Great MOD for D2: Cover for coolant and steering fluid tanks
 

For those who truly love their D2s +++

It is straightforward mod that took me only 30 minutes to accomplish with Audi OEM parts. Got satisfaction from having a bit of good company with the car :)

Audi made amazing things for their 3.3 V8 Diesel cars, for example D2 transmission undertray and wheel arches side panels,
which were not available on other D2 models, but still can be easily retrofitted: http://forum.a8parts.co.uk/showthread.php?t=6546

Now this is just another example of 3.3 V8 treasure -- decorative cover for coolant and steering fluid tanks. Audi calls it sound deadener.
It neatly hides both reservoirs and creates a nice balanced picture under the bonnet, decorating the horrible unused space on the nearside (left side).

The cover can be fastened and unfastened real quick with a coin.
In unfastened position the fasteners won't be lost since they are held in place by nice rubber washers.

Parts:

1 x 4D0 805 583 E -- cover
1 x 4D0 805 784 D -- bracket 1
1 x 4D0 805 691 A -- bracket 2
2 x 8D0 805 121 B -- quick release fastener
4 x 4A0 805 137 -- rubber washer
2 x 8D0 805 960 -- quick release bracket for fastener

£162 from TPS.

One thing you need to add to this list is one M6 nut (ideally 'washer nut' with a bit of a shoulder or simply a nut and a washer, don't know part number).
Audi or TPS will be more than happy to supply.

This M6 nut attaches the front bracket to pre-existing black bolt that sticks out of steering fluid reservoir bracket and is specifically designed to hold the cover bracket.
I believe that black bolt pre-exists on all facelift D2s (perhaps pre-facelifts will need a hole to be drilled in the bracket for the bolt, but I'm not sure).
That M6 bolt and M6 nut are clearly shown on 1st picture.

Second (rear) bracket is attached via existing Philips screw that holds coolant reservoir. Can be seen on picture 3.

The 3rd fastening point is a clip on the back of cover panel that attaches to air conditioner pipe.
Not clearly seen in the corner of picture 5, but it'll be bleeding obvious when you install the whole thing.

Everything fits nicely. Parts are pleasure to work with.

Alternatively, the kit can be found on German breaking yards much cheaper, i.e. here:
http://www.ebay.de/itm/Audi-A8-Kunst...-/302082188416

Pictures!

http://forum.a8parts.co.uk/attachmen...1&d=1484241210

http://forum.a8parts.co.uk/attachmen...1&d=1484241210

http://forum.a8parts.co.uk/attachmen...1&d=1484241210

http://forum.a8parts.co.uk/attachmen...1&d=1484241210

http://forum.a8parts.co.uk/attachmen...1&d=1484241210

http://forum.a8parts.co.uk/attachmen...1&d=1484241210

http://forum.a8parts.co.uk/attachmen...1&d=1484241210

http://forum.a8parts.co.uk/attachmen...1&d=1484241210

http://forum.a8parts.co.uk/attachmen...1&d=1484241210

http://forum.a8parts.co.uk/attachmen...1&d=1484241210

http://forum.a8parts.co.uk/attachmen...1&d=1484241231

http://forum.a8parts.co.uk/attachmen...1&d=1484241231

http://forum.a8parts.co.uk/attachmen...1&d=1484241231


Any questions -- shout


P.S. Here's how to retrofit full size steering fluid reservoir in case you noticed it: http://forum.a8parts.co.uk/showthread.php?t=12262

This is a great mod mate and I'm well impressed with how clean your engine bay is which is something I'm anal about.
On the other hand coolant reservoir was annoying me as well, especially the yellowish plastic which has discoloured over years so I've replaced it and it looks lovely - nice clean white reservoir with pink coolant which you can actually see thru. This is the look I prefer personally, but your version is great and I can already see local TPS branches getting lots of phone calls :D
I could even bet my money on first 3-5 guys on here making them phone calls :ROFL:

Well done mate +++

Nice one! +++

Definitely on my list of must-do jobs!

Thanks for the part numbers :)


I'll have to ask my mechanic to get the parts for me .... Or does anyone know a way to order from TPS without an account?

Also, how do you get your R8 oil cap to sit neatly inline with the engine cover stripes? Mine sits diagonally when fully tightened. Is it adjustable?

http://forum.a8parts.co.uk/showthread.php?t=8737

:cheers:

Brilliant. Thanks! +++

Actually, I think I prefer that Porche oil cap now. Presumably that cap needs no modification?

AFAIK Porsche cap needs no modification

Nice - looks like a mod that even I could manage :D.

Without exception you will manage it Tintin :)

I will be ordering coolant reservoir for preventive maintenance next time I do something with the car. They are prone to leakage where the header pipe enters the reservoir from top. The weak point is steel pipe to plastic junction. The places wears out eventually due to temperature stresses. I heard some horror stories about sudden leakages. So you done the right thing.

The new reservoir is not mutually exclusive with this cover. +++

That's exactly what happened to me, top pipe section and to my mate. Fact this was on my list, this issue just speeded it up.
Coolant reservoir isn't as bad horror as on R8s. They leak directly on the engine and can't remember how, but coolant gets into the engine, messing injectors as well. Seen three of them with stripped down engines last year. Horrible scenes.

Great mod +++ I was tinkering with the smaller 2.8 cover, but this one is much nicer :)

If anyone struggles to get stuff from their local TPS then drop me a line as I have an account :) I know some of the branches are more picky than others about dealing with the public, although going in with part numbers does help. I can order things and post them if needed.

And, Marcin, reference our previous discussions on oil filler caps, please note the orientation of the oil filler cap :p :ROFL:

Yes David, I have noticed it's the wrong way +++:ROFL:
Unless it's manufacturer's fault on D2s and audi have realised that and fitted oil caps on D3s the right way.
Have you got original D2 brochure by any chance including engine pics??

I checked engine pics in original D2 brochure before doing the oil filler cap mod and it is oriented horizontally, just like on pictures in this thread +++

There you go Marcin, undisputed evidence for the D2 way of doing things i.e. the right way ;)

UPDATE:

Looking at pictures from Audi user manual the small plastic cover doesn't have to be removed, but I still think it looks cleaner without it.
Googling for pictures of A8 3.3 engine revealed that almost all 3.3 cars don't have it.

http://forum.a8parts.co.uk/attachmen...1&d=1484309410

Undisputed proof Audi got it wrong first time :ROFL:
Thanks God they got it right with D3s +++ :D

Now with new coolant reservoir.

Interestingly, the bonnet sound insulation has got recesses for the plastic trim exactly where needed -- see picture 3.

http://forum.a8parts.co.uk/attachmen...1&d=1485698676

http://forum.a8parts.co.uk/attachmen...1&d=1485698676

http://forum.a8parts.co.uk/attachmen...1&d=1485698676

That's a great mod, you're right it balances the engine bay perfectly.

I want a Porsche oil cap for mine too, but Awesome GTi weren't able to confirm that it wouldn't need modifying on my car.

For me the next step is Audi R8 coolant cap.

Since Audi R8 cap has got different thread the cap needs a bit of work.

Picture demonstrates the issue.

http://forum.a8parts.co.uk/attachmen...1&d=1485719315

With the insides of R8 coolant cap removed it will be glued on the top of original blue cap with a special body mastique.

Of course, the original cap is purchased brand new before this operation to renew relief valve and gasket.

Watch this space... +++

http://forum.a8parts.co.uk/attachmen...1&d=1485719841

http://forum.a8parts.co.uk/attachmen...1&d=1485719841

http://forum.a8parts.co.uk/attachmen...1&d=1485719841

http://forum.a8parts.co.uk/attachmen...1&d=1485719841

Sealant arrived from Germany. Now caps are glued together and curing.

http://forum.a8parts.co.uk/attachmen...1&d=1485780915

http://forum.a8parts.co.uk/attachmen...1&d=1485780915

... in 48h mastique will cure. Nice and heavy D2 cap. All OEM parts +++

http://forum.a8parts.co.uk/attachmen...1&d=1485867198

http://forum.a8parts.co.uk/attachmen...1&d=1485867198

http://forum.a8parts.co.uk/attachmen...1&d=1485867198

Before and After

This is how these cars should've been produced from new +++

http://forum.a8parts.co.uk/attachmen...1&d=1485867399

http://forum.a8parts.co.uk/attachmen...1&d=1485867399

http://forum.a8parts.co.uk/attachmen...1&d=1485867399

http://forum.a8parts.co.uk/attachmen...1&d=1485867399

http://forum.a8parts.co.uk/attachmen...1&d=1485867399

http://forum.a8parts.co.uk/attachmen...1&d=1485867399

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Looks fantastic Sergey! Well Done!
Now. . . if you could just get a whole kit for me to do mine and modify the cap for me. . . hehehe :love: :p

Here's the additional "R8 cap" kit Neil on top of the basic one from the 1st post of this thread:

1. 420 121 321 -- black R8 cap
2. 443 121 321 -- blue D2 cap (better to use the new one)

3. Options for polyurethane adhesives (I used Option A)
A. Petec 94730 Car Body Sealant Adhesive Putty Black
B. Sikaflex by Sika
C. Sodudaflex by Soudal

The brake fluid and screen wash caps look like they are prime for your attentions next :)

Passats B2's came with absolutely the same windscreen fluid cap (113 955 455), but in yellow/amber colour. I think I will take that one, so all other 'functions' including oil dip stick are marked amber/yellow in colour.

There was a very good reason that the screen wash was a different colour, one of my ex's topped up her brake fluid with screen wash and then complained the washers still weren't working :ROFL:

Get one like my D2 has +++

http://forum.a8parts.co.uk/attachmen...3&d=1441312204

Women are not allowed in my cave (except to bring food)
+++

This is brilliant - all these little touches really bring the bay together. I've always hated the vacant space by the power steering reservoir and was toying with the idea of getting the small cover from the 2.8 model, but this looks far, far better and I will 100% be going for this +++:D

I have a couple of questions please.

1. Similar to you, I have a matching coolant/oil caps except mine are Porsche but the coolant cap did not fit just like your R8 one didn't. I was working on a similar mod to yours but using an epoxy but I wasn't keen on the gap between the two caps and gave up but you've given me fresh hope :D. Can I get that bonding stuff over here?

2. If yes, what prep work did you do beforehand? Any rubbing down, any cleaning etc?

picture of mine for reference

http://i1255.photobucket.com/albums/...psl3whnef5.jpg

Thanks
Rich

Hi Rich,

The bonding stuff was published on the post above.

3. Options for polyurethane adhesives (I used Option A)
A. Petec 94730 Car Body Sealant Adhesive Putty Black
B. Sikaflex by Sika
C. Sodudaflex by Soudal

I ordered the Option A from Germany: http://www.ebay.co.uk/itm/111646731729
but I'm sure Sikaflex is equally good and can be purchased from any Screwfix store.

The beauty of one component polyurethane adhesive is that it will maintain elasticity for life, which is great for temperature fluctuations in that area. In my opinion, the two component epoxy can crack with time as it is so hard.

I preferred Option A also because it is specifically designed for Automotive industry, where as Sikaflex and Soudaflex are more general purpose. Didn't want to risk expensive parts.

The first step is to remove insides from the R8 cap. Remove the valve with pliers. Then attack the bottom of the cap with Dremel tool with cutting disc attached. Start from the middle and do several cuts to remove the central part of plastic directly below the valve. Then work your way to edges with pliers. Just remove plastic by small pieces.

Before gluing I have rubbed inner surface of R8 cap with sandpaper for better adhesion and then wiped with methylated spirit to completely degrease it. This bit of preparation was over the top I must admit, but I just enjoyed taking my time.

I also removed about 0.5mm of plastic from the top of the newly purchased blue D2 cap where all the letterings are. Basically flattened the top. Done it for two reasons: 1. to make it sit 100% horisontal within the R8 cap during gluing process. 2. To save 0.5mm of height since I had a theory that the bonnet will sit too close to the top of R8 cap, which didn't prove to be the case.

The blue cap was also roughened a bit with sandpaper and wiped with methylated spirit directly before gluing.

The *important* preparation step is to mark where exactly the D2 cap will sit/point in fully tightened position in order to glue the R8 cap on top of it so it will be aligned the way you want it. For example, on my car in fully tightened position the R8 cap's handle sits fully horizontal and the warning triangle on it isn't upside down. There is only one gluing position that allows for this. It should be properly calculated. Additional allowance should be given for the new D2 cap gasket to settle with time as well since it'll become a bit squashed in the future, so the cap should be rotated further to achieve full tightness.

Allow 48 hours for adhesive to settle before tightening the cap.

Hope it helps?

Sorry - I must have skipped past the part where you list the product in my moment of excitement :D

Thank you for a very informative procedure kind sir +++

This is exactly what I thought you would say....my main concern as you state would be lining up the caps perfectly so that it sits correctly!

Posted to my Facebook today:

"I found the key to the universe in the engine of this car"

:D

http://forum.a8parts.co.uk/attachmen...1&d=1485898821

If you will mis-calculate you will always be able to correct this in future by adding circles of thin film under the gasket or grinding off the gasket a little bit, so do not worry.

Gasket itself is available as separate part number, so can be easily renewed.

P.S. I used 3M masking tape. It is great. And I use OLFA knives to cut it :)

Wroks on 2.8 too with some cutting. Thanks for this great mod.

https://lazymarcel.com/content/image...223_171110.jpg

Hi Sergey and others

I finally got around to trying to fit this cover - and it’s taken me ages! Perhaps to help others who may follow, my trouble was in locating the ‘black bolt’ to mount the front bracket. OK, so maybe I’m dafter than most, but I could not locate it from the first photo (and there are a few alternatives!). What I now understand (which may be obvious to those smarter than me) is that the power steering fluid reservoir has been lifted out of its bracket (obvious when you see Sergey’s hand in the top left of the photo!) to show the bolt.

I hope this might help those who might follow this thread and are as clueless as I obviously am!

Well done Jim

Miss my D2. Best car of all times. +++