42 into 34 does go
- Thread starter hotstuff
- Start date
hotstuff
A2OC Donor
So, for more of this story.
At this stage, I have made all the adjustments and changes that are required to accomodate the larger fuel tank. The exhaust has been removed, the fuel lines have been "bent" out of the way and the old fuel filter assembly has been removed. The dosing pump for the Webasto has also been removed for re-location and now at last the tank has been offered to the vehicle and all looks ok and good to go.
Before the final push though, I had to make provision to accomodate the new heat shields - easy enough with a Dremmel and rivnuts. The other small (what I thought) issue was that of sorting the fuel lines to the new filter and the Webasto. The cars are fitted with rigid plastic fuel line with "click on" type connectors. I have the correct terminology for these connectors and pipes somewhere and I'll post this in due course.
Of course, there are different fuel supply lines for the two tanks, so it was off to Audi again for a new supply line for the larger tank. The new pipe however does not have provision for the "T" piece to supply fuel for the Webasto pump - the later cars are in fact not fitted with the pre-heater system! The connectors used by Audi, and probably most other manufactures require a special tool to insert them into the rigid hose to create a leakproof and airtight seal. I had to cut (and yes, I cried) the new pipe and use a compression fitting to solve that problem - it is a low pressure system so it should hold with no leaks - I hope. A flexible re-enforced fuel pipe now feeds the relocated Webasto pump.
Now, to fit the new fuel filter and bracket.
OOPS!!!
There is the rather SMALL issue of the hydraulic brake lines that occupy that space. So, what do I want - brakes or fuel filter?
But wait - there's more. The brake lines run concealed within the left side lower trim which must be removed to access them. My initial thoughts were to cut the lines, fabricate new end sections to the rear axle and join them behind the trim panel. Well, alot of head scratching later and my descision was to replace the brake lines in full. Of course they are special order from Germany - 7 to 10 days, but I could at least fit the fuel filter and tidy up the fuel lines. The picture in post # 18 of this thread shows the brake lines removed and bent out of the way. Easy to remove - just cut them off at the point before they "rise" into the engine compartment and remove carefully from the top once they have been un-screwed from the ABS pump. There is a plastic shield that must be removed at the front that protects the electrical connection between the engine bay and passenger footwell electronics bay.
The fuel filter went in easily, however of the three screw locations required to fasten it, only one exists on the older cars. There is precious little space to work in that area so instead of rivnuts, I used self drilling/locking self tapper screws. Because the later filter housing does not match with the older fuel lines on the car, I also had to make up flexilble fuel pipes to connect them up. Not difficult but so time consuming.
Pics below of the new filter housing in place and the re-located Webasto pump. Note the proximity of the fitted tank to the old Webasto position - the old bolts have simply been put back. More later.
blue skies
tony
At this stage, I have made all the adjustments and changes that are required to accomodate the larger fuel tank. The exhaust has been removed, the fuel lines have been "bent" out of the way and the old fuel filter assembly has been removed. The dosing pump for the Webasto has also been removed for re-location and now at last the tank has been offered to the vehicle and all looks ok and good to go.
Before the final push though, I had to make provision to accomodate the new heat shields - easy enough with a Dremmel and rivnuts. The other small (what I thought) issue was that of sorting the fuel lines to the new filter and the Webasto. The cars are fitted with rigid plastic fuel line with "click on" type connectors. I have the correct terminology for these connectors and pipes somewhere and I'll post this in due course.
Of course, there are different fuel supply lines for the two tanks, so it was off to Audi again for a new supply line for the larger tank. The new pipe however does not have provision for the "T" piece to supply fuel for the Webasto pump - the later cars are in fact not fitted with the pre-heater system! The connectors used by Audi, and probably most other manufactures require a special tool to insert them into the rigid hose to create a leakproof and airtight seal. I had to cut (and yes, I cried) the new pipe and use a compression fitting to solve that problem - it is a low pressure system so it should hold with no leaks - I hope. A flexible re-enforced fuel pipe now feeds the relocated Webasto pump.
Now, to fit the new fuel filter and bracket.
OOPS!!!
There is the rather SMALL issue of the hydraulic brake lines that occupy that space. So, what do I want - brakes or fuel filter?
But wait - there's more. The brake lines run concealed within the left side lower trim which must be removed to access them. My initial thoughts were to cut the lines, fabricate new end sections to the rear axle and join them behind the trim panel. Well, alot of head scratching later and my descision was to replace the brake lines in full. Of course they are special order from Germany - 7 to 10 days, but I could at least fit the fuel filter and tidy up the fuel lines. The picture in post # 18 of this thread shows the brake lines removed and bent out of the way. Easy to remove - just cut them off at the point before they "rise" into the engine compartment and remove carefully from the top once they have been un-screwed from the ABS pump. There is a plastic shield that must be removed at the front that protects the electrical connection between the engine bay and passenger footwell electronics bay.
The fuel filter went in easily, however of the three screw locations required to fasten it, only one exists on the older cars. There is precious little space to work in that area so instead of rivnuts, I used self drilling/locking self tapper screws. Because the later filter housing does not match with the older fuel lines on the car, I also had to make up flexilble fuel pipes to connect them up. Not difficult but so time consuming.
Pics below of the new filter housing in place and the re-located Webasto pump. Note the proximity of the fitted tank to the old Webasto position - the old bolts have simply been put back. More later.
blue skies
tony
Mustang-owner
Donor
Tony,
Great write-up.
Now you're experienced in the mod, would you offer your services to retro-fit for other members, or is the whole process too time-consuming?
You're a very clever and patient man (with a goddess for a wife).
Very well done Sir
Cheers
Jeff
Great write-up.
Now you're experienced in the mod, would you offer your services to retro-fit for other members, or is the whole process too time-consuming?
You're a very clever and patient man (with a goddess for a wife).
Very well done Sir
Cheers
Jeff
hotstuff
A2OC Donor
Brake lines arrived from Germany last week and got them in straight away. The are shipped in very large boxes and "folded" in half - according to ETKA, thay are in excess of 3.5m long! They go in easy enough though - easier than I thought. I jacked up the left side and supported the car, then un-folded the pipes and routed them down the left side of the engine compartment and underneath. It's then just slowly feeding them along and securing them to their anchors along the left side sill. Easier with two people and all you have to watch out for is to get them to exit and bend away from the engine compartment in the correct place. I did the right channel first and then the left, secured the unions on the ABS pump and rear bracket, put the vibrator grommets on and - thats it!
Next step is to bleed the system, I tried manually at first but there is so much air that it took for ever. I changed to the pressure bleeder and drew fluid quickly. The pedal is still soft but I have to prime the ABS pump properly with VCDS, I'm sure there is still air in the lines somewhere.
So, that's the mod - all in and almost working - there's a bit more to this story which I'll try post later today.
blue skies
tony
Next step is to bleed the system, I tried manually at first but there is so much air that it took for ever. I changed to the pressure bleeder and drew fluid quickly. The pedal is still soft but I have to prime the ABS pump properly with VCDS, I'm sure there is still air in the lines somewhere.
So, that's the mod - all in and almost working - there's a bit more to this story which I'll try post later today.
blue skies
tony