Update on my £10.5k / 104k mile Noggy...

[neckarsulm]

..I've been a bit quiet about my own car following the diagnosis that the hot rattle from front of passenger side head was the cam chain tensioner so here's where I am at the mo;

I knew I had to get the thermostat replaced as it was sticking open so had budgeted for a cambelt job which would only be around 10k miles early and as we were initially thinking it was a belt tensioner rattling it would have killed two birds. However after some probing we realised as suggested on this forum that it was the cam chain tensioner.

Both cam covers were removed (the offside one just to check the cams which were in very good order).
There is a good diagnostic procedure for the chain tensioners in ELSA but we decided it couldn't be anything else so I ordered the part which was around £400. Interestingly ELSA says only start the diagnostics on the tensioner when the engine is above 80 degrees which was exactly the temp when mine would start rattling.
I also ordered all the cambelt parts inc aux belt tensioner.

It took around 4 weeks from initial diagnosis to completion yesterday due to the time pressures of getting together with my RS4 driving mechanic who as you can imagine is in demand especially as he has the correct cam locking tool. On removal the cam chain tensioner had indeed seized, the auxiliary belt tensioner which was probably original was scrap too as was of course the thermostat.

While waiting I took both bumpers to the bodyshop to be repaired and repainted. The front had a crack at the bottom of the nearside air intake and the rear had one near the load lip.
They had to drill all the rivets out to remove the reinforcer from the back bumper to get at the crack but it was all put back perfectly with new speed clips supplied for the screws in the wheel arch.
This is their web site - as an example of their work they are currently working on converting a new shape M3 saloon to an Estate.
http://www.sprintautos.co.uk/
Will post pics of the results but I am very (and not easily) pleased.

On reassembly I got flummoxed trying to pull the headlamp washer jets up to refit the painted square covers as they are really stiff and hard to grip but managed in the end by sticking a small allen key underneath the jet and pulling up.

I removed the black plastic grille inserts from the rear bumper as didn't want them masked out and I am two minds as to whether replace them or use double sided tape to secure them on as the plastic pegs on back are so flimsy that most broke when trying to remove the securing nuts.
Anyone know how much they are? They look cheap but...

I also took the opportunity to fit new clips to the front bumper centre grille which like many wasn't secure all its way around.

The scoops for the intercoolers are rivetted onto the coolers and some of these had been broken when the impact occured to the front bumper so I am in the process of rerivetting these, drilling new holes where needed.
Also got a leak from washer pump which is common - seems to be from the base of the pump.

I should have it all back together by lunchtime today though envisage the front coming off again soon to do washer leak and sort the weird sounding horn but I can live with those for now!

[grizz]

Glad to hear it's going well , I've had several 100,000+mile car's in recently and they have all been in good shape.

Keep us informed .

[neckarsulm]

Cheers Grizz.
The beast is back!
The rattle has definitely gone now so that's good.
Will need to get bumpers off again soon to refit the grilles on the back one and sort out the washers on the front.
Has anyone had trouble with the bottom of lamp washers foulding the intercooler scoops when sliding the bumper back on? Is there a technique?
Also can anyone confirm where the washer pipe within the reinforcer should sit in relation to the bumper retainer that sticks out of the chassis leg?

Misfire at idle seems better with new plugs.

Next jobs are oil change (easy compared to what has been done!), fit W8 undertray and then paint rectification followed by though interior clean.

Should have had the tailgate handle painted with the bumpers as it's got some corrosion so one for the distant future...

[Contigo]

Fair play, that a lot of work and I'm glad you have the people in the know as it would have been alot more costly.

[Virdee Autos]

Looks like your getting up to a good presentable state now....with most jobs done!

The washer pipe, on both sides, should sit behind the reinforcer/shock (where the main bolt goes through to hold the bumper)

[neckarsulm]

Cheers guys, had a great drive in it today and nothing fell off!

virdee, thanks for reply re washer pipe.
You say behind it so - just to clarify - do you have to hook it over the shock/bit where the bolt goes as you push the bumper on as naturally it would sit in front of the shock bit as the pipe resides in the reinforcer?

[Virdee Autos]

Yes hook it over the shock bit.

[neckarsulm]

Yes hook it over the shock bit.

makes sense, will do, thanks!

[neckarsulm]

£30 a piece for the rear bumper inserts + VAT is a joke which means I think they are going to get cleaned up dressed and reattached with sticky pads.
Washer pump is in stock at £30 or so - same price as one flimsy plastic bumper insert!

[neckarsulm]

Can you believe it, the mechanic that did the engine work ran his van across my offside front bumper corner today just catching the wing by the bumper too - luckily I hadn't paid him for his work yet and it's only paint, no dents.
So it's going back to Sprint in the near future when I may as well get both wings and the bumper done to sort stonechips.
I'm also going to remove the tailgate lock panel as it has the usual corrosion and get that repainted at the same time and that will be it for bodywork, I hope..

[stumpyrs4]

Doh !

[BAX123]

That is a bad stroke of luck my man. out of interest though could you pass on the price u get for the paint work, just so i've got a price comparison, i'm also looking to get my tailgate lock panel, front bumper, and wings resprayed. bloody stone chips.

Thanks in advance

Mike

[neckarsulm]

Doh indeed!

That is a bad stroke of luck my man. out of interest though could you pass on the price u get for the paint work, just so i've got a price comparison, i'm also looking to get my tailgate lock panel, front bumper, and wings resprayed. bloody stone chips.

Thanks in advance

Mike

Will do Mike, I have used a few bodyshops in the past but Sprint are a cut above and close to Greg Howells level in quality so they aren't cheap but good paintwork never is.

[mbelle]

Where are they based neckarsulm?? B'ham area?
My tailgate has the usual corrosion as well and I badly want to get it sorted, but haven't had chance to pull it off myself.

nickwigan did this himself on his Noggy - sanded it down to find it was an ali piece, so he stuck it back on without painting it - looks quite good in contrast with the mirrors and rails; I was thinking of doing this as well, as I think it would look OK (and probably quite OEM, without the respray costs) against Avus...

M

[Virdee Autos]

I did this ages ago....one of my first mods. As has been said, mine had also corrossion on it.

Bought a new one, and sanded it down with wet n dry.