S2 Avant -93

[JayCab]

It's been a little quiet these past couple of months, but I got my seats back and fitted. Side bolsters on the backrest were done. I think they don't look too bad.


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Wastegate was taken apart. I will have to order a few replacement parts before I can put this back together.


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Engine parts were dropped off to the machine shop today! After they are finished, I will have to check piston ring gaps and send the rotating assembly for balancing. After the balancing is done I can start the reassembly.



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Interesting approach with the seats there. In line bolster recovering joined back to the original leather…

Will you dye and recondition the whole lot to colour match or keep as is with the two-tone black you’ve created?

[Antsa]

While still waiting for engine parts to be machined, I did change the boots for TFSI harness connectors

Old

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New


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New oil thermostat arrived. New spring is a little longer than the old one and while I could put the new thermostat in with the longer spring, I decided to use the old spring instead.


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Injector harness was also repaired. Wiring insulation has typical failures and the tubing covering them was very brittle. Also the pink inserts in the connectors were broken.


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All new connectors from Audi. New boots were installed here also.

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Done


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[Crasher]

I just ordered a pack of ten (busy weekend planned ) from MAR Motorsport, I have nine left somewhere… the weekend went better than expected

[Antsa]

The old thermostat has an opening temp of 100 deg and the mahle replacement should have opening temperature of 83 deg. I know it's slightly below ideal engine oil temperature, but I think it's the only replacement available. I asked local audi dealer and the original 035 115 429 is NLA.

The o-ring 034 115 427 is the one that seals the thermostat housing/lid? I plan on ordering a few different sized o-rings and see what fits best. That elring part number comes up as size 12x2, seems too small for the lid?

[Crasher]

The part is straight out of an up to 1983 Golf GTI, and other cars, part number 035 115 429.

The 911 part is for an air cooled engine, with water cooled you can over cool the oil.

A problem is the O ring, 034 115 427, I use the Elring 915.718

[Antsa]

I found one from design911 website, hopefully they actually have it

Mahle online cataloque tells that TO 2 83 should still be in production, but it's getting hard to find. I visited a couple local spare part stores and asked for the mahle item with no luck

[Alex20v]

The broken oil thermostat was measured today.


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This Mahle TO 2 83 seems to be pretty close, just a little longer. I have one ordered.



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Filter housing was glass bead blasted. Now waiting for parts to arrive.


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Sump baffle plate installed. I had gotten one from forum member Thuppu, many years ago when he was still active


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where you order the Mahle TO 2 83?
Cannot find it, its everywhere sold out

[Antsa]

The broken oil thermostat was measured today.


20251015_101245.jpg


20251015_101306.jpg


This Mahle TO 2 83 seems to be pretty close, just a little longer. I have one ordered.



to283-1.jpg




Filter housing was glass bead blasted. Now waiting for parts to arrive.


20251015_102320.jpg


Sump baffle plate installed. I had gotten one from forum member Thuppu, many years ago when he was still active


20251015_141126.jpg

[Antsa]

While waiting for my parts back from machining, I opened the oil filter housing and took off the thermostat.


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It's clearly visible that the part containing the expanding wax is crooked. I heated the thermostat with a heatgun just and discovered that it won't open anymore. After a little bit of online searches, I'm thinking that a porsche oil thermostat might be suitable replacement. I will have to verify dimensions tomorrow and get one ordered if it fits. The porsche item has slightly lower opening temperature but I don't think it's going to be a problem.

[Antsa]

It's been a little quiet these past couple of months, but I got my seats back and fitted. Side bolsters on the backrest were done. I think they don't look too bad.


20250825_111845.jpg


Wastegate was taken apart. I will have to order a few replacement parts before I can put this back together.


20251006_100048.jpg



Engine parts were dropped off to the machine shop today! After they are finished, I will have to check piston ring gaps and send the rotating assembly for balancing. After the balancing is done I can start the reassembly.



20251007_123950.jpg

[Crasher]

That orange goo is horrid, it is even behind the door trims and on later cars such as a 2002 A4 where the trim fell off in hot weather, how is it so sticky but does not work?

[Antsa]

Worst was taking the the headlining off and cleaning the old orange glue residue. I think we all know how messy of a job it is.

[YELL MAN]

Looking great, redoing the headlining is a pig of a job to get right.

[Crasher]

The one I did was recovered by Myrtle who do Jag and Golf 2 headlinings, it isn't perfect but OK.

[Antsa]

Thanks Dave Fitting all these interior parts makes me feel this car will be finished someday.