By the end of March, the car had been moved out of the old location and the drive down my narrow road was epic. Not only that but the neighbour had otherwise decided to drive up the lane as I was going down…. No problem just reverse right, well… The transmission kind of refused to “R”, turning it to a bit of a panicky moment. Anyway the neighbour managed to reverse and we squeezed past each other, she gave me the “look” (she’s nice) but I don’t think she recognised me and though “what the heck is this guy doing down MY road!” lol.
Anyway. Then the transmission decided to actually reverse, go figure. Just another oxidized episode I guess.
Wipers
First job working out the wipers or lack thereof, removed the wipers unit from the car. One of the the motor brushes was not connecting. Gave it a good clean and the motor and gear work as intended but the gearbox was making a whirring noise. Ordered a cheap compatible motor with different connector. Had to open the old gearbox to figure out the way it worked, then trial and error to make the new motor work the same way, quite easy when you know how!
Then the mechanical side of it had to be modded also.
Plenum
The plenum which sits in front of the windscreen and contains air intake and more importantly the ECU box, was filled up with tiny polystyrene balls caused by the house roof being insulated with that stuff years ago, it was everywhere, and more than 6 months later, I still find them! In addition to this, lots of organic matter was also accumulated. It took me about 2 hours of using compressed air and vacuuming to get most of it, all drains were cleared.
ECU Box
The ECU box was very worring, there were traces of moisture and the ABS ECU was showing great signs of water oxidation, Thanks to the great folks at audiworld.com Forum for their recommendations to double my efforts I think I might be able to get to the bottom of the issues plaguing the electrical gremlins. I spent a whole day de-oxidizing all the ECU box connectors and sockets (a total of 18 of them!),
How to clean heavily oxidised connectors?
- Take white vinegar and a load of table salt (saturated, which means cannot dissolve anymore) preferably warm.
- Dip or brush connectors one by one in the solution for about 15 minutes
- Neutralize the acid with warm water with lots of baking soda, again to saturation,
- Compressed air dry
- Optional contact cleaner
Resulting in a car starting (almost, see below) and all engine and Transmission Faults cleared and staying so!
However, I still was facing issues regarding the main relay which prevented the car from starting, strong smell of fuel, wiggling relays in the passenger foot well remedied the situation, probably doing the same clean up exercise there would definitively help also.
Few issues still, the orange rubber seals on the box marked “Benzin” in the ECU box was giving me trouble and had to smother them both with silicone to facilitate the connectors’ insertion, as they were losing their shape when inserting the connectors.
The surrounding rubber seal of the ECU cover does allow water to seep through at the cabin side due to the fact that this cover slots into catches and does not seem to provide good seal, my tip: add atop layer of plastic sheeting slide it between the lower windshield frame and said box half way to the front and tape it on on the forward side, so far seems to sort the water ingress.
The only fault remaining after is the “606 rotation rate sensor-Faulty” which is the black thing under the passenger seat, ordered a second hand one from Latvia and voila! ABS light cleared!
Botang’s Hole!
For those in the know, this has to be the weirdest bit of Teutonic engineering I ever got to face ever. Mr Piesch, were you on holiday that day? How could you let this slip up. Basically the Botangs hole is a opening located in the back of the plenum under the AC piping (and for a RHS steering), under the ECU box, that is covered by a bit of card board painted over, that’s it! Over time, this cardboard fails and water penetrates in the cabin, on the footwell electrics, like relays and connectors making the whole left hand side of the car footwell under the carpet a swimming pool!
Proceeding to patch that hole completely eradicated the problem, except that there is also the issue with blocked AC drains by the transmission tunnel, on both sides. Yet another German engineering blunder, probably a Friday afternoon design devised around the pilsner Keg Ach, as the car had sat for 9 years, there was a lot of debris in the air system, which translate to hearing the sea when the fan is running and the passenger getting a foot shower when turning sharply to the right. The easiest side to drain the excess fluid and clean the pipes is on the left hand side, bearing in mind there is a drain on the left also! Bah. Whassever.
Still, had to contend with moisture under the rear left passenger carpet, I still don’t know where the water came from, perhaps the door seal is not too good, but it is not overly worrying, everything is dry where it matters now.





















