s2forum.com/forum/showthread.php?t=46309
                1991 Audi 200 20VTQA= http://www.s2forum.com/forum/showthread.php?t=54410
                1987 Audi Coupe GT

                Comment


                • #83
                  Originally posted by Kliminati456 View Post
                  No I don't think they are necessary but I was tracking down air leaks and air was seeping out there so I sealed em up!
                  If air was leaking out your dipstick during a boost leak pressure test then you likely have a borked one-way bleeder valve.

                  Have a look at this:

                  http://www.s2forum.com/forum/showthr...537#post709537
                  RS2'd 93 UrS4 5 spd sedan
                  94 UrS4 V8 6 spd manual avant

                  Comment


                  • #84
                    Thanks for the tip! Ill have a look into this
                    Justin
                    1990 Audi Coupe Quattro= http://www.s2forum.com/forum/showthread.php?t=46309
                    1991 Audi 200 20VTQA= http://www.s2forum.com/forum/showthread.php?t=54410
                    1987 Audi Coupe GT

                    Comment


                    • #85
                      WG spring and IA chip


                      Proper boost gauge installed


                      New breather components


                      4 wire o2


                      Old ignition switch was cracked so installed new one



                      Another box from Germany
                      Justin
                      1990 Audi Coupe Quattro= http://www.s2forum.com/forum/showthread.php?t=46309
                      1991 Audi 200 20VTQA= http://www.s2forum.com/forum/showthread.php?t=54410
                      1987 Audi Coupe GT

                      Comment


                      • #86
                        Originally posted by UrS4boy View Post
                        If air was leaking out your dipstick during a boost leak pressure test then you likely have a borked one-way bleeder valve.

                        Have a look at this:

                        http://www.s2forum.com/forum/showthr...537#post709537
                        Yup you were correct, new breather components have cleared a hiccup issue I was having.
                        Justin
                        1990 Audi Coupe Quattro= http://www.s2forum.com/forum/showthread.php?t=46309
                        1991 Audi 200 20VTQA= http://www.s2forum.com/forum/showthread.php?t=54410
                        1987 Audi Coupe GT

                        Comment


                        • #87
                          Originally posted by Kliminati456 View Post
                          Yup you were correct, new breather components have cleared a hiccup issue I was having.
                          Where is the happy dance icon when you need it?

                          Oh wait



                          RS2'd 93 UrS4 5 spd sedan
                          94 UrS4 V8 6 spd manual avant

                          Comment


                          • #88
                            haha happy dance

                            CAC exhaust and clear V8 markers

                            Last edited by Kliminati456; 20 July 2015, 09:44.
                            Justin
                            1990 Audi Coupe Quattro= http://www.s2forum.com/forum/showthread.php?t=46309
                            1991 Audi 200 20VTQA= http://www.s2forum.com/forum/showthread.php?t=54410
                            1987 Audi Coupe GT

                            Comment


                            • #89
                              Very nice, bought them right before CAC closed down?

                              Comment


                              • #90
                                Originally posted by quattrostyle View Post
                                Very nice, bought them right before CAC closed down?
                                Ebay.de actually, I missed CAC closing by a few days
                                Justin
                                1990 Audi Coupe Quattro= http://www.s2forum.com/forum/showthread.php?t=46309
                                1991 Audi 200 20VTQA= http://www.s2forum.com/forum/showthread.php?t=54410
                                1987 Audi Coupe GT

                                Comment

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