My First A2 - FSI Project Build

dj_efk said:
I would bet money on the familiar manifold flaps issue being the reason why someone has “deleted” the EML in that case. The good news is that sorting it out is a well trodden path. Bad news is that it’s a ton of work if you also consider that the plastic cooling system components will likely be at the end of their lives too.

I’d be tempted to take the engine out to do all the work at once.
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Hmmm, interesting. Makes this sound less of a DIY project than I was thinking. Biggest job I've done in the past is disks and pads and that was back in 1993 on a 1989 Cavalier GSI!

With the bodywork issues as well not sure this car is worth investing in that much work. It's not running lumpy or uneven, may give it a full service, a good tidy up and then see what I decide to do. I am very interested in @WindyMiller's car for sale too
 
So starting to move along slowly with the build..

Service kit arrived today, oil will be courtesy of a good friend and OEM spec

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Also got the drop links as recommend here as the first thing likely to be causing knocking

Fitted the TT pedals tonight, bought a cheap eBay set and the accelerator pedal cover was wrong so bought a used OEM one for that, happy with the look (excuse the dirty footwell)

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Also fitted this sticker from one of the A2 Facebook groups.
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Have this in the garage, was a bargain for £9.99 but it didn’t have the cable which I believe I need Going to spend some time cleaning the leather and see what it comes up like

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Also have these wheels and tyres, I know 18’s may be pretty harsh but I don’t mind a firm ride and interested to see how they look and what it handles like

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Things want to do soon, sort audio… have bought the diversity thing from @A2Steve (thank you!) and need to look at Bluetooth options. Needs investigation on noisy heater fans and no air con

Hopefully after full service I can also check fault codes and see what might need working on next in the engine bay


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I have a cambelt and water pump for that model, proper one from TPS, cost me £148.00. Yours for that if you want it. That looks like a nice car in the making,.

Good luck
 
Ready when you are, available because I no longer have an 1.6Fsi. Boxes unopened etc. TPS is the OE Audi supplier.
I don't think we are that far away from one another. I am in Wallingford.
 
Had a little boot today today, nothing major as went in to fit the diversity unit so now have a working radio, thank you @A2Steve

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Curious what I’m missing, guessing there should be a compressor, but what else?

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Also found this which is helpful! Only need to order
2 from @Sarge now!

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Full service coming up this weekend


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RS11SMS said:
Curious what I’m missing, guessing there should be a compressor, but what else?

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I think I can see your towing eye under the wheel wrench, you are indeed missing the compessor but other than that you've got everything. The other big gap in the foam holder is for the optional detatchable towbar. The plastic frame that has the diversity unit on the back is for a voice-based route guidance system. If your car had this, there would be a DVD unit mounted there with an access flap in the boot carpet above it, allowing you to eject the DVD without having to take the space-saver spare wheel out of the car first.
 
Aha cool, thank you

just need to grab a compressor if anyone has one!

Next question, should there be a cover on this ?

N/S Boot
 

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PlasticMac said:
Second scan looks good, just dodgy flap motor in the HVAC.
Nothing engine wise. Scan again after a spirited drive, tank full of V Power (other 98/99 octane fuels are available), making sure you go above 3500 rpm and down again, below 2500 rpm, a few times, so the inlet manifold flaps get a bit of exercise.
Mac.
@Andrew Extract of scan attached.
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New scan after circa 90 miles, don't think this looks good....
 

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Not good as you say, in fact down right ......

As you previously said time to make a decision to continue or not especially if the bodywork/paint is poor.

If you choose to fix I see as expected our old FSI friend P1031, a good place to start. Strip down and clean inlet manifold, likely to need new vacuum actuator, ballpark figure of £125 including inlet gaskets. While there attend to thermostat, good policy to replace thermostat housing as well (includes thermostat and coolant temperature), say £100. Also good policy while there to have injectors professionally tested and cleaned (£100) and replace death pipe, £20. While there might as well do cambelt, £150 you have an offer. These are only parts costs, assuming many hours of DIY labour is free.

Fuel and Lamda faults and the rest to come, turning into a nightmare. Any point for a car well into the last quarter of its lifespan?

Andy
 
If it's fixable and you intend keeping it for a while then it definitely worth repairing, if you can afford all of it then great if not then do it bit at a time starting with the most important parts. Never want to see a good car scrapped as I've spent twice what I paid for it and have no regrets.
 
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On a very minor point I note the scan is showing a radio antennae fault even after you replaced the diversity unit. I know little about this but you did check/clean the connector pins?, as likely these would show evidence of corrosion if the old unit was killed by damp corrosion.

Andy
 
Andrew said:
Not good as you say, in fact down right ......

As you previously said time to make a decision to continue or not especially if the bodywork/paint is poor.

If you choose to fix I see as expected our old FSI friend P1031, a good place to start. Strip down and clean inlet manifold, likely to need new vacuum actuator, ballpark figure of £125 including inlet gaskets. While there attend to thermostat, good policy to replace thermostat housing as well (includes thermostat and coolant temperature), say £100. Also good policy while there to have injectors professionally tested and cleaned (£100) and replace death pipe, £20. While there might as well do cambelt, £150 you have an offer. These are only parts costs, assuming many hours of DIY labour is free.

Fuel and Lamda faults and the rest to come, turning into a nightmare. Any point for a car well into the last quarter of its lifespan?

Andy
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Thanks for the detailed response, I’m fortunate that a good mate is a VW tech and has offered to help with some things in spare time, my own knowledge and experience is very limited.

One thing we have noticed today is the engine wiring loom has been messed with quite a bit (has yellow VW repair wires in places) and looks like it will be sensible to replace.

Definitely needs cambelt change too

One thing I’d be interested in just out of curiosity… what are the consequences of not fixing… the car whilst not having as much power as I expected is idling and driving OK


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Andrew said:
On a very minor point I note the scan is showing a radio antennae fault even after you replaced the diversity unit. I know little about this but you did check/clean the connector pins?, as likely these would show evidence of corrosion if the old unit was killed by damp corrosion.

Andy
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No didn’t clean the pins so will add that to my jobs list


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RS11SMS said:
Thanks for the detailed response, I’m fortunate that a good mate is a VW tech and has offered to help with some things in spare time, my own knowledge and experience is very limited.

One thing we have noticed today is the engine wiring loom has been messed with quite a bit (has yellow VW repair wires in places) and looks like it will be sensible to replace.

Definitely needs cambelt change too

One thing I’d be interested in just out of curiosity… what are the consequences of not fixing… the car whilst not having as much power as I expected is idling and driving OK


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To be fair if a car isnt running right and has faults it has every possibility of causing more damage but that said plenty of cars carry on like it until things fail or not ( i wouldnt recommend this of course), I'd ask your friend who would be very knowledgeable being a VW Tech.
 
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