S2 Avant -93

[Antsa]

So the problem seemed to be the clutch slave cylinder this time. A little tight to get to but I managed to change it after all.

This image shows the front of the slave cylinder. It's like the ring that holds the piston has slipped out

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Fortunately I had ordered a slave cylinder already. It's kind of funny how Sachs sells their own item with Audi part numbers on them, just the Audi logo grinded off

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The bleeding was absolute pain, I probably went through nearly 2 litres of brake fluid trying to make it work. I have and eezibleed type bleeding tool, but that left the clutch spongy. Today I had a little play with syringes and that did the trick, I have firm clutch now


I also received my brake caliper from repair, finally (Big thanks to Alex)! The problems along the way were many, from Brexit to Covid and non-working customs declaration software... But it's finally here!!

So I had to make a pressure test to make sure the repair had worked using the equipment pictured No leaks! I hope I can paint these this summer.

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[Antsa]

Check the return spring above the clutch pedal they snap making the pedal stay on the floor

Thanks for the tip, it turned out to be clutch slave after all

[simons2]

Check the return spring above the clutch pedal they snap making the pedal stay on the floor

[Antsa]

Just a quick update, the car now has mot, new catalytic converter sorted that

On my way to summer cottage yesterday the clutch pedal stuck to floor. The car has done this a couple of times but it has always cured itself. This seems not to be the case this time so I will have to drive home without the clutch

While I was trying to fix the stuck clutch by bleeding it, I noticed a small coolant leak from the top radiator hose. A closer look revealed a pretty badly torn hose. Luckily I noticed that before a complete rupture. A quick fix was to cut out the torn section and just put the hose back in. Hopefully it holds until I get home. I will have to order a silicone item to replace it.

[Nuvo]

I've never seen that problem with a fog lamp before, thanks for sharing your solution.

[Antsa]

So the new lambda sensor made no difference. I still have high HC on idle and high CO% on fast idle. Any suggestions what to do next?

[Antsa]

I also had my right side fog light pointing too much upwards. When I looked at the fog lights closer, there is a half moon shaped beam cutter inside the reflector/lens assembly that was upside down I thought I bought new lights from a ebay seller but this suggests that these are rebuilt units. Anyway I had to fix it.

Fog light out and the rear lid taken off

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I took out the reflector/lens assembly.

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The mounting tabs and the adjustment bar was removed...

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...and put back on the opposite sides


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Back in the casing


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This is now sorted and now I have correct beam pattern on both fog lights.

The car will be taken to another emissions test tomorrow. Hopefully everything is ok and I can take it to mot again. Otherwise it is time for a new catalysator.

[Antsa]

Also good news is that my caliper that needed fixing has arrived in the UK after all

[Antsa]

Lovely weather to do some turbo installing

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Turbo in together with new Bosch lambda sensor. Why does it have to so tight to get all the nuts in place?


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This nut is especially annoying to reach


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So I made a tool to make life even a little bit easier


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Fits like so. Not the best but it helps.


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Everything put together. The engine bay looks horribly dirty That's probably because it is I took a little test drive and no leaks anywhere so far. I will take the car for emissions test next week and see if anything I did made a difference. Otherwise it is time for a new catalysator.


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[Antsa]

Thanks! The car is great but I don't know about my skills

Basecoat is Spies Hecker 295 series solvent basecoat, top coat is same brand Permasolid 8034 HS clear.

[Dobby84]

Hi, Great project and top skills.
Can you tell me what basecoat and clear coat you used for the panels?

[Antsa]

I have been a little lazy updating the thread. The local machine shop did not want to fix the bleed nipple threads on the caliper, so I sent it over to Alex to fix it. Unfortunately due to brexit&covid Posti has a hard time delivering parcels to UK and my caliper has been on its way for two months now The best part is that no one has got any idea where they are and I'm a little worried that the caliper is lost. I guess I only have to wait if it somehow finds its way to the UK.

I also failed MOT last week due to emissions and have a leaking turbo The turbo just got back from the company who serviced it a couple months back and they said there is nothing wrong with it. The only things left should be blocked oil drain or crank ventilation and they both seem fine to me. Oil drain flows freely and there is no clogs in the breather system and all the valves in it are relatively new

I have ordered a new lambda sensor that I can hopefully fit tomorrow with the turbo. The old lambda was a Delphi item but the new one will be Bosch. Hopefully I will get a new emissions test made next week to see if the new lambda has sorted my issue.

[Antsa]

I guess it is Honestly though I think they will be out of my price range

[Error404]

Time for custom Titanium pistons now Antti?

[Antsa]

The calipers are finally back after blasting. Before starting to do the painting I decided to take the calipers fully apart. Turns out that the bleed screws and the crossover pipe can be pretty tight in the aluminum alloy caliper I managed to get everything out but I stripped the threads from one hole . I took the damaged caliper to a machine shop to see if they can fix it.

On the other hand good thing it happened now and not after they had been mounted on the car Other setback is that I have to blast them again to get rid of the oxide layer that quickly forms on top the bare aluminum surface.



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While still recovering from the little setback a I cleaned & inspected all the pistons. A few of them had a few nicks that could be felt with a finger so I will be needing a few set of pistons. They are a pretty expensive investment, but that's probably what you get from buying used calipers

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