Hi All,
Guess it is time to call it what it is - a project and my daily really. Audi TDI 90 (2005, bought at 134k miles now at 152k). Project will be slow as it is my daily driver as well.
As i am saving for other things project will be slow, main things on agenda currently are:
1. sort out turbo piping - blew the pipe off the turbo replaced with new pipe/clips - still a boost leak somewhere (could be EGR spewing oil/crap though as it is leaking oil per #2). Suspect leaky intercooler however upon inspecting it does look alright and not bent/damaged, if weather is nice will remove turbo pipes and give it a blow to check if it does loose air (with one end sealed).
Will need to check rest of turbo piping as boost is under what is expected and running rich/poor economy.
Hopefully sorting this out will fix poor economy, as not sitting at 35-45mpg... It does not change much if i drive nice or drive like a mad man, even similar on highway...
2. sort out EGR/Turbo as it appears to be what is leaking oil - access looks to be a pain. Also Turbo
3. there is a bit of a rattle/whine when accelerating at low rpm. not sure on this one might be nothing.
Engine does vibrate a bit more than i'd like if taking off in 1st without throttle, goes smooth at 1300+ RPM so will probably do wishbone mount and then one on gearbox to see if that resolves it. Could be EGR causing it being clogged up/spewing oil and other crap in too i guess.
Will start with gearbox and dog bone mounts and see how it goes. Dogbone looked potentially original so wouldn't be surprising if that cause additional rattle.
4.Check brakes as front left disk seems like it is not wearing evenly - had post for it and have an idea what i'll need to do just need to get around to it - probably will get a sit of discs and pads and do a proper cleanup/service on the fronts. Rears look excellent so will go with the trusty if it ain't broke don't break it.
Front and rear brakes done. Rear was dragging a little but not really enough to notice, only could tell when spinning it by hand, can hear pad contact and it would slow down quickly.
5. Install an Under-tray/shield. Either plastic OEM or if a friend of a friend is willing have a metal one made. Not sure why i'd need a metal one, mountain climbing/zombie apocalypse readiness and its cool.
Low on the list this.
6. It does drink more fuel than it should by quite a bit - hopefully will be fixed with turbo/intake plumbing otherwise down the rabbit hole i go. Currently #1 on suspect list is the boost/air leaking but could be something else as well, once i rule out boost leak will go grasp at straws i guess.
That is all for the technical side really, rest are quite minor, though will try to tackle the poor fuel economy next and do the engine mounts at same time, hopefully. Will depend on weather and mood on the weekends really.
Fit Bose set and Cruise Control - Done by Timmus
Fit Leather seats (thinking normal leather rear 3 seat bench and front seats out of TT/A3 or similar, quite love the look of one in new (now ex) A2Steve's project car) Will likely go with front leather from another car and leave fabric in back unless something well prices comes around.
Will give a spin at re-upholstering door trims with leather/fabric material - still looking into options, probably faux leather/alcantara type stuff on foam backing with some glue after stripping the trim,if anyone have decent condition door cards i can experiment with would be great. Have some door cards for experimentation, will need to buy/source some material etc.
Additional sound insulation to look into.
Replace cracked front bumper (if anyone has one in good condition in what Audi call Akoya Silver, Pearl Effect i promise not to hurt it)
Replace power window switches with fully working ones - I have them I am just lazy.
Done so far:
New clutch/DMF
Remap bump to 110bhp
New tires and imaginary alignment done by Halfords so front tires will need replacing with re-alignment shortly. - now with fresh tires alignment.
Bose and CC fitted. Could do with Bose grilles but don't see them worth the price.
Tidied up plastics under the car which taken care of some of the rattles and some of the turbo plumbing, will go a bit deeper and probably replace the pipe that connects to inter cooler at the bottom for good measure and add a bit of rubber bumper to the metal section so it doesn't rub against the sump.
About 3k miles on new clutch going smooth - i could feel a little bit of vibration after swapping it on the clutch pedal but it has went away, guess wearing it in.
Sorted Brakes in case these were rubbing/causing low mpg, no improvement however braking is super super smooth now. Odd as old disks and pads looked to have over 70% left.
Sorry it's a bit scattered, just put together to serve as a list of to do/done sort of thing for crossing things off, will snap a few pictures as well when i get the chance to give her a wash, just a akoya silver sport spec TDI 90 really.
Feel a bit ashamed looking at some other members going through project cars seemingly every few months and taking me weeks to get around to slip under the car.
Guess it is time to call it what it is - a project and my daily really. Audi TDI 90 (2005, bought at 134k miles now at 152k). Project will be slow as it is my daily driver as well.
As i am saving for other things project will be slow, main things on agenda currently are:
1. sort out turbo piping - blew the pipe off the turbo replaced with new pipe/clips - still a boost leak somewhere (could be EGR spewing oil/crap though as it is leaking oil per #2). Suspect leaky intercooler however upon inspecting it does look alright and not bent/damaged, if weather is nice will remove turbo pipes and give it a blow to check if it does loose air (with one end sealed).
Will need to check rest of turbo piping as boost is under what is expected and running rich/poor economy.
Hopefully sorting this out will fix poor economy, as not sitting at 35-45mpg... It does not change much if i drive nice or drive like a mad man, even similar on highway...
2. sort out EGR/Turbo as it appears to be what is leaking oil - access looks to be a pain. Also Turbo
3. there is a bit of a rattle/whine when accelerating at low rpm. not sure on this one might be nothing.
Engine does vibrate a bit more than i'd like if taking off in 1st without throttle, goes smooth at 1300+ RPM so will probably do wishbone mount and then one on gearbox to see if that resolves it. Could be EGR causing it being clogged up/spewing oil and other crap in too i guess.
Will start with gearbox and dog bone mounts and see how it goes. Dogbone looked potentially original so wouldn't be surprising if that cause additional rattle.
Front and rear brakes done. Rear was dragging a little but not really enough to notice, only could tell when spinning it by hand, can hear pad contact and it would slow down quickly.
5. Install an Under-tray/shield. Either plastic OEM or if a friend of a friend is willing have a metal one made. Not sure why i'd need a metal one, mountain climbing/zombie apocalypse readiness and its cool.
Low on the list this.
6. It does drink more fuel than it should by quite a bit - hopefully will be fixed with turbo/intake plumbing otherwise down the rabbit hole i go. Currently #1 on suspect list is the boost/air leaking but could be something else as well, once i rule out boost leak will go grasp at straws i guess.
That is all for the technical side really, rest are quite minor, though will try to tackle the poor fuel economy next and do the engine mounts at same time, hopefully. Will depend on weather and mood on the weekends really.
Fit Leather seats (thinking normal leather rear 3 seat bench and front seats out of TT/A3 or similar, quite love the look of one in new (now ex) A2Steve's project car) Will likely go with front leather from another car and leave fabric in back unless something well prices comes around.
Will give a spin at re-upholstering door trims with leather/fabric material - still looking into options, probably faux leather/alcantara type stuff on foam backing with some glue after stripping the trim,
Additional sound insulation to look into.
Replace cracked front bumper (if anyone has one in good condition in what Audi call Akoya Silver, Pearl Effect i promise not to hurt it)
Replace power window switches with fully working ones - I have them I am just lazy.
Done so far:
New clutch/DMF
Remap bump to 110bhp
New tires and imaginary alignment done by Halfords so front tires will need replacing with re-alignment shortly. - now with fresh tires alignment.
Bose and CC fitted. Could do with Bose grilles but don't see them worth the price.
Tidied up plastics under the car which taken care of some of the rattles and some of the turbo plumbing, will go a bit deeper and probably replace the pipe that connects to inter cooler at the bottom for good measure and add a bit of rubber bumper to the metal section so it doesn't rub against the sump.
About 3k miles on new clutch going smooth - i could feel a little bit of vibration after swapping it on the clutch pedal but it has went away, guess wearing it in.
Sorted Brakes in case these were rubbing/causing low mpg, no improvement however braking is super super smooth now. Odd as old disks and pads looked to have over 70% left.
Sorry it's a bit scattered, just put together to serve as a list of to do/done sort of thing for crossing things off, will snap a few pictures as well when i get the chance to give her a wash, just a akoya silver sport spec TDI 90 really.
Feel a bit ashamed looking at some other members going through project cars seemingly every few months and taking me weeks to get around to slip under the car.