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D2 - Engine Bay Everything under the bonnet

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  #1  
Old 12th February 2018, 11:01 AM
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Goran Goran is offline
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Thanks Mikki, good advice I will keep laundry powder well away from the car
Yes on my car the delivery pipe is one piece. Looks like its well protected (crimp joints covered by thick foam rubber) and already painted.
Only the return hose has the crimp joints exposed.

I found this not-so-good site which has some D2 manuals on it. Seems that the banjos on the pump are both 50nm so need to be quite tight. I couldn't find settings for the ones on the rack end but I will assume 50Nm also as one of them is high pressure.
The high pressure hose bolt on the pump is a real pain, the hose fr the reservoir is in the way. I'll have to loosen it and move that hose to get to the bolt.

http://workshop-manuals.com/audi/s8_...iew/page_3803/

Its funny how when doing something else you find unrelated things. I think I found my gearbox oil leak. The hoses/pipes look good and dry all the way to the radiator. But on the gearbox one of the banjo bolts appears to be missing a washer, and that pipe and bolt are covered in oil. So that's my next job, to replace that bolt or at least the washers. At least it looks like I dont need the out of production hoses! for now...

Last edited by Goran; 12th February 2018 at 11:04 AM.
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Old 12th February 2018, 11:08 AM
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Goran Goran is offline
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Found the info for the rack banjos on the above site. Weirdly the high pressure hose bolt is 40Nm, the return hose bolt is 50Nm.
Oh well, who am I to question Audi instructions
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Old 12th February 2018, 01:14 PM
MikkiJayne MikkiJayne is offline
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Could be because they are different size bolts so they want different torques to get the same clamping pressure on the crush washers
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Old 13th February 2018, 10:35 AM
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Goran Goran is offline
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You are so smart, I would have never thought of that

For me it turned out more than 1 day's job, I thought I could get a shallow socket to undo the bolts at the rack, but quickly realised it would not fit. I have one of those gooseneck/offset spanners but that would not fit either. So I went on a stroll to halfords to get some spanners. Now I manage to loosen most of the bolts, but what almost finished me off was the two 10mm bolts in the rubber+steel clip holding the pipes close to the bulkhead so they dont wonder into the spring. Audi put this clip right behind the spring they are a pain to get to. Plus the rubber they go through makes them spring back when you try to unwind them half a turn.
For those bolts luckily I had a tiny 10mm spanner I bought from a pound shop for my rc planes. It did the trick because it could fit behind the spring and do a half turn on the bolt. Also a manual rubber flexi drive helped but its not great quality, it was almost not flexi enough. It helped speed up the bolt after it was already loose.
And by then it was dark so I left final removal and re-fitting of new pipes for another day. What a job!

I was thinking if anyone wants to torque up the rack bolts with a small torque wrench, something like this small crows foot might work.
https://www.ebay.co.uk/itm/Flare-Nut...QINYNVRpEb4B6Q

I forgot to say, anyone attempting this job, you will need 22mm and 19mm wrenches and sockets. The bolt on the pump is 22mm, the bolts on the rack are 22mm and 19mm
And a tiny 10mm spanner for the bracket in the wheel well, a flexi drive will be useful too. And if like in my case your pump to reservoir pipe is blocking the other pump bolt you will need a 24mm socket to loosen and move that pipe out of the way.

Last edited by Goran; 13th February 2018 at 10:42 AM.
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Old 17th February 2018, 04:02 PM
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Goran Goran is offline
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Please ignore some of the things I wrote, I completely forgot my steering wheel is on the wrong side
RHD probably doesn't have those wheel well brackets as the pipes approach from a different direction?
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Old 17th February 2018, 07:44 PM
MikkiJayne MikkiJayne is offline
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That bracket is there on RHD as well, and its equally vexing to access
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  #7  
Old 19th February 2018, 01:21 PM
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That's a shame! I was hoping you guys would have an easier time of it.
I sill haven't finished the job, caught the Ozzie flu the same day, only now back to normal.
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