My A2 'blog'...

You could always go for that extra cylinder and drop in the 4pot 1.9L engine... that would presumably run more smoothly than a 3pulse engine. I believe it's a Polo engine? I'm sure someone else will know.


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<tuffty/>

Member
Nah.. not interested in a 4 banger for the A2... too much paper work lol... engine swaps are frowned upon insurance wise and I really rather like the 3 pot...

Most modern tdi's are heavy... some 400 kilo's on the A2 so power to weight is in its favour... something pleasing about p*ssing a bigger newer car off in a little marmite 1.4 ;)

<tuffty/>
 

ecoangel

Member
Good stuff, thanks for the tandem pump gasket info! By the way if you're interested in racing/track day stuff come over and see my A2 petrol project.

Cheers
 

<tuffty/>

Member
Wow... its been a fair old time since I have posted here but to be fair I haven't had anything to post about as the old girl has been doing what she does and gets me to work and back without drama...

She's had a service including the fuel filter and I will be doing a belt in the new year as thats coming up to 5 years ago since I did that job (one of the first jobs I did when I got her)

An engine build is still planned but touch wood everything is still ok there for now so will search for a suitable replacement in readiness in the new year...

The only other thing planned is to do a little work retro fitting an RNS-E and factory bluetooth to the A2... I have recently been doing this work to my S3..
20181208-96dpi-IMG_9841-HDR.jpg


A Mk1 RNS-E with a MFSW from a 2016 A5, single stage A3 8V airbag and factory Bluetooth with phone integration and SDS voice control for the whole shebang... I am also going to be replacing the DIS on the S3 with the Color MFA from the crazy russian guys...

The plans for the A2 are a little more conservative... just the RNS-E and BT unit will go in initially... I don't have a full DIS on the dash but will look into that later...

I have now got hold of the double din cage for the A2 and I have an A4 climate control unit I can potentially use to modify to fit... I have another RNS-E and BT unit on its way and have a spare wheel module should I decide to go MFSW on the A2...

I also built a harness that allows me to be able to recode all the newer CAN based units (wheel module and BT module) on the bench to prep for retro fitting... I am currently looking at getting a similar thing installed into the S3 so I can actually code the RNS-E to be an S3 for the startup screen but currently it won't work on my 8L due to differences in CAN comms...

Anyhoo... the work on the S3 is mostly done now so need to keep my hands busy... pretty much topped out the power at just under 620hp on the hardware I have so nothing new will happen there...

No big plans for the A2's engine though... just looking to get a fairly low miles AMF code engine (mechanically the same as my BHC) and replace bearings/rings etc... I have a low mileage turbo to go in and if I can get one for the right price I will also look at the MYP Passat 6 speed gearbox swap..

Finally it wouldn't be much of an update without a couple more pictures... not done as much this year as I would have liked but will make a decent and potentially achievable new years resolution to address that :)

Been trying a few different techniques to push my moon pics... here is the result of that
20181020-wm96dpi-stacked_20181018.jpg


A couple of drips
20180913-wm96dpi-IMG_5343-Edit.jpg


20180913-wm96dpi-IMG_5336.jpg


<tuffty/>
 
Hey Tufty! That is a strange coincidence! I was thinking yesterday ‘I wonder how Tufty got on with his S3 engine rebuild? He’s not been on here in ages!’ Weird!

Let’s try ‘I haven’t won the lottery in AGES...’ (I’ll let you all know )


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<tuffty/>

Member
Couple of bits turned up today so hooked them up on the test rig to check they all worked

First the Bluetooth unit...
20181212-96dpi-IMG_20181212_141419.jpg


Connected to the bench harness to check it over...
20181212-96dpi-IMG_20181212_142232.jpg


...a pretty good bargain at £55

Another bargain at £175 was this RNS-E
20181212-96dpi-IMG_20181212_154319.jpg

Again hooked it all up and all was good here too...

20181212-96dpi-IMG_20181212_155615.jpg


Been looking at full DIS clusters... seems to be a couple of variants... 8Z0920980J appears to be the right one for the 1.4tdi but have also seen 8Z0920980Q which from what I have seen suggests its from the 1.2tdi..

Pin wise the A2 cluster looks similar to my S3 so I assume the DIS cluster will require the same sensor inputs (most of which I am no doubt missing)... will need to work through that lot and make a loom up to add them or 'adapt' them out with resistors or similar at least for the time being

Still undecided on fitting a MFSW though... I have a spare wheel module that I have coded up ready if need be... if I do go down that route I will most likely source a black wheel for the S3 and use the one from the S3 which is more anthracite than black...

<tuffty/>
 
Last edited:

Tomscar

Member
Couple of bits turned up today so hooked them up on the test rig to check they all worked

First the Bluetooth unit...
20181212-96dpi-IMG_20181212_141419.jpg


Connected to the bench harness to check it over...
20181212-96dpi-IMG_20181212_142232.jpg


...a pretty good bargain at £55

Another bargain at £175 was this RNS-E
20181212-96dpi-IMG_20181212_154319.jpg

Again hooked it all up and all was good here too...

20181212-96dpi-IMG_20181212_155615.jpg


Been looking at full DIS clusters... seems to be a couple of variants... 8Z0920980J appears to be the right one for the 1.4tdi but have also seen 8Z0920980Q which from what I have seen suggests its from the 1.2tdi..

Pin wise the A2 cluster looks similar to my S3 so I assume the DIS cluster will require the same sensor inputs (most of which I am not doubt missing)... will need to work through that lot and make a loom up to add them or 'adapt' them out with resistors or similar at least for the time being

Still undecided on fitting a MFSW though... I have a spare wheel module that I have coded up ready if need be... if I do go down that route I will most likely source a black wheel for the S3 and use the one from the S3 which is more anthracite than black...

<tuffty/>

Looks like an exciting project Tufty and I look forward to following your progress, best of luck with it ... Tom :)
 

<tuffty/>

Member
Oil change time again so decided to drop the sump and give it and the oil pickup a clean... fairly common issue in the 20v world so seemed worth a punt considering the old girl is at 208k miles..

The sump can be tricky to remove... there are 4 bolts flywheel side of which the middle two are partially hidden... I used a 1/4 10mm socket on a wobble extension and managed to get these out...

The sump was a little oily...
20190414-96dpi-IMG_20190414_111731.jpg


There is no oil pickup pipe like the 20v's have on this engine... instead its integrated into the plastic windage tray...
20190414-96dpi-IMG_20190414_111723.jpg


Plastic things sat in oil are always fun... especially with high mileage engines... I managed to break off one of the retaining clips as its brittle as you like but got it off to reveal...
20190414-96dpi-IMG_20190414_120611.jpg


...it was then I found the source of the rattle I have had since buying the car...
20190414-96dpi-IMG_20190414_120635.jpg


I was aware of the little 3 pots tendency for the balance shaft chain assembly to fail but wasn't expecting the noise to be this...as you can see in the picture the tensioner pad appears to be pitched over a little at an angle and this is allowing the chain to ride down into the block causing a little wear...

Its been like this for 5yrs and 53k miles so will get the bits together along with a cam belt and get it sorted.. at least I know what the noise is now :)

Gave the sump an initial clean in the kerosene wash tank...
20190414-96dpi-IMG_20190414_120728.jpg


...followed by a hot wash in the high pressure tank then into the aquablast unit..
20190414-96dpi-IMG_20190414_123146.jpg


20190414-96dpi-IMG_20190414_125821.jpg


20190414-96dpi-IMG_20190414_125844.jpg


Does a good job on aluminium but you really have to make sure its fully flushed to get the blast media out...

Clean off all the old sealant using a non marking flat edge and a bit of scotchbrite... brake cleaner softens the sealant nicely...
20190414-96dpi-IMG_20190414_133812.jpg


Refitted the plastic tray...
20190414-96dpi-IMG_20190414_134045.jpg


Applied sump sealant... and fitted it up...
20190414-96dpi-IMG_20190414_134616.jpg


Refitting can be tricky... I have a solid flywheel and you have to hook the sump into the back of the flywheel to get it past the plastic tray..

The old girl is in need of a little TLC and had planned that for this year... she needs new discs/pads up front, cambelt and now the chain and tensioner doing..

I also have some new glowplugs to fit but kinda dreading attempting to get the old ones out..

That said the engine looks in decent condition from what I could see so hopefully it will hold up for a while longer... I will need to revisit the tandem pump gasket again too as thats started weeping again softening my new coolant hose...

Other things on the 'to-do' list were the engine mounts but seems mine has the stupid expensive alloy gearbox mount so might just source the metal bracket off an early A2 and use a cheaper alternative as its a little 'wobbly' to say the least

Lots of things to do including actually taking some pictures as I have not done anything at all this year but the biggest thing to do is to rebuild the S3's engine as she decided enough was enough last month...

20190303-96dpi-IMG_20190303_133146.jpg


Keeps me busy... lol

<tuffty/>
 

<tuffty/>

Member
Did a few things today.....
20190428-96dpi-IMG_20190428_101725.jpg


Discs were looking a little worse for wear and felt almost like they were warped so took advantage of the easter discount codes and got some decent replacements...

Removed the old discs and pads...
20190428-96dpi-IMG_20190428_112220.jpg


...they were looking pretty nasty...
20190428-96dpi-IMG_20190428_112202.jpg


Made sure I cleaned up the caliper pins to prevent the normal issue of destroying threads... wire brush followed by a thread file...
20190428-96dpi-IMG_20190428_113105.jpg


...and all done..
20190428-96dpi-IMG_20190428_110036.jpg


Calipers are looking a bit tired/corroded and the nearside front brake hose is looking very tired indeed so will have to replace that next and look out for some calipers...

So next job was the gearbox mount... I have been trying to source a alternative gearbox mounts as I have the 'alloy' version and last quote I got from TPS was for around £200... aftermarket stuff was looking non existent... so did a bit of digging around and seems a similar mount is used on the 1.4tdi Arosa

Found that Quinten Hazell do one for the Arosa and was a more manageable £44.... only difference being the lack of the mount for the extra brace...
20190428-96dpi-IMG_20190428_120553.jpg


Getting at the mount bolts was 'fun'... had to undo the arch liner and drop the box down as far as it would go (once top two bolts were undone) to get to the three bolts holding it to the gearbox...
20190428-96dpi-IMG_20190428_120301.jpg


Old mount was shot...
20190428-96dpi-IMG_20190428_120634.jpg


I removed the extra brace... its construction is fairly basic and while I am sure there is a particular reason Audi decided to fit this on the A2 specifically I have not seen this on other 1.4tdi engined VAGs so feel I am not really losing much... push comes to shove I have kept the old mount and I can cut up a QH mount to get the insert out in one piece and press it into the old mount instead...

While under the car I noticed that the oil drain was still weeping... I have the parts to sort this... I bought a new fitting for the block but didn't get a new drain as they are £50 from VAG and the main issue is the seal to the block fitting...

So I had a spare one off the bargain low mileage turbo I have and lapped the fittings with very fine valve paste...
20190428-96dpi-IMG_20190428_124728.jpg


I had by then run out of time and tbh enthusiasm lol...

I have a bunch of other parts to fit soon too...
20190428-96dpi-IMG_20190428_124613.jpg


...so will do it all then

<tuffty/>
 

<tuffty/>

Member
Today I sorted the brake hose issue... the joys of a 16 year old car with over 200k on the clock meant that I couldn't just change the hose... that would be too simple lol..

The offending hose....
20190505-96dpi-IMG_20190505_101604.jpg


...and the joys of old cars...
20190505-96dpi-IMG_20190505_101623.jpg


20190505-96dpi-IMG_20190505_101714.jpg


Wasn't holding much hope for that lot to come apart easily sooooo...
20190505-96dpi-IMG_20190505_101956.jpg


....brand new TRW hoses and a brand new pair of genuine VAG calipers that I bagged for a mahoosive £58 from eBay...

First job was to seal the reservoir to minimise fluid loss while undoing the hoses..
20190505-96dpi-IMG_20190505_103754.jpg


Next job is to undo the hard pipe from the hose...
20190505-96dpi-IMG_20190505_103355.jpg


I used a little penetration oil to help while unscrewing it and unbolted the bracket to get batter access to remove the clip and hose from the bracket as they are normally pretty corroded in there..
20190505-96dpi-IMG_20190505_104436.jpg


I used a special tool to stop further fluid leaks while sorting the rest of the job out..
20190505-96dpi-IMG_20190505_104448.jpg


The nearside was far more corroded...
20190505-96dpi-IMG_20190505_105905.jpg


...so aqua blasted both brackets (which are aluminium) and painted them
20190505-96dpi-IMG_20190505_115207.jpg


....end of part one...

<tuffty/>
 

<tuffty/>

Member
...part 2

When I replaced the uprights I stupidly left the offside hose support bracket on the old uprights.... the new hose was just sat on the upright once installed so would be rubbing... the MOT fellas would not be impressed with that and I would rather not have my hoses rub through after just replacing them soooo....

Used a bit of stainless weldrod to form a bracket...
20190505-96dpi-IMG_20190505_123112.jpg


... with a little tweakage...
20190505-96dpi-IMG_20190505_124309.jpg


That will do until I get around to sourcing a genuine replacement...

And all done...
20190505-96dpi-IMG_20190505_125612.jpg


20190505-96dpi-IMG_20190505_130414.jpg


Bled the brakes all round to replace the fluid as its been in there a while and jobs a good un... Brakes feel great and its nice to know the A2 is safe once more...

In other news... as I eluded to in a previous post the S3 has had a minor setback with the rod deciding to make a bid for freedom... the damage was minimal thankfully and the rebuild cost was tolerable but...

I bought this instead...
vr6.jpg


...and yes... it will be turbo charged ;)

<tuffty/>
 

Edwrai

Member
...part 2

When I replaced the uprights I stupidly left the offside hose support bracket on the old uprights.... the new hose was just sat on the upright once installed so would be rubbing... the MOT fellas would not be impressed with that and I would rather not have my hoses rub through after just replacing them soooo....

Used a bit of stainless weldrod to form a bracket...
View attachment 51050

... with a little tweakage...
View attachment 51051

That will do until I get around to sourcing a genuine replacement...

And all done...
View attachment 51052

View attachment 51053

Bled the brakes all round to replace the fluid as its been in there a while and jobs a good un... Brakes feel great and its nice to know the A2 is safe once more...

In other news... as I eluded to in a previous post the S3 has had a minor setback with the rod deciding to make a bid for freedom... the damage was minimal thankfully and the rebuild cost was tolerable but...

I bought this instead...
View attachment 51054

...and yes... it will be turbo charged ;)

Do the chains while it’s out!!


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O07JESTER

Member
Did a few things today.....
View attachment 50722

Discs were looking a little worse for wear and felt almost like they were warped so took advantage of the easter discount codes and got some decent replacements...

Removed the old discs and pads...
View attachment 50724

...they were looking pretty nasty...
View attachment 50723

Made sure I cleaned up the caliper pins to prevent the normal issue of destroying threads... wire brush followed by a thread file...
View attachment 50725

...and all done..
View attachment 50726

Calipers are looking a bit tired/corroded and the nearside front brake hose is looking very tired indeed so will have to replace that next and look out for some calipers...

So next job was the gearbox mount... I have been trying to source a alternative gearbox mounts as I have the 'alloy' version and last quote I got from TPS was for around £200... aftermarket stuff was looking non existent... so did a bit of digging around and seems a similar mount is used on the 1.4tdi Arosa

Found that Quinten Hazell do one for the Arosa and was a more manageable £44.... only difference being the lack of the mount for the extra brace...
View attachment 50727

Getting at the mount bolts was 'fun'... had to undo the arch liner and drop the box down as far as it would go (once top two bolts were undone) to get to the three bolts holding it to the gearbox...
View attachment 50728

Old mount was shot...
View attachment 50729

I removed the extra brace... its construction is fairly basic and while I am sure there is a particular reason Audi decided to fit this on the A2 specifically I have not seen this on other 1.4tdi engined VAGs so feel I am not really losing much... push comes to shove I have kept the old mount and I can cut up a QH mount to get the insert out in one piece and press it into the old mount instead...

While under the car I noticed that the oil drain was still weeping... I have the parts to sort this... I bought a new fitting for the block but didn't get a new drain as they are £50 from VAG and the main issue is the seal to the block fitting...

So I had a spare one off the bargain low mileage turbo I have and lapped the fittings with very fine valve paste...
View attachment 50731

I had by then run out of time and tbh enthusiasm lol...

I have a bunch of other parts to fit soon too...
View attachment 50730

...so will do it all then

<tuffty/>
Hi,sorry to jump in so late on this thread.I am interested in how your getting on with the QH mount.I have a tdi90 ATL engine listing to the right (shot mount).I have found similar mounts to the QH on European eBay shops.im wondering wether to just leave the brace off as I've seen this mount advertised as OEM for polo 1.9 130bhp.So I guess the brace isn't for the power of an A2?
Cheers
Martin
 

<tuffty/>

Member
Hi,sorry to jump in so late on this thread.I am interested in how your getting on with the QH mount.I have a tdi90 ATL engine listing to the right (shot mount).I have found similar mounts to the QH on European eBay shops.im wondering wether to just leave the brace off as I've seen this mount advertised as OEM for polo 1.9 130bhp.So I guess the brace isn't for the power of an A2?
Cheers
Martin
Hi mate.... so far so good with the mount.. I don't do many miles these days but the juddering on start is gone and the initial vibrations have settle now that the mount has bedded in

<tuffty/>
 

<tuffty/>

Member
Absolutely agree just found this thead and read it from the start, I only wish I had your skills 👏
Thanks dude... its honestly not as difficult as its sounds...

I should be posting up the cambelt change and oil pump drive change swap soon... not had the time to actually do the work but the car needs an oil change so I need to time that with the rest of the work...

Thankfully the A2 doesn't need the amount of work the S3 does... and as an update on the S3's progress (seeing as I am here) here are a few pics of that....

20190526-96dpi-IMG_20190526_123938.jpg


20190608-96dpi-IMG_20190608_094527.jpg


VR6-pistons.jpg


20190629-96dpi-IMG_20190629_142104.jpg


20190701-96dpi-IMG_20190701_161209.jpg


20190714-96dpi-IMG_20190714_134511.jpg


20190921-96dpi-IMG_20190921_192018.jpg


And of course the noise ;)


<tuffty/>
 
I was thinking only yesterday ‘Where is Tufty? I really need a ‘fix’ - no one is doing a build log just now!’.

What a brilliant coincidence that here you are with some juicy V6 pics to keep me happy.

Thank you!


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