S2 avant

[Vorsprung durch Technik]

Got the engine back in tonight. Massive thanks to Andy10v for assistance

Nice!

Yes, he's a star in my book and always very helpful.

[Mikes2]

Had to make up new fuel lines across the bulkhead. The old ones that had been cut had compression fittings on them from when it was being diagnosed by the garage (not very well I might add).

By the time I cut these off, the lines were too short to reach across.

Reused the old ends and joined up to the braided lines. Compression joints used to join up with the originals.








Started some re-assembly. Breather system was cleaned out as it was a right mess. During disassembly my carbon canister valve broke.





I think I have a spare for this

[Mikes2]

The timing belt needs done on this car. It's been idle for 8 years so not taking chances.

The car is an air-con model so was aware of the VAG3256 problem. I bought a Klann equivalent to test. The bolt doesn't come out the tool without chopping it. Rather than destroy a brand new tool, I ordered this tool to use instead.





Bought direct from the manufacturer.

I currently have a 10v snub mount on the car, as the original is stuck to the air con compressor. This tool just misses the snub mount, so I used an axle stand tube over it to lock the tool against. Worked perfectly.

crank bolt came off with the torque wrench only set at 350 Nm.

If anyone is interested in buying the Klann tool, send me a PM. It's a KL-0280-14

[Mikes2]

Timing belt changed today.

Also replaced the water pump. The original one from 1993 (LUK) was still in there.

[John.]

Making progress Mike.

[newsh]

Nice [emoji106]
What's next?

[Mikes2]

short of a turbo oil line gasket.

Need to try bleeding the clutch again. if that doesn't work, I'll have to get a new master cylinder.

After that, spark plugs, oil change, oil + air filter, new radiator and air con system, drill out the exhaust holes in the cats which I had to grind off, replace the clamps and repair / replace the fuel lines underneath

Hopefully will get it running, then I can sort some running gear issues before taking it for test

[macspring]

Helpful thread.

Thanks for sharing the parts numbers, photos and other details of the various jobs, etc., sounds very familiar.

Once you are tenacious, resilient and have the funds, it should end 'happy ever after', wel for a while at least.

[Mikes2]

Clutch master cylinder is fubar.

Leaking like a sieve.

[Mikes2]

Was fitting the alternator on today. There's an interference suppressor mounted by the passenger side headlight.

Can anyone confirm where the two wires attach ?

[Mikes2]

Finally got the clutch sorted. Bled afterwards. Took a bit of persuading to get the fluid flowing but all sorted now. Pushed about 400ml through

Old master cylinder leaking for a while













new part made by Boge

[Mikes2]

The fuel lines under the car had all been chopped and damaged by the garage who previously had it





Removing the heatshield at the front for inspection revealed the usual corrosion, although not as bad as others I've seen.






Rest of the lines generally poor







Replaced all 3 with kunifer pipe

[Nuvo]

In my experience joining fuel pipes with bare rubber fuel hose rather will dry out, harden and shrink with time and you'll be nipping up the clamps every once in a while to stop a weeping leak. A braided fuel hose would be better, with a Wade coupler would be the best solution IME.

[Mikes2]

Had similar on my 90q 20v for about 10 years now with no problems on the return.

The feed will get fixed when I change the fuel filter. I want to get the car running first before tackling that job as I'll need ramps to do it. Can't work on it from the pit

[Mikes2]

Time to fit a new radiator. The original looked like it had been leaking at some point plus it was also covered in air conditioning leakage.

A new Behr was used.










The bottom radiator mount (893 121 273) is not available any more.
The old one was damaged by the cowboy garage who basically left a trail of destruction round the car. Everything they touched was either damaged or bodged. On this occasion only 1 stud was left.

Approximate dimensions are 42mm long by 40mm diameter.

I purchased an off the shelf anti-vibration mount. It comes with long threads which need adjusted to length.













This car came with air con. The old condenser was something else that was destroyed

Fitted a new one and attached it to the radiator.





I then turned it over and attached the fan to the rear.






Fan wiring is fairly straightforwards. There is no connector on the ABY. The wires are hardwired to the motor. + is clearly marked with the black plastic - black / red wire. Brown is the other for earth.









I dropped the complete assembly in one go into the car.