UrS4 Restore

[alexqts]

Ok so thought it was about time I created a project thread and added a few pics. I picked this car up about a month ago now, and have slowly started to restore her.

I have wanted a 100 S4 for a very long time and have now finally got one

This is how I picked her up, gave a quick wash.







Rear light cluster on the boot was letting in water badly, I have cleaned up the inside of the boot and removed the old light cluster ready for spink's replacement



After spending a few solid days cleaning, suddenly the clutch started acting up. She is in my garage for the time being until I can afford to get that done. In the mean time:

Headlights and indicators have come off for a clean up / replacement. The drivers side projector needs a new reflector due to water ingress. Grille also removed for a good clean.



Spent the day giving her a good wash and polish, removed minor scratches and finally a decent coat of wax, it has made a huge difference.

Sorted out rear badges to my taste, boot trim is on the way



I have also fitted a new master and slave cylinder. Most important things at the moment are a good service, fixing a coolant leak (could be serious as it's leaking quite a bit and can't visually see it) and the clutch!





Will keep this thread updated with any progress I make, have a huge list of things to do and would love to bring her down to ADI next year looking good! Big thanks to trist28 who sold me the car, he is a great guy and has an amazing collection of Audi's and others!

[s2_wot]

Lots of potential with this one. Keep the progress reports coming

I've seen your recent post about the clutch, it's very unusual the manner in which it has failed. Make sure and grab some photos when you get the gearbox removed.

[urS6Tom]

Ok so thought it was about time I created a project thread and added a few pics. I picked this car up about a month ago now, and have slowly started to restore her.


Rear light cluster on the boot was letting in water badly, I have cleaned up the inside of the boot and removed the old light cluster ready for spink's replacement

Agree there's a lot of potential there Any mods on the car at the moment?

I've got the same problem with water ingress on my S6 Avant. Is it possible just to change the rear light cluster seals, or does the whole cluster need replacing?

Cheers,
Tom

[alexqts]

Yeah that was quite a shock, but no trace of it now - lucky the tyre compartment is not metal If you remove the bolts for the light cluster inside the boot, it is then possible to get something between the boot and light cluster to separate the old seal, you have to be careful as I nearly broke the old cluster tying to get it off. I see no reason why you couldn't clean both surfaces up and re-apply a new seal, it is nasty stuff though.

Apparently the seal used is called Butyl Tape, so have ordered this to re-seal the new one, the grey was cheaper and doesn't matter as it cant be seen anyway.

what I ordered:
http://www.ebay.co.uk/itm/2809988182...84.m1438.l2649

Mine was leaking through cracks on the front of the cluster and not through the rear seals, is yours cracked on the front at all?

Have no mods at the moment but looking to go to ~RS2+ spec once the car is working correctly

[alexqts]

Lots of potential with this one. Keep the progress reports coming

I've seen your recent post about the clutch, it's very unusual the manner in which it has failed. Make sure and grab some photos when you get the gearbox removed.

Yes was only driving it for 2 days, but it was sitting for a while before I picked it up so not sure if that had anything to do with it. I would like to do the clutch myself but don't have a way to get it off the ground safely, spoken to white cottage quattros and think he will be doing the work for me when I get the money together. Only good thing is it allows me to work on stuff I wouldn't normally have the time to do.

[targus]

whats up with the clutch?

[alexqts]

whats up with the clutch?

Originally thought either the slave or master cylinder had gone (both had fluid leaks) but after replacing both the clutch would still not disengage. After doing a fair bit of reading about stuck clutches I decided to start her up in 1st with the clutch pedal pushed in, clutch held for a few cranks and then unstuck itself. Clutch now disengaging and can select all gears but slipping badly. Bits of broken clutch were flying out of the small hole in the bell housing! So the gearbox needs to come out

http://www.s2forum.com/forum/showthread.php?t=61896

[alexqts]

On Classic Audi but thought I would update the thread here also!

So it's been a while since I posted here (over a year) but I'm back and the UrS4 project is a go-er again! Hope everyone is well. Been away mainly due to lack of free time. Finally have a bit more time and £££ to get this done. House is also being sold so need to get her out of the garage and breathing again!

Looking to get her back up and running in about a month from now if all goes well.

How she looks this weekend:











Work done so far
Flywheel resurfaced
New flywheel bolts
New Sachs OEM Clutch, PP, Bearing
New master cylinder
New slave cylinder
New VR rear main seal and gasket
New thermostat and housing
Rear facing core plugs replaced due to rusting out
New plastic-head coolant adapter
All new turbo/wastegate gaskets & bolts
Full engine and engine bay clean

Still to do
Fresh OEM fuel filter
Fresh OEM Oil filter
New oil - any recommendations?
New plugs
Possibly new engine mounts
Performance cone filter
New spark plugs
timing belt?

Finally managed to get the clutch hydraulics working this weekend. Pushing the car in 1st gear engages the drivetrain and rests on engine compression. Depressing the clutch allows free movement of the car - so guess that's as good as it gets for now.

Everything I have done here has been learnt for the first time. Really enjoying the experience this car is giving, but just want to drive it now!

Have a feeling I should do the cam belt before I put it back together, but think I need a helping hand for the first one as I don't want to screw it up. If anyone is local would be up for helping a first-timer I would be more than happy to pay all expenses and lots of beer / food!! I might start a thread about that later though.

Nervous about starting it up Hopefully iv'e done it all correctly. Most concerned about the rear main seal and clutch work- the assembly lube is a year old now so hoping it will hold up, did take lots of care and attention when installing. Don't think I could handle pulling it all apart again!

All the pictures I have from the build are here if anyone is interested, lost a few on a dead hard disk though. Might be a few pics of my twin turbo enemy also!

https://drive.google.com/folderview?id=0B43gOUAeyiLWNGxhS2FsTlJfZDQ&usp=sharing

[Vorsprung durch Technik]

That's a very nice car! Good to see someone really looking after one of these and going to the trouble to do the job well. Maybe if you speak nicely with a certain guy down your way he might help you with your cambelt. I'm in Rickmansworth not too far from you and wouldn't mind being there to see it happen.What do your reckon John?

If not maybe would could buy the necessary tools together and do it ourselves.I don't have the tools yet, been busy saving/buying bits and pieces for my S6 estate and then just bought an S6 saloon which thankfully has ony just had it's cambelt done but i still need to do my estate.Just a thought if your up for it.

[Error404]

Nice project, good to see an old urS getting some love. I have an nice condition oil cooler duct if you want a replacement for what's left of yours
Keep the pics coming

[alexqts]

That's a very nice car! Good to see someone really looking after one of these and going to the trouble to do the job well. Maybe if you speak nicely with a certain guy down your way he might help you with your cambelt. I'm in Rickmansworth not too far from you and wouldn't mind being there to see it happen.What do your reckon John?

If not maybe would could buy the necessary tools together and do it ourselves.I don't have the tools yet, been busy saving/buying bits and pieces for my S6 estate and then just bought an S6 saloon which thankfully has ony just had it's cambelt done but i still need to do my estate.Just a thought if your up for it.

I have been looking on ElsaWin this morning and it seems that the following tools are needed. How many of those are actually needed - maybe someone could inform us?



Thanks, that sounds like a good idea.

As long as the tools are not crazy expensive I would be happy to try and buy them, that's presuming you can still buy them? Maybe someone would be prepared to hire them out for a small fee

The only part that really worries me is undoing the crank bolt and then having to torque it back up again. The rest doesn't look to bad from what I can read.

Thing is I don't have loads of time left to get this car running, so would need to to get the belt changed in the next week or two really. If anyone has the tools, or could let me know where I might be able to acquire them - please let me know.

Guess if the worst comes to the worst I could get it running and do the belt at a later stage. Can't see any evidence in the service history of it being changed, so not even sure how old it is! Any way to tell if the belt is safe?

I presume rotating the engine to TDC by aligning the cam, crank and flywheel marks verifies that the engine is timed correctly? I want to make sure the belt has not slipped while I have been working on it.

[Error404]

You only really need 3256. But you can make one if need be. I am sure someone has on you can borrow.

[alexqts]

Mostly back together now, start day tomorrow! Let's hope everything is good. Not sure what to expect to be honest!

Everything back together with new OEM oil filter and fuchs 5w40 oil. Drained old filter and sump then replaced with 4.5l. When checking the oil it is showing ~1mm above the top groove, so guessing it should be good and not over-filled.







Also fitted new air filter - and before it gets said it probably is a heat pump like that! - I will be sorting a heat shield / relocating! Plan is to go Holset HY35 / HX35 when everything is running well, so not to fussed about it at the moment!

Going to record the start tomorrow - so will see what happens

Still need to get the PAS pump sorted, unfortunatly threaded one of the hydraulic line banjo bolts. Ordered up a new bolt, luckily the thread on the pump looks ok, otherwise new pump.

Presuming everything runs as it should the cam belt will be next job on the list!

[UrS4boy]

Also fitted new air filter - and before it gets said it probably is a heat pump like that! - I will be sorting a heat shield / relocating!

And there I was, just about to congratulate you on your warm air intake system.

[alexqts]

So it has been over a year since my last post!

Unfortunately sat on my driveway for a year after a successful drive back, and the garage is now long gone. RIP.

In that time a few jobs have been done.

Headlights restoration. I swapped out the internals from a C4 A6 projector light. The reflector had deteriorated due to water ingress.







In the meantime she had new oil, aux belt, oil filter, MFTS and a few other bits and bobs.

The instrument cluster was also in need of work. Bulbs had gone and the check display was like a chessboard when it even displayed anything. I bought a spare of ebay to practice opening it up. Then moved on to the real item. I also wanted the dials brighter so ordered 2w replacements in place of the stock 1.2w?



Replaced all bulbs with new 2w variants.



Next I moved attention over to the check display. Reheated with a heatgun carefully and cleaned all contacts with cleaner. This seems to have completely fixed the issue so far!



New dials:





Some of the paint is peeling off the dials but to be honest I am too afraid to start removing the needles of the gauges. I can live with it as it's not too bad.

And now finally after nearly 4 years of work she is back on the road! Went for MOT last week. x2 new lower suspension arms done and need to get a fog light holder for the rear as the other rusted out. They seem to be softer with the older cars, lets see what happens when I go back cat-less



Smoke / water is gone from exhaust after a hard run and completely warm.Seemingly no coolant loss. Driving like a dream, seeing 2.1-2.2 bar overboost but dont always manage to hit it every time, seems like it makes you work for it! Still suprisingly quick in stock form (if it is stock) and that coming from a car that was ~380bhp RWD and lighter.

Still driving around with tools in the boot, convinced it is going to break down. Let's hope not for a while. I am actually enjoying driving it for the first time. .

Up next is:

- Replace cigarette lighter ring light / unit.
- Mirror switch lights , new unit on order.
- New Pioneer DAB radio with multi-colour display that can be toned down, tuned to match the dials.
- Heater motor replacement as the existing is vibrating and not flowing much air.
- Various switch lights to be replaced.
- After-run pump and fan not working. Works if I short the pins on temp sensor. Will replace.
- cambelt
- new seats if I can ever find them
- Wings repaired / replaced, possibly a door or 3
- Exhaust, RS2 / GT spec, lowered, bolero's ...etc...etc..!

Never ending basically but having this as a daily driver (short trips) has really suprised me. For a car with so many miles >206k that has been off the road for so long, its really performing well!