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Thread: TDI90 front end rebuild.

  1. #1

    TDI90 front end rebuild.

    A few weeks ago I purchased what I thought would be a very simple repair which I hoped would be on the roads by now. Boy was I wrong.

    The car in question is an 04 TDI90 with almost all the trimmings and 75k on the clock. It was listed as a cat D so I had hoped to replace just a few panels and maybe the radiator.




    Much worse damage than I had thought.

    After much swearing and being unsure whether to break it or not I decided the first and best thing to do was to remove the engine.
    This move revealed a world of horrors which the weak stomached amongst you might want to scroll past



    As you can see there is cracking to the chassis and the front rails are not in the right position. Ouch.

    This is when I made the decision to break. I started looking online at what prices I could get for things when I see A2steve has parts I would need to repair. Contacted him and I collected a full front panel and crash bar.


    Sent from my iPhone using Tapatalk

  2. Users that liked this post:

    chubbybrown (12-05-2017)

  3. #2
    Gently Using a blow lamp, some hydraulic rams and a chap who specialises in chassis repair we moved the front legs until they matched a set of datums taken from my tdi75. The front panel then bolted straight on.



    At this point I realised it could be repaired. I again contacted Steve and fallan as he had just listed a new breaker and was able to purchase everything from them to put the car back together.





    Now I'm waiting for an aluminum welder to come and weld up a crack I've taken the dash out and replaced it with a dash I got from Steve. I was able to cut the centre console out of the airbag damaged double din and put it into the undamaged single din dash.


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  4. 16 users that liked this post:

    + Show/Hide list of the thanked

    A2Steve (12-05-2017), a2sumo (12-05-2017), Alan_uk (12-05-2017), chubbybrown (12-05-2017), Cronus7 (02-06-2017), Darren C (12-05-2017), Fallan (12-05-2017), J3FVW (12-05-2017), Louis (12-05-2017), martin 54 (12-05-2017), miller68 (12-05-2017), Pinkythelabrat (12-05-2017), rosscanning (12-05-2017), Sarge (12-05-2017), Special edition (13-05-2017), Vonnie (12-05-2017)

  5. #3
    Join Date
    May 2013
    Location
    Aberdare, South Wales
    Posts
    3,352
    Thanks for uploading the photos Mike. Looks like you are doing a great job. Good to see my parts going to good use.

    This is such a well specced TDI with that level of damage, had it got into other hands (myself included) it would have been broken for parts.

    My hat goes off to you for having the balls to take this on and saving a very nice A2.
    Steve
    0779zero965448

    Lots of parts/spares for sale - please click the link

    http://www.a2oc.net/forum/showthread...equest-A2Steve



    2004 Audi A2 1.4 TDI 75 SE

  6. 3 users that liked this post:

    ecoangel (13-05-2017), putyourmittenson (13-05-2017), Special edition (13-05-2017)

  7. #4
    Join Date
    Nov 2005
    Location
    Milton Keynes
    Posts
    2,124
    Hats off and a bow Sir. Great to see such passion and effort to see the repair realised and also to keep this nice looking example on the road.

    Also, good to see the breaker cars play a key part and underpin a cost-effective restoration.
    Now:
    1.6 FSI SE [2004] - Cobalt Blue

    Open-sky system, climate control, heated platinum leather sports seats, unique professionally tailored sports steering wheel, all-round electric windows, cruise control, full DIS, komfortblinker, auto-dimming rear-view mirror, /S-line gear lever, TT pedals, front stowage tray, rear cup holder centre console, heated mirrors, HIDs, LEDs, OEM mud-flaps, collapsible spare wheel & retro-fitted mounting bracket, ScanGauge, 17" BBS multi-spoke alloy wheels (Summer), refurbished OEM SE 16" 6 spoke alloy wheels (Winter).

    Was:
    1.4 TDI [75] 'Special Edition' [2005] - Akoya Silver

    1.4 Petrol 'Special Edition' [2004] - Silver
    [Mrs C's]

    https://www.youtube.com/watch?v=ES-JVFNwFV4

  8. 2 users that liked this post:

    J3FVW (12-05-2017), sunsurfer (17-05-2017)

  9. #5

    TDI90 front end rebuild.

    Yes without these cars being broken by members who haven't got overheads and eBay fees to cover it would be impossible to repair and maintain these cars satisfactorily and economically.


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    Last edited by putyourmittenson; 12-05-2017 at 08:33 PM.

  10. #6
    Finished putting the dash back together this evening. Hadn't realised the passenger seatbelt had gone off as well so the interior isn't quite finished yet.


    Outside on the front of the car I've loosely attached the bonnet and bumper to check panel gaps and it all looks good.


    This car has the full winter pack which would mean headlight washers. But I can't find a bumper with these in so current solution is to blank off and go without which is a shame. So if anybody out there can help with this I would be very appreciative.


    Sent from my iPhone using Tapatalk

  11. 6 users that liked this post:

    Darren C (12-05-2017), ecoangel (13-05-2017), JIGSAW (12-05-2017), JoshuA2 (17-05-2017), S2Dicky (14-05-2017), Special edition (14-05-2017)

  12. #7
    Ive a Tdi i bought with very light damage, ive been running her around for the last 6 months bullet proff reliabilty and always starts on the button and just flew through the MOT , problem is my project TDI will be back on the road in a few months so ile have no need for her but its worth more in parts than it is to sell as its a damaged repaired, even though it was just plastics damaged and has all the goodies opensky, double din , leather, dis , bose which all add up to more than its worth id imagine....

    Great Rescue there putyourmittenson , id of ran a mile with chassie damage but glad youv got someone to come sort it out , youl probally find yourself in the same shoes if you ever come to sell her
    Audi A2 TDI SE , Working sky , Bose , Dis , rear electric windows , Red leather .... Daily Driver

    Audi A2 1.4 16valve

    AUDI A2 SE 1.4TDI dirty diesel dog, Rebuild in progress , next stage custom stainless manifold and VNT Turbo

    Project A2 Quattro Twin bike Engined Transplant, custom paintwork, bodykit front and rear bumper update with A6 sport Grill .

  13. #8
    Quote Originally Posted by putyourmittenson View Post

    This car has the full winter pack which would mean headlight washers. But I can't find a bumper with these in so current solution is to blank off and go without which is a shame. So if anybody out there can help with this I would be very appreciative.


    Sent from my iPhone using Tapatalk
    Been after one with headlight washers for about 8 months i think there like gold dust , i did the same just disconected the pump wiring and blanked the water outlet pipe
    Audi A2 TDI SE , Working sky , Bose , Dis , rear electric windows , Red leather .... Daily Driver

    Audi A2 1.4 16valve

    AUDI A2 SE 1.4TDI dirty diesel dog, Rebuild in progress , next stage custom stainless manifold and VNT Turbo

    Project A2 Quattro Twin bike Engined Transplant, custom paintwork, bodykit front and rear bumper update with A6 sport Grill .

  14. #9
    Yes I know once complete it won't be worth as much as other undamaged cars but i like to think that it won't be for sale for a long while at least.

    As for the bumper I've messaged just about every ebayer breaking an A2 and can't track one down. I suspect as soon as this non washer bumper is painted the correct one will turn up.

  15. 2 users that liked this post:

    E T Oddie (12-05-2017), Fallan (12-05-2017)

  16. #10
    Join Date
    Nov 2005
    Location
    Milton Keynes
    Posts
    2,124
    Guessing that the bumper with washers is different on the inside to a standard one? Otherwise, I'm just wondering if there is any mileage in using the washer jets from the broken bumper and using it as a template to make new holes in the standard bumper.
    Now:
    1.6 FSI SE [2004] - Cobalt Blue

    Open-sky system, climate control, heated platinum leather sports seats, unique professionally tailored sports steering wheel, all-round electric windows, cruise control, full DIS, komfortblinker, auto-dimming rear-view mirror, /S-line gear lever, TT pedals, front stowage tray, rear cup holder centre console, heated mirrors, HIDs, LEDs, OEM mud-flaps, collapsible spare wheel & retro-fitted mounting bracket, ScanGauge, 17" BBS multi-spoke alloy wheels (Summer), refurbished OEM SE 16" 6 spoke alloy wheels (Winter).

    Was:
    1.4 TDI [75] 'Special Edition' [2005] - Akoya Silver

    1.4 Petrol 'Special Edition' [2004] - Silver
    [Mrs C's]

    https://www.youtube.com/watch?v=ES-JVFNwFV4

  17. 2 users that liked this post:

    S2Dicky (14-05-2017), sunsurfer (17-05-2017)

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