Bringing my TQS back to life!

Gops

Badger 5 Edition
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Location
Coventry
Hi all!

Some of you may remember me from the 8L section where I had a Badger 5 S3 with 605bhp! Since then I've had a few BMW's and now im back to an Audi!

So why have I bought one?

Well, it was more for a father and son project with my dad. I bought Bill's old 1.8TQS which I planned to get fixed up (it wasnt in the best condition but for the money it was well worth buying) so thanks to bill for selling me the car!

So.. What happened to it? Well because its age the tensioner had crapped itself, so it was rattling like hell. So I decided to park it up and come up with a plan, which originally was to stroke it and gain as much power out of it as possible. this just felt so wrong. It's a rare and classic car which I feel needs restoring and appreciating for now. I may change my mind later and stroke it but for now, I want to restore its glory.

Its not in the best conditon, so the first job is to get the engine running, which I could just easily get a new tensioner and service it, but I want it to last long. So the engine is coming out and I'll send it over to bill for some rods and a general rebuild, a K04-015 and thats pretty much it! Why not bang in something crazy in? Well I just don't think its worth doing to such a rare car. Plus, I want to use this as my daily car so a little bit more power I can be happy with.. 200bhp plus would be nice enough for now.
 
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Engine is out! Took me some time to get it out, couldn't get my 8mm allen key to bite on the balance rod on the gearbox and after much swearing and a few cries, I managed to get this out with the help from Mr J (dad). Next thing to do is pay Badger 5 a visit soon, bribe him with some samosa's and get this into him when he's not busy. I would rather things done right and well and bill's craftsmanship is worth every penny! Gearbox is being sent to Gas n gears for a refresh!

This isn't a fast build so we're taking our time with this.
 
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Looking forward to this one gops! Hopefully wont take you and mr j too long to get on it! :whip:
 
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Looking forward to this one gops! Hopefully wont take you and mr j too long to get on it! :whip:

Thanks Rav! I’m going to remove the gearbox and send the engine down to Bill next week, the bores really need checking to make sure it’s okay, hoping not to spend big bucks rebuilding the engine, found a K04-015 for £120! Besides that the car actually looks very young underneath. I found a place to refurbish my AC compressor and my steering rack (be silly not to do this whilst the engine is out) and the inside just needs cleaning. Found a double din unit in the US with the Climate unit so I’ll be ordering that to put an apple CarPlay unit in the car.
 
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Good to see you back @Gops i will look forward to reading your progress. Enjoy the build with your dad. :)
 
Not bad not bad, will be an interesting build. Wish I had the money and time to do this to mine. I agree though, these are modern day classics now, so be a shame to go doing irreversible mods etc.
 
I really haven't done much!! I've left it through winter and only just really started again!!

So I've managed to strip most off the engine to get it over to bill in the coming month, gearbox is ready for Gas n Gears, although they are very busy so i'm waiting for a response off them to get my box in.

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The garage is a mess and full of spiders, so we spent more time trying to get that sorted and cleaned up. Alternator and AC pump are going off to a refurb company as well as the PAS rack.

Things to buy:

  • Turbo
  • Manifold
  • Downpipe
  • SMIC
  • Some Coolant pipes
  • Some boost pipes
  • New engine mounts
  • New gearbox mounts
  • Starter motor
  • flywheel
  • clutch
I found some wiring that I'd like to repair and the interior is horrid and full of mould but for now, I'll send the parts away for refurb and hopefully get them back so I can start reassembling again.
 
So, I have some good updates on this car!

Engine will be going in with a new turbo and manifold. Spec of this engine was a shocker but glad that Bill and Alex sourced a stonker for me!!

Gearbox is off for a check over.

B5.5 Passat Wipers I have restored and they look sublime!

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Headlining is out of the car. I tried to save it but couldn’t do so, so I’ve ordered some new material which I will retrim

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Double din Centre console is now in, ready to go!

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Refurbed cluster is in which is now calibrated and DIS works!

Headlights have been sent off to trups for Bi-LED conversions!

I found a milltek exhaust for it! Haha yes!!!!

I have a set budget on this car for now, but I’m hoping to get the engine and gearbox inside the car soon. It needs new pads and discs, the rest would be fine for now and can be done at a later stage.

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Nice work, glad to know I’m not the only one throwing money at an old B5.

How hard is the headliner to get out with all the glass in?
 
Nice work, glad to know I’m not the only one throwing money at an old B5.

How hard is the headliner to get out with all the glass in?

Thanks bud! Everyone keeps asking me why I throw money at it, but I can’t help it! The headliner isn’t too bad to remove, front seats need to be down or out and the rears can just be pulled down. Then pull it out of the tailgate, try not to crease it too much but It will come out.

I also got rid of that spoiler!

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It’s now a 1.9 tdi! Half tempted to keep the badges on! But S3 Rav has given some good advise to remove the badges. Will do it once I get it back from bills.

Gearbox is coming back to me with no issues or work required to it. Parts are impossible to buy so
It’s best just to keep it the way it is.

Headlining and a post trims will be retrimmed in black. I have however forgot about the sun visors.. will have a look at them to see what I can do with them.


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So, some good updates on this car. I managed to source a good engine that’s capable of many horses. For those who remember, it’s probably better spec than my S3’s engine was. However the tiny turbo I’m whacking on makes no odds to it at all. I’ve been thinking for ages to upgrade to a G25 but I cba just yet. Engine is down at B5 to which I need to send the whole car down. I was going to put it all in myself but my parents need this car out of the garden to start some building work at the house so, I have no choice but to bribe bill with food to help!

Before I send the car down I need to get things done on this car, so everything I took out needs to go back in:

Need to fix this wiring on the rear light
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Sorted:
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Then needed to sort out the window that didn’t go down. Checking the switches, I have 12V switched when using both switches. Took the regulator out and it seems that the motor doesn’t want to turn.

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So ordered a new/used regulator and then felt the need to sort out the wiring. Audi have unprotected door harness’ for some reason (usually to bring down cost). It’s not inlined anywhere obvious so I could only use the anti-abrasive tape so far as my fat hand would let me:

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Get the junctions sorted first
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Full AB tape with anti rattle tape on the door card breakouts.
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Now I wasn’t happy with how Audi routed this harness right past the spring under the regulator, it clashes hard against the spring, which is a big no no. There should be a 6mm static clearance from the spring or 19mm dynamic clearance from rotating parts. This instance, both parts do not have a dynamic envelope around it, so I drilled a hole in black metal frame and attached a T-on clip. Then routed it back to the second hole but only half taped the T-on clip to reduce the stress on the harness:

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Now that’s better and I can sleep at night! I needed to sort out the seats. Rears and fronts in and cleaned again.


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With merky water!

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I also sorted and painted the corners (not like Midas but just enough so that the new wheels look
Good)


Rear before

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Rear during
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Rear after
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Followed this on for all corners

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Also cleaned the gearbox
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After:
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It’s pretty much ready, just needs the stuff sorted to take up to B5. Hoping to sort it out this week for a Saturday departure over there if Bill has space. We’re getting there slowly!

Happy Sunday all!
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Wheels have come back!

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Cars been dropped off to B5! Bill is super busy so it’ll be there a while, but for now it’s time to wait and focus on my house.

I did find a bonnet and two front wings for the car but I’ll get them swapped out when I get it back!

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Those wheels look awesome, really inspiring me to get my own redone.
What’s it having done?
 
It's just having its engine back in, hopefully I can head up to B5 this weekend to fuel the B5 team with Samosas again :D
 
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Good work gops!! Looking forward to seeing this in the flesh!

Love the wheels btw!!
 
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Gooding of the evenings all!

I hope everyone is doing well!

For those who do not know, I’ve got the car back off Bill! He’s managed to get the engine done, honestly it looks amazing, can’t thank him enough for that!

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So why did I get the car back? Well truly because it would of just racked a massive bill to get sorted, as things weren’t exactly straight forward since parts were all over the place, it’s hard for B5 and his team to piece it all together. So Bill gave me the option of taking it back and doing it, perfect since my dad has just built his garage and it’s all ready to take back. Thankfully it arrived back and is now sitting pretty in the garage:

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I’ve since bought some taller axle stands, a better battery charger and some parts to fix the compressor so I can start tackling the little jobs… first up was fitting the parts to the gearbox

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The slave cylinder was broken so I changed that
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Next was to take out the rear diff, as that’s leaking like anything. Whacking that thing out was a pain, the bolts were just old and seized, but luckily we have enough height and space (and patience) to get it out, drop the diff ready to have those seals changed

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Next thing to do is get some fixings from audi. Most of the fixings don’t have a zinc nickel coating which should give 1000hrs of salt spray before corrosion, and since most of these bolts are below the “wade line” they’d need to ensure proper coatings. That said, whatever Audi have released onto this car to use should have these coatings on. I’ll ask to see if they do tomorrow when I go down. Also need to order a centre prop shaft bearing as that’s seen better days!

Next stop - fix diff and put it back in! I was also going to do the Milltek exhaust but I’m missing the centre section and I can’t actually remember if I ever had one, so I may need to get one made.


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Nice nice Gops..can't wait to see the progress on this.
 
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Thanks Rav! Did a few more bits tonight and gathering parts from Audi as well..

Rear diff was cleaned up ready to get the seals. The seals were available from Audi as they use it on Lamborghini diffs also! So let’s get going.

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The coupling was a 6mm hex bolt that came out pretty easy with the impacter to reveal the seal:
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Loads of grit and crap seems to be in the passage way so I cleaned it all up ready for me dad to pop the seals back in:
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And done!
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Repeated it for the other side as well which was filthy! Sadly forgot to take after pics of that side but it’s literally the same as the other side.

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Sorted!! Just need to clean up more of the grease and grime off the diff body itself. Whilst doing so, I started to look at the prop shaft to see what the centre bearing looked like.. as per usual it was *****:

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I really didn’t want to do this, But I have no choice. There is a dark side development where I can pop
It over the bearing, but the bearing sounds like an old sliding wardrobe, so rough and horrid. So I have no choice but to remove it and refit with a new one. I’m just going for a normal bearing off Autodoc. I will document the process but there is a really good YouTube video that shows it’s to the T. It doesn’t end there I’m afraid, the prop shaft CV joints are dented and horrible. I know we did this as when we tried to tie up the shaft to send to B5 we tied it up with some rope that got so tangled and ruined it! There are no options that I can see that are direct serviceable parts… until I found this thread :


The seems to be a replacement being used which is the Meyle 214 498 0033. These are on Autodoc for £30 each. I’ll have to get these done, it doesn’t feel right getting the car done so I’ll be getting this sorted. I’ll also get the driveshaft balanced afterwards… so more work to do! I’ve also identified the right fixings for the exhaust which is good.

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Next stop is to go to B5 tomorrow morning, then finish off the rear diff and get that back onto the car. Then I’ll get onto this prop!

More to come!


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Evening all!

Tough little day today! Managed to get the milltek sorted!
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Thankfully that’s ready to go. Been working on filling the diff with oil but obviously with 25 years of life being on that nut, it wouldn’t budge. So used some Asian persuasion and managed to get it open

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I’ve ordered 2 new nuts off the net so that’ll replace these. Drained the oil as well:
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Looks lovely! Haha. Whilst that’s on the side I also tried to drain the gearbox but I didn’t have the special 1/2” so I’ve ordered that and also another 2 of the drain plugs incase they also need a telling off.

So whilst that’s on the side, we started to take off the centre bearing

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My dad pretending to work!
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It wasn’t actually that bad. It came out pretty okay. Just need to get the parts to reassemble the whole prop and get it over to Dave Mac propshafts in Coventry for a balance and paint!

So on the order list:

- centre bearing
- x2 drain plugs for transmission
- x2 drain plugs for diff
- cv joints for prop
- new radiator

When they arrive I’ll get onto to dealing with refitting everything! Hope everyone is having a good weekend!


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Thank you both! The car is coming along slowly, I hope one day it’ll be as clean as Midas’ car!

Done a little more this weekend, started off with the rear diff, filled it with oil and fitted new fixings to the fill and drain holes:
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Did the same with the gearbox as well
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Then we started on the prop shaft, we need to get it over to the balancing shop so started on refitting the centre beating and then the CV joints from either side. As you can see below the old ones were way past it
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New ones ready to be fitted
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I won’t lie. They were a PITA to get one side on, it was just so tight. The other side was perfect, but managed to get them on the prop ready to send for
Balancing tomorrow
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So with that done, time to get the diff back onto the car. Note if anyone is doing this, fit the rear half-shafts first before fixing the diff to the mount!
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Obviously used new fixings on the half shafts
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With that done, also fitted the Milltek, just because I wanted to see how much better it looked
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You can see the bore difference from the original and milltek
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The original one isn’t in bad condition, might be worth having if someone wants it.

Soooo then, what’s next? Well wiring…
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I wanted to do an ICM delete but the parts are super expensive for what is just some reworked harnesses. I’m going to find the repair harness from
Audi tomorrow, if they don’t have it then I’ll have to get them from the states.

It’s quite simple, the 5 pin has a ground and also has the circuit for the extra pin on the newer coils. It’s not that hard, just need some high-temp black tape and some anti-abrasive to wrap the rest of the branch up. Once I get the repair harness I’ll make a start and do a proper write up with some circuit
Diagrams and rework instructions incase someone wants to tackle it.

For now though, that’s enough. I’ll be getting some gearbox-engine bolts and nuts just so we can crack on with getting the engine back in the car! Car still looks crap with the paint but hopefully it’ll run right.

Until next time! Have a great weekend!


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Good evening ASNers!

It’s been a little while I’ve updated this thread. I’ve been pretty busy with life and work but I’ve made small progress on the car.

The first being coil pack wiring harness. I bought it from the states as no one sells them here anymore. I had to cut into it as it’s made for those with oil level sensors. Cutting, splicing and heat wrap the areas I feel needed them (waiting for a coil pack former to come from eBay to keep it tidy)
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So that’s done, tested and I see 12V when connected to the battery so nice work there!

Next was to get the prop shaft I had balanced from Dave mac. There seems to be quite a few weights added to them so I’m grateful for his work on this!

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Obviously new bolts on the prop centre bearing! I’m missing the heat shield so I may have to buy some material and form my own, or find one on eBay from a car being broken. Need to do this before I fit the rest of the milltek. Speaking of which, I have the new exhaust clamps
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Proper milltek as well so should fit nicely. Next, was the fuel filter. The most stupid design I have ever seen. I broke the bracket so we had to improvise and fix that (well my dad actually fixed that!) also put new washers and since it’s 2 washers per side, they weren’t cheap!!!!
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The tank was a bad dream to fit back. Hated doing this, hopefully won’t need to touch this for a while!

So what’s next? Well the flywheel and clutch need to go back onto the engine, bolts should be here on Tuesday. Then the engine can be mated to the gearbox so that’s up next. Engine bay needs cleaning and dressing so it’s ready to accept the powertrain… exciting times!


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Good evening!

So this weekend not much has happened. I’ve
Managed to get the coil pack wiring former fitted:
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From there I wanted to get the flywheel and clutch fitted to the engine:
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I did try get the both together but it was a little
Difficult without any help, so will leave that til next week so I can draft my dad to help me.
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Almost there! Once the engine is back together with the gearbox, we can get it back in. I could do with cleaning the engine bay up a little.. so that’s next. I did think that we needed a whiteboard in the garage so I fitted that too:

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So far so good! Things are coming together. I need
To get some fluids, a centre heat shield, and reassemble the exhaust.

Tis all for this weekend! Have a great week ahead!


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Good evening all,

It’s been a while, but I’ve made a little more progress on the car. Engine and gearbox have been mated:

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The turbo had no studs fitted so i got some off eBay and got the hot end fitted to the car, since it’s extremely difficult to get that done when the engine is back in:

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Was a bit of a nightmare but had to open some holes in the Milltek down pipe because it’s just help in well with M8’s. Next job is to get that engine into the car.

Firstly needed to get everything ready

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Then start to offer up the engine

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Had to remove the driveshafts to make space

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Bit of swearing and some jigging around
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And she’s in!

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We must of snagged the clutch slave pipe because it’s all bent. So we’ve got it bent back into place hit need to make a bracket to hold it. I want to get the clutch bled first because if the pipe leaks then it’s now time to take the engine back out to fix it rathe than build it all up.


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Looking great gops. Looks to me that your dad's doing all the hard work and you're just taking the pics!
 
Looking great gops. Looks to me that your dad's doing all the hard work and you're just taking the pics!

Thanks Rav! It’s getting there, and dad loves snacks whilst I work haha!

Been getting on with bleeding the clutch. To which it worked well a part from when the brake reservoir burst!
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I wasn’t using more than 20psi but I think when I change this. I’ll use 12-15psi when it’s done so had to order a new one from Autodoc.

Also ordered some new breather pipes, and as much as I wanted to fit a catch can, for now I’m going to leave it as standard.
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So now I can crack on with connecting the car up to the powertrain. Having to remember where everything goes is a bit of a mare but I think I remember! The shafts need to go back into place as well as the gearbox shifter. Brakes will need bleeding as soon as I get the new reservoir.


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So, the new reservoir is here with the breather pipes and coolant pipes. For those who don’t know, I have a new radiator which I bought some new pipes and a temp switch which felt right. We’ll see how these keep temps consistent from the OEM one.

My dad has already built the rad pack back up with the new rad, just needed the new pipes. Breather pipes were welcome as I thought about a catch can but for now I want to see if it starts so let’s get it to that stage before I modify anything.

Next stage is to get the brakes and clutch bled again, with the new reservoir and the new pipes so I can start the rebuild properly. I still need to get the engine oil, power steering oil and coolant before I start the car. These are on the list after Xmas so by then I hope to have the cars brakes bled.

Everything else seems okay, just need to get the shafts back in and the prop connected so that it all turns. I have a week off now so hopefully me or my dad will have some time to get this sorted. Hope everyone had a great Christmas!


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Good morning all!

I hope everyone has had a lovely Christmas. I’ve done some work on the car during the holidays but not much. Both front shafts are back in and the prop is also back in
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The only issue is getting that gear linkage back in, but I’ve misplaced the fixing for the stabiliser rod so I had to go back to eBay and buy another one just to take the fixing out!

I’ve bought all the fluids, g12evo, millers CRO and power steering fluid. I already have 5 litres of dot4 fluid and have already bled the clutch, so it’s just a matter of doing the brakes once all is sorted. I’ve also managed to get a copy of elsawin and etka on my laptop now which is a massive win! Helps a lot with the rebuild.

Next, I should be able to get the linkage sorted, fit the heat shield on top of the prop and finish fitting the exhaust onto the car. The engine bay needs finishing as I need to finish the routing of the wiring, connect everything. I plan to crank the car in a few weeks, so the next few weeks will be busy


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Good evening all! I hope you are having a splendid NYE!

Done quite abit today, managed to find the alternator link lead and fit it to the starter. Should have done that when the engine was out really because it was not easy to fit!
594c5d9c13736ccc1eca02e99868e316.jpg


Next was just a task of wiring everything back up. It was a task remembering what was what, but elsawin surely helped a lot.
716b02e3582b7e2e16b30ab9f2ee5c49.jpg

46d7a2b63f44ab8bd8bcdfe4670fe71b.jpg


Some things still not plumbed in, but most items such as the injectors, shafts, all the engine sensors are connected and ready to go. I do need a washer for the power steering union, but will have to order that from Audi when they open back up. I now have engine oil, Power steering oil and coolant so when the front end is back on, I’ll fill them up.

Not long now til the first start! I have ordered a stabiliser bar with fixing from eBay. So once that arrives I can fit that and the gear linkage. Fit the heat shield and get the exhaust fitted properly.

Happy new year to you all! I wish you and your families the best for 2024! :)


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Good evening all! I hope you are having a splendid NYE!

Done quite abit today, managed to find the alternator link lead and fit it to the starter. Should have done that when the engine was out really because it was not easy to fit!
594c5d9c13736ccc1eca02e99868e316.jpg


Next was just a task of wiring everything back up. It was a task remembering what was what, but elsawin surely helped a lot.
716b02e3582b7e2e16b30ab9f2ee5c49.jpg

46d7a2b63f44ab8bd8bcdfe4670fe71b.jpg


Some things still not plumbed in, but most items such as the injectors, shafts, all the engine sensors are connected and ready to go. I do need a washer for the power steering union, but will have to order that from Audi when they open back up. I now have engine oil, Power steering oil and coolant so when the front end is back on, I’ll fill them up.

Not long now til the first start! I have ordered a stabiliser bar with fixing from eBay. So once that arrives I can fit that and the gear linkage. Fit the heat shield and get the exhaust fitted properly.

Happy new year to you all! I wish you and your families the best for 2024! :)


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Looking good gops. Makes me try to find some will power again with mine, had a nightmare over the last 3 months. Great to see your progress.
 
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Looking good gops. Makes me try to find some will power again with mine, had a nightmare over the last 3 months. Great to see your progress.

Thanks bud! I’ve had a right weekend with the car. Last night it ended with the car looking like this:

abd63a1ccc0671dd20186af981f4e6df.jpg


Managed to get the whole car piped up ready to get the exhaust on and the front end on. The exhaust ended up being a right little pain but my dad did that all by himself, so kudos to him for that as it wasn’t easy at all. I tackled the front end where we bought a new radiator but, the one we bought had the wrong key ways to fit the pipe. So I had to dremmel them down to fit. Success!

With the fluids all filled, I started to see the radiator temp switch was leaking. Not sure why as it’s brand new, so need to have a look at that. Nevertheless I tried to start her but nothing happened. No crank or anything. I had 2 ignition connections on the starter solenoid so switched that over and again, nothing. Then I checked that the switch carries 12V to which I did, even at the inline under the ECU. Then i realised that there must be something with the earth and hey presto I didn’t even do the nut up! Did that, still nothing! Switched the connectors again and it cranked! First hurdle complete, and with the car cranking it eventually started

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The idle was a little lumpy, I see a vacuum line that has split, so tied it around with some tape; will need to get another one of them. Also realised that the oil temp gauge was off the charts, but the oil wasn’t even that warm. The connector had broken off which mustn’t have sent the right signals, so I will have to fix that.

The last issue was quite a big one, I’m getting gearbox oil leaking from the bell housing. It’s coming through the inspection hole at the bottom only when I engage the gearbox. So it may be that I haven’t fitted the sleeve guide or the input shaft seal may be leaking. Not the best news but looking on the bright side, the engine runs sweet. Oh yes the airbag light is also on but that shouldn’t be too much of an issue.

So a few teething problems, no big deal.. these things happen. I’m glad the engine runs! I’ll be getting the car warm a few times before I drop the oil for another batch. So it’s not over yet, now
We have the task of getting it road worthy!


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Good evening all!

So from the last post, the engine was started and worked! It settles nicely now, idle does fluctuate but I think there may be a few air leaks which I can sort later.

The bigger issue was the oil leak which I believe was the input shaft seal on the gearbox. I can’t remember changing it so my money is on that. Either way I need to remove the gearbox so I cracked on with that.

First thing is to get the Cat off, need that to access the bolts near the starter and also the driveshaft bolts. I dropped the exhaust, took the cat off to reveal something that this car doesn’t usually have - space to work!!!

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I have since removed the cat, undone all of the prop shaft bolts which I will have to replace anyway. All that is left are the stabiliser bolt which I’ll take off when I have some access, and then the actual bolts holding it on to the engine.

There are 2 coolant leaks, one from the radiator temp sensor and the second from the oil cooler just trickling down. I’ll need to reseat the pipe, and if that doesn’t work I’ll replace it.

Last one is the thermostat. When I tried to run the car up to temp it wouldn’t really go past 80c. I’m not actually sure why or if it just needs time to settle. But since the car is half detrimmed anyway, I might just drop the coolant and change it. Had anyone else had the same issue?

Next time I should be able to report on the state of the gearbox and anything I missed!


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