Ben's 95 90 Quattro 20vT - now with corn power!

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Re: Ben's 95 90 Quattro 20vT - now with corn power!

Postby Grillage » Sun Apr 07, 2019 3:43 pm

Yes, there is a third output on the other side but it’s not active
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Re: Ben's 95 90 Quattro 20vT - now with corn power!

Postby Grillage » Sun Apr 07, 2019 4:56 pm

With this all sorted, there’s still a list of things that need addressing.

The cold start sucks. It takes a bit to get the thing started the first time in a given day. But warm/hot starts are great. It wasn’t so bad on pump gas but e85 tune is worse.

Also I’ve been chasing a slightly wonky idle for a while. Just now I decided to test unplugging the various sensors in the engine bay to see the difference it makes. Nothing really made a difference until I unplugged my n80 - and the idle is fixed. Should I even be using the n80 anyway? Seems like just leaving it unplugged is the way to go.

The 4 rib alternator pulley needs shaving to be properly aligned. I currently have the old 6rib pulley on but with the 4 rib belt all the way inside. I think I can machine the Rs2 one narrower to move the belt in a few mms. The belt on it when I pulled it all apart yesterday had started to split from misalignment.
Image

I still get some electrical wonkiness. From time to time I get the fuel pump relay sticking when I turn off the ignition. There are two ways to fix this, pop the FP relay out of the fuse box and reinstall, or unplug the VEMS harness. Unplugging VEMS seems to create more issues. Sometimes the fuel pump primes forever but i think that might have something to do with poor connections from unplugging/repluggung the VEMS. When I go through and make sure all the pins are aligned properly and plug everything in, that doesn’t happen. Anyway, I tried moving the FP Relay signal per Marc’s instructions when I had this problem and it went away for a while. It’s back now.

That’s about it. I am going to take the car in for a good detail before Carlisle and have someone else do a good waxing. I hate doing that stuff.

I can’t remember if I mentioned but I have a set of blue weave CF trim coming soon as well! Can’t wait to install that. Blacking out all the wood will transform the inside of the car as well.
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Re: Ben's 95 90 Quattro 20vT - now with corn power!

Postby Grillage » Sun Apr 14, 2019 4:48 pm

A couple more updates - the N80 being unplugged seems to have solved my cold start as well. I'm never plugging it back in.

Also, I pulled that RS2 pulley from the alternator and cut off the snout of it. it fits much better and in line now:


Image
Image

I used an angle grinder to level it out all the way. Basically just putting it on the alternator and spinning until there was no wobble left
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Re: Ben's 95 90 Quattro 20vT - now with corn power!

Postby Grillage » Fri May 03, 2019 7:07 pm

More work going on over here.

I took the car for an alignment now that the 5 lug and brake swaps are done. The shop told me not to waste my money on an alignment due to the wear on CA bushings and Ball Joints.

I go AK Motorsport bushings (track density) and OEM ball joints installed. I really didn’t expect to use the 20 ton harbor freight press as much as I have over the years. The new Ball joints were rubbing on the rotors so I needed to pull the rotors back off and grind down the wear spots and all is good now.
Before:
Image


After grinding:
Image


took it back to the shop and it feels great now that everything is aligned. Feels fantastic on the highway.

But now that brings me to the biggest issue to fix before the Carlisle drive. The steering rack

I have about 2” of play in the wheel and it’s super irritating when going straight. This was made even more clear after I did all the suspension bits on the Cabriolet - Struts, CA Bushings, strut mounts and tie rod ends. (I was on a roll after the white car’s work). The Cab feels really good now and makes the steering on this car extra obvious.

I didn’t want to chance it and miss Carlisle by pulling the B4 rack and sending to Jorgen so I pulled a 97 Cab rack from the junkyard in N KY on Wednesday. They got it today and I hope to have it back next weekend. It will make the highway drive much more pleasant.

I am chasing down a few other issues though.
Biggest one is an oil leak that appears to be coming from one of the oil sensor/switches:
Image

I swapped out the big one yesterday and it didn’t solve it. I’ve ordered a new small one - hopefully that does it but it is a BITCH to get to those with the radiator and shrouding in place.

The other things on the list I started attacking:

Gas gauge was reading 100% full - I think I fixed that this afternoon. Pulled the FPR and turned the key to ON and rotated/wiggled the sender around until it seemed to find a good place.

My auto HVAC unit started behaving super weird a couple days ago. It would blow full power with the lights off and occasionally flash. Clearly wonky. I have a spare but it’s an early B4 orange colored unit. Anyone have a known good RED unit?

The lens on the Boost gauge I put in the center console is now removed. I detailed its install earlier in this thread but today pulled it back out to remove the glass. Now looks better inside the Instrument Cluster.

That’s really about it other than a good detail cleaning before the drive. I want to wax and wash the outside, do a clay bar etc.
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1995 90 Quattro 20VT - 1994 Cabriolet - 5 speed - 1987 Porsche 924S

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Re: Ben's 95 90 Quattro 20vT - now with corn power!

Postby PRY4SNO » Fri May 03, 2019 7:36 pm

When you do the rack it's a good time to upgrade to the Mercedes Bilstein damper ala Funkweasel on MG.

https://www.motorgeek.com/viewtopic.php?p=577759

Pictures are down but the PNs he used are still up. I got one and it's much more beefy.
Find me on Instagram @pry4sno

|| 2010 Golf Sportwagen TDI /// Farmenwagen
|| 1992 80 quattro 20v /// Eventual AAN'd Winter Sled
|| 1990 Coupe quattro /// Because Racecar

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Re: Ben's 95 90 Quattro 20vT - now with corn power!

Postby Grillage » Fri May 03, 2019 7:59 pm

Good call! Ordered!
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Re: Ben's 95 90 Quattro 20vT - now with corn power!

Postby jbrentd » Fri May 03, 2019 10:10 pm

It sucks to do all that work just to find out it makes other issues stand out. Don’t some cabriolet racks have the shorter lock to lock ratio? If so, hope you got one.
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Re: Ben's 95 90 Quattro 20vT - now with corn power!

Postby Grillage » Fri May 03, 2019 10:11 pm

They do, but I didn’t. I’m happy to get this one up and running then find a short one eventually.
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1995 90 Quattro 20VT - 1994 Cabriolet - 5 speed - 1987 Porsche 924S

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Re: Ben's 95 90 Quattro 20vT - now with corn power!

Postby pilihp2 » Tue May 07, 2019 4:22 pm

PRY4SNO wrote:When you do the rack it's a good time to upgrade to the Mercedes Bilstein damper ala Funkweasel on MG.

https://www.motorgeek.com/viewtopic.php?p=577759

Pictures are down but the PNs he used are still up. I got one and it's much more beefy.


Do you know which partnumber it is?
ATM 0004635132 or ATM1244630432 ?
-Phil
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Re: Ben's 95 90 Quattro 20vT - now with corn power!

Postby PRY4SNO » Tue May 07, 2019 10:21 pm

pilihp2 wrote:
PRY4SNO wrote:When you do the rack it's a good time to upgrade to the Mercedes Bilstein damper ala Funkweasel on MG.

https://www.motorgeek.com/viewtopic.php?p=577759

Pictures are down but the PNs he used are still up. I got one and it's much more beefy.


Do you know which partnumber it is?
ATM 0004635132 or ATM1244630432 ?


Had a look through my email and didn't see the invoice, so I'll confirm when I'm home from work in June if it's not urgent.
Find me on Instagram @pry4sno

|| 2010 Golf Sportwagen TDI /// Farmenwagen
|| 1992 80 quattro 20v /// Eventual AAN'd Winter Sled
|| 1990 Coupe quattro /// Because Racecar

|| Spare parts for sale
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Re: Ben's 95 90 Quattro 20vT - now with corn power!

Postby pilihp2 » Tue May 07, 2019 11:07 pm

PRY4SNO wrote:
pilihp2 wrote:
PRY4SNO wrote:When you do the rack it's a good time to upgrade to the Mercedes Bilstein damper ala Funkweasel on MG.

https://www.motorgeek.com/viewtopic.php?p=577759

Pictures are down but the PNs he used are still up. I got one and it's much more beefy.


Do you know which partnumber it is?
ATM 0004635132 or ATM1244630432 ?


Had a look through my email and didn't see the invoice, so I'll confirm when I'm home from work in June if it's not urgent.

I ask because he listed two and he wasn't certain either. hahaha.
all good.
-Phil
87 5ktq - 20vt
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16 KTM 690 Duke - 2 wheeled hooliganism

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Re: Ben's 95 90 Quattro 20vT - now with corn power!

Postby Grillage » Wed May 08, 2019 7:08 am

I ordered the first one he mentioned. I'll confirm that it fits (or return it and put my old one on). I'll comment on that old thread too and confirm it.

The damper shows up friday. The rebuilt rack came yesterday. Jorgen quoted 3-10 business days - they turned it around in one. I hope to get everything done by saturday.

Another box showed up today that had me even more excited:

Image
Image

This is the Aronmatic set. (http://carbondesign.hu)
I wanted this to be as OEM as possible so I opted for the blue weave like Audi did. Also I bought a new black surround for the climate control and would have for the aux gauges too if I could have found one. I ended up buying the aux gauge trim from him too and am trying to figure the best way to mount. I peeled the wood off of an extra set I have so I could get the metal backing by itself. Remember that B3 and B4 are different and this is a B4 set. He suggested that I glue directly to the wood piece but that wouldn't look very good. I think I'll try epoxy or maybe even construction adhesive when I get home tonight. the surfaces that need to glue together aren't exactly flat so there will be a bit of fill involved.
Image


Before and after on the first door card:
Image
Image
CURRENT
1995 90 Quattro 20VT - 1994 Cabriolet - 5 speed - 1987 Porsche 924S

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Re: Ben's 95 90 Quattro 20vT - now with corn power!

Postby ChrisAudi80 » Wed May 08, 2019 11:00 am

Looks fantastic, but I wonder why your door cards are different from mine. My door cards there are two pockets next to each other in one line. Pics in my thread.
Mine's a 95 too, but was a 2.0.
96 S6 auto
95 80Q AEB VEMS
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Re: Ben's 95 90 Quattro 20vT - now with corn power!

Postby Afterthought » Thu May 09, 2019 7:40 pm

Grillage wrote:I still get some electrical wonkiness. From time to time I get the fuel pump relay sticking when I turn off the ignition. There are two ways to fix this, pop the FP relay out of the fuse box and reinstall, or unplug the VEMS harness. Unplugging VEMS seems to create more issues. Sometimes the fuel pump primes forever but i think that might have something to do with poor connections from unplugging/repluggung the VEMS. When I go through and make sure all the pins are aligned properly and plug everything in, that doesn’t happen. Anyway, I tried moving the FP Relay signal per Marc’s instructions when I had this problem and it went away for a while. It’s back now.

.


I had a similar issue with my VEMS but on the radiator fan . Intermittently the rad fan would run when the ign was off but battery was connected . I was driving that fan with p259 and it seemed like when key was off and everything was at rest that switched signal wire to the relay was grounded.
I changed this by using the same signal wire from VEMS to switch the Relay but I changed the power source to the relay from batt to switched power and the problem went away.
I’m not sure if that same solution would work for the FP relay because switching the power source to the relay away from a battery source might cause voltage drop under load.




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Re: Ben's 95 90 Quattro 20vT - now with corn power!

Postby sayoda » Sat May 11, 2019 8:51 pm

That carbon fiber is gorgeous !!!!

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Re: Ben's 95 90 Quattro 20vT - now with corn power!

Postby Grillage » Sun May 12, 2019 11:35 am

sayoda wrote:That carbon fiber is gorgeous !!!!

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Thanks!

I couldn't get the aux gauges piece to mount properly so I just plasti-dipped the existing one to black:
Image
CURRENT
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Re: Ben's 95 90 Quattro 20vT - now with corn power!

Postby Grillage » Sun May 12, 2019 11:36 am

Afterthought wrote:
Grillage wrote:I still get some electrical wonkiness. From time to time I get the fuel pump relay sticking when I turn off the ignition. There are two ways to fix this, pop the FP relay out of the fuse box and reinstall, or unplug the VEMS harness. Unplugging VEMS seems to create more issues. Sometimes the fuel pump primes forever but i think that might have something to do with poor connections from unplugging/repluggung the VEMS. When I go through and make sure all the pins are aligned properly and plug everything in, that doesn’t happen. Anyway, I tried moving the FP Relay signal per Marc’s instructions when I had this problem and it went away for a while. It’s back now.

.


I had a similar issue with my VEMS but on the radiator fan . Intermittently the rad fan would run when the ign was off but battery was connected . I was driving that fan with p259 and it seemed like when key was off and everything was at rest that switched signal wire to the relay was grounded.
I changed this by using the same signal wire from VEMS to switch the Relay but I changed the power source to the relay from batt to switched power and the problem went away.
I’m not sure if that same solution would work for the FP relay because switching the power source to the relay away from a battery source might cause voltage drop under load.


Sent from my iPhone using Tapatalk


I'll look into this for sure. thanks!
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PAST
1993 Audi 90 CS Quattro - 1990 CQ - V8 - 1995.5 Audi S6 - 1993 Audi V8 - 2013 A5 Prestige - 2011 A4 Avant - 1986 Maserati Biturbo Spyder
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Re: Ben's 95 90 Quattro 20vT - now with corn power!

Postby Grillage » Sun May 12, 2019 11:55 am

So a good news bad news update:

Got the steering rack installed and problem solved!

I literally couldn't have done it without the bendy 17mm wrench:
Image
Image

I can also confirm that the Bilstein steering damper works:
Image
Merc part : ATM 0004635132
Bilstein part 18-002461

on to the bad news:

My brake booster broke right away on the test drive. I was driving and heard a click, then no more assist. I took it apart this morning and found that this plastic piece broke inside causing the inability to hold vacuum:
Image

So now I'm frantically working to find a replacement Phaeton booster before I leave for Carlisle thursday. I had the foresight to take Wednesday off as well so I should be in good shape. I am heading to the junkyard now to see if there are stock boosters that will work with the Phaeton's bigger diameter MC (the 27mm MC is why I chose that setup over a regular A4 or A6)
Car-Part.com has a couple somewhat close. Also A8 seems to be interchangeable and there are a lot more of those close.

Lastly, I never knew that the Airbag trim pieces were removable. Here's how you do it.

note that not all the Airbags have the rivets to drill out.

Image
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Image
CURRENT
1995 90 Quattro 20VT - 1994 Cabriolet - 5 speed - 1987 Porsche 924S

PAST
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Re: Ben's 95 90 Quattro 20vT - now with corn power!

Postby jbrentd » Mon May 13, 2019 7:53 am

Love the carbon fiber. Sorry to hear about your booster troubles. Sending you positive junkyard vibes.
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Re: Ben's 95 90 Quattro 20vT - now with corn power!

Postby Grillage » Mon May 13, 2019 7:59 am

Thanks, I found one yesterday from a 2007 A4 in great shape. I got it all connected, bled and when I went to drive, the pedal was super squishy.
I also think I know how I broke the old one. Has to do with Clevis length and install.

Need to re-bleed but had to cook dinner for the wife (mothers day and all) and then Game of Thrones, and Jameson - so no more work last night.

Also reached out to Error404 on S2 forum who makes the kit I installed to see if he had insight on whether the a4 booster would work with the Phaeton MC. He says some of the pushrods inside the booster are variable lengths and I could swap the Phaeton one over if they're different. Of course I was already installed before seeing his comment so I don't know. My "squishy" pedal could be zero MC pushing for an inch or so and then squishy. not sure. I'll investigate more tonight
CURRENT
1995 90 Quattro 20VT - 1994 Cabriolet - 5 speed - 1987 Porsche 924S

PAST
1993 Audi 90 CS Quattro - 1990 CQ - V8 - 1995.5 Audi S6 - 1993 Audi V8 - 2013 A5 Prestige - 2011 A4 Avant - 1986 Maserati Biturbo Spyder
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Re: Ben's 95 90 Quattro 20vT - now with corn power!

Postby Grillage » Mon May 13, 2019 8:26 pm

Got this squared away!

The push rod inside the booster was indeed shorter causing the pedal to barely engage the MC.

Image

I swapped in the Phaeton rod into the A4 booster and I’m good to go! Pedal is hard as a rock and brakes feel great. Steering is fixed and all is well with the world. Carlisle here I come!
CURRENT
1995 90 Quattro 20VT - 1994 Cabriolet - 5 speed - 1987 Porsche 924S

PAST
1993 Audi 90 CS Quattro - 1990 CQ - V8 - 1995.5 Audi S6 - 1993 Audi V8 - 2013 A5 Prestige - 2011 A4 Avant - 1986 Maserati Biturbo Spyder
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Re: Ben's 95 90 Quattro 20vT - now with corn power!

Postby DE80q » Mon May 13, 2019 8:52 pm

Sweet! I'm glad it was a semi easy fix! See you this weekend!
"If you can't find one, make one"

Dallastown, PA
1991 Audi 80 quattro (10vt project)
1991 Audi Coupe Quattro (project: my first 20v)
2007 Mitsubishi Raider(Dakota in disguise)
2019 Chevy Cruze RS hatch (wife's little red sporty car)
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Re: Ben's 95 90 Quattro 20vT - now with corn power!

Postby alxdgr8 » Sun May 19, 2019 11:15 pm

What was the reason why you think the first broke? I've got the same kit waiting to go on my UrQ with a B8 S5 booster/MC.

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Re: Ben's 95 90 Quattro 20vT - now with corn power!

Postby DE80q » Mon May 20, 2019 6:10 am

It was good to hang out with you this weekend Ben! This car is amazing!

Did the changes made fix the "cheap whiskey" smell under hard acceleration?

Also, I did make my purchase yesterday...
"If you can't find one, make one"

Dallastown, PA
1991 Audi 80 quattro (10vt project)
1991 Audi Coupe Quattro (project: my first 20v)
2007 Mitsubishi Raider(Dakota in disguise)
2019 Chevy Cruze RS hatch (wife's little red sporty car)
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Re: Ben's 95 90 Quattro 20vT - now with corn power!

Postby Grillage » Mon May 20, 2019 7:06 am

alxdgr8 wrote:What was the reason why you think the first broke? I've got the same kit waiting to go on my UrQ with a B8 S5 booster/MC.

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A couple things - When I pulled it from the Phaeton at the upull yard, I didn't know how the rod was connected to the brake pedal. Eventually (it was raining on me and I was about to give up) I just yanked the brake pedal toward me hard and the metal ball on the end of the threaded rod from the booster popped out of the plastic socket on the brake pedal. Pretty sure it cracked then but still worked. When I reinstalled the booster after my steering rack job I had to pull from that same backside to get it through the firewall and I believe that's when it REALLY broke.


I now know that there is a VW special tool for removal - but also another way to remove. On the junkyard A4 I got my replacement from, I basically unscrewed the ball piece and it pulled right out (in photo below at top):
Image

So basically, don't be a dumbass, and you'll be fine!
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PAST
1993 Audi 90 CS Quattro - 1990 CQ - V8 - 1995.5 Audi S6 - 1993 Audi V8 - 2013 A5 Prestige - 2011 A4 Avant - 1986 Maserati Biturbo Spyder
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