Black Mambo TDi75

So bit the bullet today and jacked it up, axle stand under the drivers front side. Wheel off
Wheel arch out (urghh)
Set about taking everything off and around the webasto to replace it with a working onor from the club. Despite having circuit board restored for free the unit wouldnt fire due to glow pin\flame reader.

It's a fiddly long job with lots of 10mm nut and bolts and plenty or witing clips and hose spring clips in insane positions...

Eventually it popped out the top all disconnected. Its a classic A2 just fits kind of job!!! Not for those who get angry quick or are short of time.

See photos of devastation it's left behind..as a help to anyone stupid enough to do this, under the wheel arch there two metal plates that hold the heater via bolts in the sidewall. Don't use a ratchet ring spanner on these like I did then bget it stuck between the two plates by undoing the bolt all way out!!

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I've already got some 11mm spring clips to put the fuel line hose back on, replacing the lovely crimped ear type use once, mangle off types like on the vacuum pipe on the tandem pump.

When I get daylight again I'll fit the new ish one a pray for cold weather or just buy some plumbers freeze to test it. Don't know why but it's so exciting a working webasto one a cold day. Will be gutted to say least if it doesn't work.
 
CrispyEdd said:
So bit the bullet today and jacked it up, axle stand under the drivers front side. Wheel off
Wheel arch out (urghh)
Set about taking everything off and around the webasto to replace it with a working onor from the club. Despite having circuit board restored for free the unit wouldnt fire due to glow pin\flame reader.

It's a fiddly long job with lots of 10mm nut and bolts and plenty or witing clips and hose spring clips in insane positions...

Eventually it popped out the top all disconnected. Its a classic A2 just fits kind of job!!! Not for those who get angry quick or are short of time.

See photos of devastation it's left behind..as a help to anyone stupid enough to do this, under the wheel arch there two metal plates that hold the heater via bolts in the sidewall. Don't use a ratchet ring spanner on these like I did then bget it stuck between the two plates by undoing the bolt all way out!!

View attachment 115297View attachment 115298View attachment 115299View attachment 115300

I've already got some 11mm spring clips to put the fuel line hose back on, replacing the lovely crimped ear type use once, mangle off types like on the vacuum pipe on the tandem pump.

When I get daylight again I'll fit the new ish one a pray for cold weather or just buy some plumbers freeze to test it. Don't know why but it's so exciting a working webasto one a cold day. Will be gutted to say least if it doesn't work.
Click to expand...
You can "encourage" it via VCDS, without the freezer spray.
Mac.
 
PlasticMac said:
You can "encourage" it via VCDS, without the freezer spray.
Mac.
Click to expand...
Thank you, yes if I can get my mate round sooner I'll give it a go again. He's a busy chap though and I only have vcds lite so can't activate it. We tried it before and we know the fuel pumps ok just didn't ignite. Jobs for the weekend now though.
 
Webasto been working well last few days, satisfying.

Just performed and oil and filter plus air filter for its 150k birthday.

Whilst underneath I notice a tiny oil leak, seemed to come from turbo oil return pipe, sure enough the outer one nipped up so hope that's that..

Will keep on using it everyday, last tank 63mpg in cold. Chuffed.
 
Keys in webasto on, first drive with remapped ecu in place this morning. TOuch smoother in the low end then pops alive in the later stages of RPM circa 2600 rpm and really flies! THe map graph targets 300nm and about 120 bhp somewhere over 3000rpm but in reality i never go that deep into revs so looking around 100bhp in real life.

INterstingly the test on the original map revelaed 82bhp, would that be stadnard? Maybe the engine is well screwed together??
 
CrispyEdd said:
Keys in webasto on, first drive with remapped ecu in place this morning. TOuch smoother in the low end then pops alive in the later stages of RPM circa 2600 rpm and really flies! THe map graph targets 300nm and about 120 bhp somewhere over 3000rpm but in reality i never go that deep into revs so looking around 100bhp in real life.

INterstingly the test on the original map revelaed 82bhp, would that be stadnard? Maybe the engine is well screwed together??
Click to expand...
My understanding is that the injectors are a nominal 25 HP each giving a theoretical 75 HP from three. In practice they deliver a little more each and 80+ is about right.
Can't recall who told me, could have been Audi years ago as they were impressed by how my 75 compared to a 90.
 
So the eebasto worked but not for long. Error no flame turns out to be the fuel pipe blowing off and possibly damaged. Its blown off under the car after the fuel pump on the outside of the tank. Likely sludge old fuel put back pressure on the union. Will investigate at weekend!!

For now econ button prevents any pumping of diesel into the streets...

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After a few weeks of problem free driving, which is about as much as an A2 likes to offer you, we had an abs light show. Vcds indicated rear right sensor mechanical fail.
Luckily it came out with no issues, which amazed me, I actually laughed out loud. So I'm good to go again. 5mm hex bolt seen better days but gently does it and it came out.
 
Whilst led under neath I took a look at the webasto pump. Oh gosh it's corroded!!

I can see what's done to fail, the spigot pipe has sheered clean off. Now I can see how it goes together and the shape size of it I can order another one. Not easy to find but some reconditioned ones on ebay for the eu look good.
The brand name was odd was expecting webasto!
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So on receiving a new to me pump from a bmw, I set about replacing it.

As you can see the pump was insanely corroded. In fact as I tried to remove the rear feed to the pump, it too broke off and I now had fuel leaking out non stop.
Extreme hone mechanic pressure ensued, but I managed to remove the clip on the pipe and stuff the new pump in after ten minutes. Phew!
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The webasto then fired up on second attempt after priming itself ...utter winter joy, what a device.
The acrid smoke from the little exhaust has never been so well received.
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CrispyEdd said:
So on receiving a new to me pump from a bmw, I set about replacing it.

As you can see the pump was insanely corroded. In fact as I tried to remove the rear feed to the pump, it too broke off and I now had fuel leaking out non stop.
Extreme hone mechanic pressure ensued, but I managed to remove the clip on the pipe and stuff the new pump in after ten minutes. Phew!View attachment 116675View attachment 116676

The webasto then fired up on second attempt after priming itself ...utter winter joy, what a device.
The acrid smoke from the little exhaust has never been so well received.
View attachment 116677View attachment 116678
Click to expand...
Nice to see Mambo enjoying a festive Gin and Tonic ;)
 
Hello Edd,

Great news Sir. Having the Webasto working as it should is truly awesome,

I’ll be swapping the Webasto in the OEM A2 when I get an opportunity. Thanks for all the advice on here and elsewhere.

Kind regards,

Tom
 
No worried Tom, call me if you do get stuck on the webasto work, lord knows I've seen enough of mine, having had it out twice.
 
This is what -7 looks like on my temp sensor, the webasto was magnificent, 8-10 mins idling and it was almost too hot inside the car! Fill defrosted and temp gauge lifting. Brilliant mechanical device.

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Also found a hard touch analogue unit and new cupholders to smarten the dash area. Thank you @nod 😊

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You'll see my stereo is missing, this is because I broke it trying to remove it. Bent the facia and ruined the screen. Tbs were stuck and it just went horribly wrong!!
 
So the webasto doesn't work, glow pin short, sadly have to remove again maybe!! Anyway been a while and lots have happened will post more updates but basically I'm installing:

1. Newly painted bonnet via my dad and me
2. Black heated leather se seats
3. Electric seat cubby.
4. Front bumper with headlight washer and bottle.
5. Refurbed headlights.
6. Rear parking oem sensors and bumper swap.
7. Heated washer jets to go with mirrors
8. Alloy wheel swap to 16 five spoke optional oem wheels.

Lots of work. When done it will then be full suspension swap and fabia vrs brakes upgrade.

Here's bonnet

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