Today I.....

Certainly, the temp sender was a Febi Bilstein unit from here. I wanted a big brand for this as could see that any inaccuracy could affect engine running as well as temp gauge readings. Pretty O.K. service, took about four days to arrive but good comms.


Thermostat was an Intermotor. I Googled around this and Intermotor actually have a pretty good name. I've never had a problem with their stuff and it used to be the go-to name back in the day of points and condensors (ask an old person, they'll tell you what these are kids). I also took the view that a thermostat is an incredibly low-tech thing with age / corrosion being main cause of failure. Be aware it comes with a variety of O-rings so be careful to rescue the old one for comparison purposes. Good seller, item arrived within three days I think.


Temp gauge now rock solid and car warmed up much quicker (judging not by the gauge but by heater outlet temps, albeit using a completely un-calibrated hand as a reference).

Therefore concluded as is normal for this car, if there was an option for one or both things to have faults, it will be both :rolleyes:

In fact it managed to score an impressive failure rating of three out of two: I had taken the under-tray off so I could capture the coolant effectively. Successfully carried out the obligatory 'drop the O-ring' and 'drop the U-clip' procedures. In grubbing around the back of the gearbox looking for these (and very much enjoying the whole experience, what with it being perfectly clean and all), noticed the driveshaft heat-shield was loose and rubbing on the gaiter. Took that off, removed the anti-crush spacers (that had fretted loose due to tiny contact areas), and replaced with dinner-plate sized washers. Another job done.

A quick mention on both jobs:

Temp sender: I removed the engine cover, turbo pipe and the bracket that holds various wires next to the sender (one 10mm nut). After many goes trying to pull the sender plug off but not being able to squeeze the retaining clip hard enough whilst levering the plug, I removed the sender still attached to the wiring and then pulled the plug. Obviously you don't need to do this the other way. I 'glued' the O-ring to the sender with rubber grease after it fell off the first time. How I chuckled. Put a rag under where you're attempting to fit the U-clip: the slots aren't easy to see (at my age), and it's very easy to misjudge it and have it drop down in all of the cables and hoses around here. If you didn't want to drain the cooling system, get the new sender ready (with O-ring 'glued' on), and you'd be able to switch them in a few seconds and barely loose any coolant.

Thermostat: obviously you'll be draining the whole system, which you just do by pulling the thermostat hose off. Be aware that when you pull the thermostat itself out after removing the housing, another lot of coolant will rush out. Before you start, have a look at the two bolts that hold the housing on. The upper one is easy enough, but the lower one is very deceptive: access looks easy, but there's actually very little room to work. I got away with it with a combination of two 10mm spanners and one 5mm Allen key (mine had Allen hexes in the centre). If you Google around this on here you'll see people have bought special socket-holders that do the job nicely. I found though that by using two makes / ages of combination spanners and the Allen, I was able to do the job just fine, just took a while to get it to spin undone, and then a while to tweak it up fully. I remcommend you have a dress rehearsal by trying to loosen the bolt before you drain the system. If you need another tool, nothing lost, you've not drained the system down. If you can undo it, say, half a turn, you're going to be fine and can carry on. Also, be aware it initially looks as though the housing won't clear the alternator bracket casting: it will, it just needs a wiggle.

Finally: don't forget to bleed the cooling system if you did drain it: there's a Crossed-Head plastic screw near the radiator top on the right hand side as you lean into the engine bay: crack this after filling the system as far as you can. You'll hear air coming out and suddenly stop. Do this again after you've run the car up. Note: put interior heater to full temp - fan off, as this allows any air bubbles in that area to be expelled.

Finally, if you have a Webasto (like me), there's a bleed screw right at the back of the unit when viewed from front of car. Look at the brake fluid reservoir, and it's tucked to the left of that. I've got usefully slim hands / fingers, so I can reach down there (just) with a finger from each hand just touching the screw. It's heavily knurled and about the size of a penny coin so quite easy to turn. The downside is I had to completely remove mine before it started bleeding, which was then a fiddle to put back in: especially as the engine was running at the time.

Check your coolant level a few times over next week or so, esp after first couple of drives. If you're mixing up coolant from a concentrate, use distilled water for the mix: it's unbelievably cheap, leaves you a useful container for carrying pre-mixed screen-wash (or gin, or whatever) and doesn't contain the impurities that tap water does.

For reference, I'll tidy this post up and dump it in the Bale / Break thread for reference as this thread moves so fast things quickly get buried.
I was wondering how you’d get on with the coolant issue, especially the removal of the thermostat housing! I ended up buying a min-socket set for about £12 (photo attached below), it’s proved perfect for tackling jobs like this.
 

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I was wondering how you’d get on with the coolant issue, especially the removal of the thermostat housing! I ended up buying a min-socket set for about £12 (photo attached below), it’s proved perfect for tackling jobs like this.
Yep, I have the same set, 2 in fact, one for each car. Really useful!

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Front bumper changed today due to some nasty splits in the black bottom part. Thanks to Hef for the the replacement bumper!

Quick wash later and it looks very brown in the evening sunlight.

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Looking much better Steve. Do you plan to move it on once you have the A2 you want?
 
Looking much better Steve. Do you plan to move it on once you have the A2 you want?

I may keep it for a while, it will have to go at some point in the near future I would imagine.

Looks like it needs top mounts potentially, left side is a quite noisy. Other than that it’s fine the engine pulls really well almost like it’s had a remap, I’m sure it’s not had one though!


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Just fired up mini-DIS as per this thread here so thanks to the contributors to this:


Best free mod so far by far! Literally took two minutes.

I'm not sure where it's got the MPG from as it's not been started since I did it, so imagine this is over the last few weeks / months. Either way, it's not at all representative as all the car's done is sit in my workshop being warmed up (as above), moved about on the drive, one MOT (more idling) and about three trips locally.

I simply changed the last digit from zero to five as per the thread. It already had correct code for UK car (therefore I guess MPG) and the smaller tank. Therefore with my UK TDi with 34 litre tank and mini-DIS enabled my code went from 09430 to 09435.

In theory, as I drive off it'll turn into an instantaneous reading. Apols for dust / dog hairs etc. Must put my glasses on when detailing ?

Naturally I'm now on a mission to get that number as high as I can whilst we have the warm weather! I'm only going to drive downhill.

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I don’t think you will get it to change much from 57mpg
I’ve done about 4000 miles & it is pretty much nailed at 57

Hth
Keith
 
Drilled 2 drain holes in the rear spoiler and fitted brand new HEKO wind deflectors.


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I was wondering how you’d get on with the coolant issue, especially the removal of the thermostat housing! I ended up buying a min-socket set for about £12 (photo attached below), it’s proved perfect for tackling jobs like this.

I like that! so much in fact I've just ordered one. Thanks for the tip ?
 
I don’t think you will get it to change much from 57mpg
I’ve done about 4000 miles & it is pretty much nailed at 57

Hth
Keith

Well, my 1.4ton Passat PD 130 Sport's on 49mpg since I've had it, and that's including a several thousand miles with a car trailer behind it (and lots of gentle Sussex-Norfolk trips I'll admit).

Surely I'll get it into the sixties: we're up to 59 now I've been out today (20 miles in two ten mile trips, mixed driving).

Nice to be at the stage where I can actually start to use the thing, although the list keeps being added to, albeit at a fraction slower than I can cross them off so I 'think' I'm gaining on it. It's certainly a completely different character to Lasi the AUA non-OSS car.
 
You should expect low to mid 60’s depending on how you drive it
Stick to 55 to 60 mph on a long drive and you should hit 70+mpg best I had With the std gearbox was 74 mpg on a 430 mile round trip from st Anne’s to aberdare with two people and a gearbox extra on the return leg
120 miles motorway at 70mph the rest A/B roads at 55/60 mph

I’ve not done any proper running since fitting the JDD gearbox but I’m certainly expecting some extra mpg. It looks promising as on a few drivers I’m seeing 115mpg on the mini dis on the same piece of road I was seeming about 95 to 100 mpg Fingers x

Cheers. Paul


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I was wondering how you’d get on with the coolant issue, especially the removal of the thermostat housing! I ended up buying a min-socket set for about £12 (photo attached below), it’s proved perfect for tackling jobs like this.

I Love that kit, I have used it a lot and it is perfect to Keep in the car in case of
 
Today we clicked over 180k to celebrate I bought a 87deg thermostat and will see if that speeds the warming next week.
I may have got that wrong but won't an 87 C valve open before a 90 C valve. This would cool the engine coolant earlier by allowing it to the radiator.
 
Afternoon everyone, hope you’re all keeping well.

Today the Twist paint I ordered arrived from Germany. I had come across it during a google search but discounted it as it looked to expensive for what I wanted to do. Someone did mention (think it was @A2Steve) (found the thread and it was @TYP 8Z) it in one the the recent threads so I thought I’d go for it.

So how good is it......?

I’ll let you be the judges.

Here is the paint that arrived:
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Here is the fuse cover that needed to be corrected, a job which someone had already attempted but the colour match wasn’t quite right.

Original colour looks to be Swing:
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This is what it looked like after a previous owner (possibly @Jellybean) attempted to repaint it Twist, great painting but just not quite the right colour:
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Stands out I think you’ll agree and it has been making my OCD kick in every time I sit in this lovely A2.

Here is what the same Swing, incorrectly colour matched fuse cover now looks like after 5 minutes of prep and 20 minutes (4 light coats with 5 minute intervals) painting:
410E5B9F-429B-4183-B76C-476E816F9310.jpeg

Pretty good me thinks. Could I improve my painting skills, probably! I’ll practise on the next item to be painted which is...

This, yes the next thing to be recoloured is my Swing Rear Cup Holder, unless someone has a Twist one they’d like to do a swap with:
B337FA36-B03D-4C45-B37A-1CF99DFF900B.jpeg

Stay safe everyone,

Kind regards,

Tom
 
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Today the Twist paint I ordered arrived from Germany. I had come across it during a google search but discounted it as it looked to expensive for what I wanted to do. Someone did mention (think it was @A2Steve) it in one the the recent threads so I thought I’d go for it.

So how good is it......?

I’ll let you be the judges.

That's very impressive.
 
Amazing result @2work . I recommended the Volico twist paint few times here albeit I never used it myself. Very convincing outcome!
Did you buy the clear protective paint too from Volico? I'd be useful to see how durable the paint is....
 
Amazing result @2work . I recommended the Volico twist paint few times here albeit I never used it myself. Very convincing outcome!
Did you buy the clear protective paint too from Volico? I'd be useful to see how durable the paint is....

No I didn’t purchase their clear coat.

I’m yet to apply a clear coat yet but will be using a Halfords product (which I have from a previous repair on the A6) as the Volico product seemed to expensive my eyes. After leaving the fuse cover a few days I’ll see how durable it actually is by rubbing it over a few days. Its feedback I need before venturing onto the rear cup holder.

As you can see the colour match is pretty much perfect so I can only but guess that the other colours they sell are equally as good.

Kind regards,

Tom
 
Will you be testing the clear coat out on a spare bit of trim to ensure there is no reaction with the base coat

Cheers Spike
 
I may have got that wrong but won't an 87 C valve open before a 90 C valve. This would cool the engine coolant earlier by allowing it to the radiator.

No 87 degC is correct for a nominal 90degC running temp

Paul


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Will you be testing the clear coat out on a spare bit of trim to ensure there is no reaction with the base coat

Cheers Spike

Absolutely yes Spike. That last thing I would want to do is ruin the finish I already have on the fuse cover and the rear cup holder once it’s done.

Kind regards,

Tom
 
Today I.... (ok and yesterday :) )
On one car I... Removed a legacy data tracker, Replaced my repaired instrument cluster, Fitted some replacement trim pieces, Added CarShades and Cleaned the seatbelts so they retract smoothly now.

On the other, Changed the Filters for Oil, Air and Pollen. Changed the Oil and Experimented with different trim cleaning options.

All easy second nature stuff to most on here but a challenge for me. an enjoyable couple of days.

Oh and saved £60 on the car insurance!!

Thanks to A2OC for the the resources, info and talents for all things A2! ?

:)
 
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