1990 Audi 100 Avant turbo. Op Project Creep

Really enjoyed this thread. Something awesome about an old car still doing what it was designed to do. Bookmarked.

New hose turned up today. Had to cut it down a bit but it fits nicely and seems thicker than the bmw one. It's also red.


Job jobbed

Thought I'd give a little update on the daily.

All has been going well since the boost hose has been fixed.

The radio the car came to me with was a horrible Tevion modern flashy Bluetooth thing. Wired in so that it's permanently on unless you power it off and speakers wired in wonky, the fronts being font left and rear right and the opposite wired in for the back. Also intermittent in operation.
Anyway, while driving the facia decided to ping itself off onto the floor. The little plastic tab thing had broken off.
And in the bin it went.

I fancied something a bit more period.
Had to have red display to match the car, aux lead, tape player and preferably rds radio and some half decent output.
Found this

Came with a fault with the tape deck. It all functioned properly except slow playback which just turned out to be the belt had jumped off the motor pulley.
Wired it into the car having removed a lot of scotch blocks. The existing wiring only allows it to run on battery power, no switched power so I need to run a wire from somewhere so it comes on automatically.

It all works though. I've got the aux working through the ai-net CD changer port.
Just need a cage and the surround to finish it off.

Next on the to-do list. Brakes
After having to brake sharply I got a grinding noise from the brakes.
Nursed it home thinking it was the fronts. The brake wear indicator is snapped on one of the fronts and they looked low so ordered new pads.

Took old pads of only to find they still had meat on them.


Turns out its the rear
The pad material has separated from the backing.


The front discs are also warped and some rust is starting to appear at the rear edge of the front wheel arch so thought sod it and started stripping everything down for a refresh. Wanted to paint the front calipers red to match the rears anyway.


The extent of the rust. It's actually just part of the front wings the sills are fine.



New metal welded in both sides


And painted for now in jotun epoxy paint. I will repaint one day.
I also took the time to strip, rust treat and paint the struts.



Front calipers have received a lick of paint


I've ordered front and rear caliper rebuild kits and sliders, front and rear discs and pads, flexi hoses and front wheel bearings as there's a bit of play.

Edit*
The brake refresh is very much a temporary measure to keep it roadworthy.
I plan on upgrading to bigger discs and audi Q7 brake calipers for the front. Not sure on the back yet. The whole front end will need re-bushing as well as a lick of paint. Before all that though, the 5 speed box I have needs fitting as the 3 speed auto is dire. To do that I might need to buy a scrapper for all the bits

Will do. Was planning on doing either that or running a new ignition switched supply form the fuse board. I need to have a fish around anyway. The electric windows are run from a switch with only the fronts working, which I presume is too get around an electric window module fault and the switches on the dash don't light up with the headlights on. There's something funny going on.

Gearbox came out today


There's a couple of jobs I want to do while the gearbox is out and access is so good

The brake bomb needs changing as I can feel it recharge while braking


And I want to change the central steering rack Bush. This would be a nightmare with the gearbox in.



Other than that, the flywheel will need changing. Not sure if I need one that's specific to the mc-2 engine as there seems to be 2 probes. One counting the starter ring teeth and one looking at a pin which I presume is tdc.



Both frame rails look good but have light surface rust so I'll sort that.



And the bracket that holds the horns on looks like it could do with some intervention before it gets too bad


So coming up next will be lots of cleaning and painting

Cheers

Great to find other RR's suffering / addicted to Project / Mission Creep

I reckon it would still be a ballache replacing them in situ though as you'd have to remove the driveshaft anyway which means either removing the driveshafts or disconnecting the strut from the lower ball joint which is half the job anyway.
Either way I'm about to invest in one of those hydraulic press things as I've got the two ball joints as well as all the bushes to replace.
I haven't measured the anti roll bar. I'm assuming it's the same as the quattro one in which case there are poly bushes available. The sleeve in the old Bush was so rotten it had crumbled into two pieces.

Maybe the exhaust is the original then. The cat seems to be mild steel. According to ETKA the exhaust should have the cat and then two silencers. Mine is straight from turbo to the cat and then cat to the backbox, which is what's making me think it's been replaced.

I reckon I'm going to have trouble finding a flywheel as there's seems to be a lot of different ones about and mine has the pin for the sensors.
Also my manual gearbox has a cable speedo drive but I need an electronic one. Not sure if I can just remove that end drop the electric on in yet. Probably not because audi

Good point and not something I'd thought about and it turns out they're externally balanced. It would be prudent to get any second hand flywheel refaced anyway so I will get the new flywheel balanced to match the flex plate I've taken off.

I'm confident I'll be able to get the flywheel with the correct pin in it which would save a lot of mucking about

I was hoping something like that was possible lol. Apparently the mc-2 has the heaviest and strongest Rods that audi did in any 5 cylinder, so they don't like to rev much because of the weight but they're incredibly strong units. Should cope with some small imbalance but hopefully I can get the new flywheel pretty close