TDI90 front end rebuild.

putyourmittenson said:
So yesterday I finished bolting everything back in place and put the battery back on. First turn of the starter and the engine fired right into life.

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It sounds good. Only issue I had was a split intercooler. But have overcome that by managing to pick up another this morning. Once I had bled the clutch I could back it of the workshop and finally be able to wash it and see what the car was like under the dust and mud.

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The car looks pretty smart so now.
The body panels have been taken to get painted and I can now start focusing on clearing all of the fault codes. Of which there are many.



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So, did you reset the crash sensor? I have the same issue, is there a crash sensor somewhere?
 
Looking really good; you're not hanging about. Is the colour match good bearing in mind the panels have been painted in isolation?
 
Darren C said:
Looking really good; you're not hanging about. Is the colour match good bearing in mind the panels have been painted in isolation?
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Colour match looks good. They had a front wing to match with, Although I won't really know until I get the car outside.
As much as it would have been nicer to take the whole car to the paint shop and get it properly blended it would have just been to expensive considering the value of the car.


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The bonnet is on! I've now got lots of fettling to do to get the panel gaps in a satisfactory way.

Once done I can begin to finish the car off.
Still left to fit;
Passenger side seatbelt
some interior trim
Front Passenger seat
Front fogs
3L aero kit

I'm on the look out for a scuttle panel for the later style washer jets and The rear bumper scuttle panel with no clips broken.
I will need to get the windscreen replaced aswell before it's next mot also, has anyone had any experience of getting this done without going through insurance.


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The 3L refers to the 1.2 tdi A2/Lupo left hand drive models which were available to buy on mainland Europe only. These cars were super frugal... figures suggest that they could do up to 100mpg. As well as magnesium parts, automatic gearboxes and other weight saving bits they were fitted with additional underbody panels known as the aero kit which reduced air resistance and increased MPG.
 
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putyourmittenson said:
Still left to fit;
Passenger side seatbelt
some interior trim
Front Passenger seat
Front fogs
3L aero kit

I'm on the look out for a scuttle panel for the later style washer jets and The rear bumper scuttle panel with no clips broken.
I will need to get the windscreen replaced aswell before it's next mot also, has anyone had any experience of getting this done without going through insurance.


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I may have a set of Fog Lights, with panels soon... Watch this space.
 
Having now cleared most of the fault codes I'm still left with a few outstanding ones which i need to address.

00778 - Steering angle sensor (G85) 005 - No or incorrect Basic Setting/Adaptation

01218/00588/00655 - are all airbag and seatbelt related. They should clear once ive fitted a seatbelt and passenger seat.

65535- Internal Control Module Memory Error- 00-00 - -


For code 00778 I understand i need to recalibrate the steering angle sensor but when i removed it i forgot to tape it in place so unsure if it has rotated +- 360 degrees or even 720 degrees. Any help here?

65535 i believe to be relating to the airbag control module and because of the crash. I think it is a component which cannot be reset and needs replacing.
From this thread http://www.a2oc.net/forum/showthread.php?21992-where-is-airbag-control-module-on-2001-A2 i need item number 8Z0959655F. If anyone has any knowledge on this then i would be greatly appreciative.
 
putyourmittenson said:
Having now cleared most of the fault codes I'm still left with a few outstanding ones which i need to address.

00778 - Steering angle sensor (G85) 005 - No or incorrect Basic Setting/Adaptation

01218/00588/00655 - are all airbag and seatbelt related. They should clear once ive fitted a seatbelt and passenger seat.

65535- Internal Control Module Memory Error- 00-00 - -


For code 00778 I understand i need to recalibrate the steering angle sensor but when i removed it i forgot to tape it in place so unsure if it has rotated +- 360 degrees or even 720 degrees. Any help here?

65535 i believe to be relating to the airbag control module and because of the crash. I think it is a component which cannot be reset and needs replacing.
From this thread http://www.a2oc.net/forum/showthread.php?21992-where-is-airbag-control-module-on-2001-A2 i need item number 8Z0959655F. If anyone has any knowledge on this then i would be greatly appreciative.
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Hi,

On the slip ring / steering angle sensor there is a small circular "window" in the corner. When the ring is in the straight ahead position an orange indicator appears and can be seen through the window. If the ring is turned one or more rotations in either direction from straight ahead, the orange indicator disappears and the window is black. If the steering is centered and you can see the orange indicator then its OK. If not, you will have to move the ring until you can see the orange indicator and then fit the steering wheel in that position (whilst keeping the steering in the centered dead ahead position).

regards

Andrew
 
Ive done the steering angle sensor reset myself as the sensor got moved when my car was in peices and threw up a fault code, if you remove the steering wheel and look at the sensor, at the top corner youl see a small circular hole , if you hold the to pins, lugs that go into the steering wheel and turn them as if the steering wheel is being turned youl see it turns yellow or black depending where your centered , now what you need to do is work out the center of the yellow showing in the window, hole by turning the sensor, as if your turning the steering wheel left and right and work out where the middle of the yellow is from when its black left or right .... hope that makes sense... if not ile try to explain better, Ive also got another Airbag controller modual if you can not clear your fault codes when youv replaced faulty airbags ect...

Regards Gary

ops seems Andrew replied while i was typing lol
 
Cheers for the reply aswell. Doesnt sound to tricky and hoping it clears the fault.

JIGSAW said:
Ive also got another Airbag controller modual if you can not clear your fault codes when youv replaced faulty airbags ect...
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I think i will need another control module even once I've refitted a seatbelt and passenger seat because the data is stored on the module and can't be reset. Is the part number on yours '8Z0959655F'? as this one relates to a module for side guard and a non disabling passenger airbag.

Cheers, Mike
 
My TDI im breaking has passengers airbag key in the glove box and the display on the ultrasonic sensor so possibly the same controller ile have a look see at the part number, youl have to give me a few days as it will need all center console removing to check
 
ah yes I'm after a slightly different control module, from the thread i linked above the module is different depending if you have the passenger airbag key.

8Z0959655F is what i believe i need. there is one or two on ebay for £70+. But I've noticed that audi a3 ones have the same part number albeit 8P not 8Z, prices for these start at £10. Does anybody know if it would work? for the price i think its worth a try as long as it won't trigger all airbags.
 
Just looked at the steering angle sensor and the yellow marker doesnt appear at all. It gets close when its wound anticlockwise the whole way but not really. also noticed there is slight resistance at one point whilst turning it. i suspect it has been damaged when the airbag went off.
Anybody got a spare?
 
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