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What's in the workshop this weekend? . . . General VOD
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Well, I bought another one :p This one literally saved from death with not a moment to spare! A friend has a unit on a scrap yard, so when a D2 rolled in, he called me straight away. FL1 3.7 Quattro, sport seats, blown gearbox. "I'll be there in 2 hours" +++
£600 later, I had this: http://forum.a8parts.co.uk/attachmen...1&d=1555919842 http://forum.a8parts.co.uk/attachmen...1&d=1555919842 http://forum.a8parts.co.uk/attachmen...1&d=1555919842 A one-owner 3.7 quattro, with sport seats (not a Sport model mind). It was bought new at Exeter Audi as a company car, and then at the end of its company service was bought from the company by it's driver and kept by him until about six months ago when the gearbox failed at 117K. It appears to have had the same private plate from new until it was disposed of. I could tell as soon as I opened the door it had suffered some serious water ingress - it smells like a locker room and there is mould all over the place. Still, a decent haul of parts for the money. At least, that was the plan :ROFL: I got VCDS on it to read the gearbox codes and see just how exploded it was, and curiously there were no 'incorrect ratio' codes normally associated with a blown 5HP19, just loads and loads of sensor and solenoid failures. The ECU was the same - it had three pages of codes :eek2:, and the ESP unit also had half a dozen. I immediately went under the bonnet and opened up the electronics box to find it dripping wet inside :tuttut: Could it really be this easy...? All the ECU codes cleared fine, as did a couple of TCU codes once I'd cleaned up all the body harness connectors. I had a spare FL ESP unit so I just swapped and recoded that, and that was also fine. I didn't have a spare TCU of the right code though, so pulled that out and opened it up... http://forum.a8parts.co.uk/attachmen...1&d=1555919842 http://forum.a8parts.co.uk/attachmen...1&d=1555919842 http://forum.a8parts.co.uk/attachmen...1&d=1555919842 http://forum.a8parts.co.uk/attachmen...1&d=1555919842 Oh dear! Still, I had some time so I got out the isopropyl alcohol and a toothbrush and got scrubbing. After an hour of it sitting on a hot radiator I put it back in. http://forum.a8parts.co.uk/attachmen...1&d=1555919842 Result! :cool: It drives absolutely fine, and no more drivetrain fault codes. It really was that easy +++ http://forum.a8parts.co.uk/attachmen...1&d=1555919842 http://forum.a8parts.co.uk/attachmen...1&d=1555919842 To celebrate, I gave him a bath and named him General Vod :D http://forum.a8parts.co.uk/attachmen...1&d=1555919842 http://forum.a8parts.co.uk/attachmen...1&d=1555919842 http://forum.a8parts.co.uk/attachmen...1&d=1555919842 Only two minor bits of body damage http://forum.a8parts.co.uk/attachmen...1&d=1555919842 http://forum.a8parts.co.uk/attachmen...1&d=1555919842 Of course now he's working and has a name, he can't be a parts car any more can he? :tuttut: |
Well that has to be the shortest "What's in the workshop this weekend?" thread ever, but great to see another D2 saved from the crusher. +++
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I'm not finished yet :ROFL:
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Amazing how some people just simply can't be bothered to find out what is wrong. When there is obvious water ingress then it is highly likely to cause issues. Having said that, it gives opportunities for others (MJ) to buy them cheap with an 'easy' fix.
Well done MJ, you deserve some easy ones, although as you have said, 'this one isn't finished yet'! |
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The crazy thing is that it's already had a gearbox rebuild at some point! I guess it must have been out of warranty so when it started having problems again they just bailed on it rather than investigating.
This is my hit list prior to MoT on Tuesday: http://forum.a8parts.co.uk/attachmen...1&d=1555928832 Not on the list is 'remove swimming pool from driver's side carpet' and valet the interior so it doesn't smell of old socks :o |
Good work and it’s just so important to keep as many good D2s on the road +++
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Would you not replace both front springs as a pair?
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Nice save +++
What's your plans for the car? Courtesy car perhaps, for when those of us who don't have another vehicle need to leave our cars with you? :) |
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I should have known better than to question it :D |
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I'm going to stick him through an MoT and just drive him about while I decide his fate +++
The engine bay is the dirtiest I've ever seen :rolleyes: http://forum.a8parts.co.uk/attachmen...1&d=1556022905 A broken front sping to deal with - this and a torn balljoint boot on the lower front arm on the same corner are the only mechanical issues. Maria at Prestige sorted out a replacement spring of the same spec for me before the long weekend +++ http://forum.a8parts.co.uk/attachmen...1&d=1555922260 Ugh. We all know what this is http://www.corradov8.com/pics/banghead.gif That is not getting fixed before the MoT! :p http://forum.a8parts.co.uk/attachmen...1&d=1555922260 The 3.7 has an additional oil cooler for the gearbox, as well as the standard one in the radiator. Lots of silly plumbing in this corner because of this. http://forum.a8parts.co.uk/attachmen...1&d=1555922260 Factory towbar +++ http://forum.a8parts.co.uk/attachmen...1&d=1555922260 Well, this is the source of the dampness in the cabin :( The driver's side carpet is utterly soaked, despite being dry on the top http://forum.a8parts.co.uk/attachmen...1&d=1555922260 I spent quite a while squeezing the water out of the foam like a sponge, then mopping it up with a towel. Its amazing how much it can hold under the carpet http://forum.a8parts.co.uk/attachmen...1&d=1555922260 I got out as much as I could by hand and then left the dehumidifier running overnight. Its going to take a few days of this to dry it out. http://forum.a8parts.co.uk/attachmen...1&d=1555922260 I dealt with most the mechanical stuff today (next post) and will start cleaning up the interior tomorrow / Wednesday. There are a bunch of electrical issues to sort as well since the moisture has got in to quite a few modules. The folding mirrors have a mind of their own, the column clicks but doesn't move, and the speedo and fuel gauge are both intermittent. The drains probably all need cleaning too :rolleyes: |
Can you detail what products you use and how you go about mould removal and carpet cleaning in the interior when you do it please Michaela?!
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Can anyone else see the images MJ linked to in post #11 above? I noticed the links in the email notification, but they don't appear to be working.
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Oops http://www.corradov8.com/pics/banghead.gif
I know what happened there. I'll fix them at lunch time +++ Fixed :) |
Images now showing :)
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Looking through the MOT history, it seems the car has had the absolute bare minimum maintenance for most of its life. There are failures on tyre tread depth and a number of issues that are advisories one year then failures the next.
I get the impression that, if it wasn't for the MOT failures forcing the work to be done, the owner would've just continued to drive it until something fell off. |
Not unusual for a 19 year old barge to end up on banger economics for its last few years. It can be hard to justify spending money on a 2nd or 3rd car in a household when it’s not worth a lot.
In it’s favour, it has small miles for it’s age and a rebuilt autobox. Certainly has a good bit of life left in it in the right hands. |
The MoT history is an interesting contrast to the actual condition of the car actually. The owner probably never even lifted the bonnet, but the garage who looked after it since 2005 actually did a pretty good job, and used mostly genuine or good quality parts as far as I can tell. The oft-mentioned front CV boots are either genuine or Lobro, fitted with the proper clips. All four brake discs are genuine. I suspect it probably went for an annual service and MoT at the same time since it only did 5-7000 miles a year, so the garage just fixed what was necessary.
I suspect when the gearbox 'failed' a second time the rebuild was out of warranty so they just gave up on it and sent it for scrap. I've taken 6 litres of water out of the interior so far :rolleyes: |
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Supported the upright with a strap while I swapped the strut and lower arm over
http://forum.a8parts.co.uk/attachmen...1&d=1556050538 I keep a spare flange nut to use as a drift in these occasions so I can hold a socket on it and give it a solid hit with the lump hammer to pop the taper loose http://forum.a8parts.co.uk/attachmen...1&d=1556050538 Boot deteriorated, and most definitely no longer 'preventing the ingress of dirt' :rolleyes: I replaced it with a good used one for now. http://forum.a8parts.co.uk/attachmen...1&d=1556050538 Looking quite good from here :) http://forum.a8parts.co.uk/attachmen...1&d=1556050538 A hose on the end of the shop vac can reach underneath the heater to suck all the debris out of the drains http://forum.a8parts.co.uk/attachmen...1&d=1556050538 With the passenger side output flange heat shield removed I can just get my hand to the drain outlet. I use the same green hose but this time attached to the compressor so I can blow any remaining debris out of the drains. http://forum.a8parts.co.uk/attachmen...1&d=1556051144 The list is growing :tuttut: http://forum.a8parts.co.uk/attachmen...1&d=1556050538 These are the last ever genuine D2 air filters :( http://forum.a8parts.co.uk/attachmen...1&d=1556050538 Does anyone recognise this logo? http://forum.a8parts.co.uk/attachmen...1&d=1556051128 OE rear discs cleaned up enough to bed in some dirt cheap pads . These discs will be replaced if I keep the car http://forum.a8parts.co.uk/attachmen...1&d=1556050538 The front discs are also OE and in pretty good condition so I put some TRW pads on these http://forum.a8parts.co.uk/attachmen...1&d=1556050538 Lower the front end on to axle stands so I can tighten the suspension bolts with the weight on them http://forum.a8parts.co.uk/attachmen...1&d=1556050538 This is the extent to which you have to go to dry out wet carpets. I took about 3 litres out with towels, and the dehumidifier has taken a litre per night out and is still going. http://forum.a8parts.co.uk/attachmen...1&d=1556050538 I'm really hoping it can take the remaining water out overnight so I can put the interior back together tomorrow, since the MoT is 08:00 on Thursday... . |
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I knew I had a real problem the first time with my wonderful old PF when water started spraying out of the rear vents behind the armrest...…. :eek: Since then I've just got more accepting of the inevitability of it all and "just deal with it" as necessary. :( |
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It's like watching one of those old 'Your Life In Their Hands' programmes where you cover your eyes when they show you the patient being 'worked on'. |
I think the logo is "do not bend" rather than "no Mick Jagger's Allowed" :D
http://forum.a8parts.co.uk/attachmen...1&d=1556051128 |
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ps ...maybe ~I should look under the driver side carpet |
Because it's been painted, and its not leaking anywhere :)
The second cooler is there because the 5HP19 is on the limit of it's capacity with the V8 in front of it. The Allroad 2.7TT (265hp) has the same setup. |
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They seem to be readily available in the USA also but surely a decent aftermarket like MANN would be just as good.
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Yeah there are a few still in stock at various places, but now NLA from TPS. There are a few choices of aftermarket filters which I shall investigate before these are gone. The annoying thing is that the aftermarket ones are more expensive than genuine!
No update on General Vod tonight I'm afraid cos I'm too tired. I only got in at 10pm, but he's ready for MoT at 8am tomorrow +++ |
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I see it passed with no advisories! Well done MJ |
Of course ;)
He drives really nicely too, in a floaty american barge type of fashion, which copes admirably well with the terrible roads round here, but isn't so great at changing direction! Two things still to fix - the speedo is intermittent, and the fuel gauge has a mind of its own. For the former I suspect a bad connection either at the sender or in the ECU box, and the latter I'll just change the level senders and see what happens. |
Well done to the General and his Owner!!
Another 3.7 V8 lives another year +++ |
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Thanks for the reminder, I grabbed one too +++
Mine is due in June/July so good timing. I hope it turns out that Mann used to make the oem filter anyway that would be good. |
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After doing sterling work as a loan car / daily driver, General Vod is back in the workshop for some pre-sale maintenance before he goes off to live with Bert :)
He needs a bit of a bath too, after bimbling around the lanes of Devon for a couple of months! http://forum.a8parts.co.uk/attachmen...1&d=1578820104 The first job was suspension (which creaks) and brakes (which squeal). The original calipers were pretty crusty and one of them was partially seized which explains the squeaking. http://forum.a8parts.co.uk/attachmen...1&d=1578820104 Mike came over to help and between us we swapped both complete front corners from Sergey's 3.7 as this was all OE parts in excellent condition. As Vod had a groaning bearing, and Sergey's front setup was the steel hubs from the 20" cars, we swapped the whole lot - all the arms, tie rods, uprights, bearings, discs and calipers. The only parts to stay were the springs and dampers as Sergey's was a sport and Vod isn't. As a daily for wafting around the countryside on 17" wheels and balloon tyres, there's no need for sport suspension ;) Vod's factory sport recaros and comfort suspension is a lovely combination. http://forum.a8parts.co.uk/attachmen...1&d=1578820104 http://forum.a8parts.co.uk/attachmen...1&d=1578820104 We got the suspension finished just after lunch so pulled the front end to do the timing belt. http://forum.a8parts.co.uk/attachmen...1&d=1578820104 Last done in 2010 - he's done 60K miles since then. As with the rest of the car, everything in here is in really good condition and was fitted properly by someone who cared about the quality of their work. Off-brand parts though, which will be replaced by INA. http://forum.a8parts.co.uk/attachmen...1&d=1578820104 The first time I got Vod on the lift I could see the telltale pink stains which are indicative of a failed oil cooler pipe http://forum.a8parts.co.uk/attachmen...1&d=1578820104 Unusually the pipe was still intact, but it was leaking around the o-ring in the block. You can see the pink stain again here where its been dripping http://forum.a8parts.co.uk/attachmen...1&d=1578820104 Finished here for Saturday night http://forum.a8parts.co.uk/attachmen...1&d=1578820104 |
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O-rings? The pipe has four grooves, but the Audiworld site seems to only show two being used on the pipe and one on another part. It also mentions another o-ring they suggest replacing. This is the bit that has me confused: 3 each O rings, part #077-121-437. 1 each oil seal/gasket, part #077-115-441. I've provided a link to the page in question below: http://www.audipages.com/Tech_Articl...reinstall.html Where do you get the o-rings from? I'm finding dealer prices of £7 each, so was thinking of just buying a metal pipe with o-rings provided instead, like this one: https://www.ebay.co.uk/itm/273203362499 |
It might take 7 hours as a standalone job if you stop a lot for tea and biscuits, but once the front end is off its less than 2 hours extra work, most of which is selecting the right combination of hex bits and extension bars to get to all the bolts. I do this pipe as a matter of course on an engine-out service since it's simple to get to.
A word of warning trying to do it with the engine in - the bolts have shallow socket heads (simply for the schadenfreude - there's no technical need for it) and while they are not done up to massive torque, they do have a considerable amount of stiction. On the engine stand I will always give them a sharp tap with a hammer before taking them out, otherwise they have a tendency to round off. If you rounded one in the car then its game over and engine out to recover it. Its almost impossible to hammer the hex key in to them because the chassis leg is in the way so I either used a long punch or an extension bar to just shock the top of each bolt, before tapping the hey key in gently. They all came out that way without too much of a fight. The factory plastic pipe has a single o-ring at each end, and the water pipe which connects the cooler to the back of the engine has another of the same o-ring. The metal one has two each end. Your link is the same one I have in my grey S8 btw. I buy the o-rings 20 at a time from a bearing shop for pence each rather than paying the silly dealer price. The oil cooler seal isn't available on its own any more. You can only buy it as part of a kit (077198405) which is four times the price and full of stuff you don't need. |
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I did come across that seal kit, but couldn't figure out what all the bits were for. |
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Not much progress today as I'm waiting on parts. Got the oil cooler back on and the timing gear off.
http://forum.a8parts.co.uk/attachmen...1&d=1578858643 The rest of the time was spent dismantling the alternator to replace the bearings as they are very noisy, but I didn't get any photos. More tomorrow. |
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The alternator dismantled and awaiting bearings:
http://forum.a8parts.co.uk/attachmen...1&d=1578950844 They are just standard bearings which hopefully will arrive on Tuesday. This is the INA belt kit that I use. Part number 530 0452 10, usually around £240. http://forum.a8parts.co.uk/attachmen...1&d=1578950844 http://forum.a8parts.co.uk/attachmen...1&d=1578950844 |
I have fixed a starter motor in my C4 100 before. People told me I should not bother.
My starter motor repair
https://sites.google.com/site/aboutm...ssembled01.JPG Most people, and mechanics for that matter, have seemed to be hell bent on suggesting to me that the only remedy is to remove and replace these sort of components. Kudos to you MJ for refurbishing instead of throwing away the alternator! I am surprised to see how costly the timing belt is on these cars compared to the C4's I have been accustomed to servicing. |
That's a good price for the INA kit. The parts when ordered separately are (as many will know) in the order of £600.
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