Do you need the orange hose between the turbo and IC? If so i have a fully functional one i dont think i am going to use ever.
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Audi RS2 -94 Swe
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So, today was work day in the garage, i woke up a little late but i think i managed to do as much as i wanted to today.
The block was cleaned with break cleaner from dust and stuff since i clenaned it last time with brushes. Blew it off with compressed air in all channels.
Cleaned the oil jets for piston cooling and installed them, loctite and 10Nm according to manual.
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Oil jets installed in the block:
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Bearings installed in the block and lubed up with assembly lube:
45764-12e6f0cddf2a4b4a5c8219623f8c4079.jpg
Crankshaft cleaned for the last time. Put some lube on the bearing surfaces and on the surfaces for the thrust washers:
45764-341a86858c8ce8e3e49efd65712198a6.jpg Crank installed with factory bolts, no need to change them according to manual. Torqued to 65Nm with oil between contact surface and bolts. Bearing caps should be intalled with bearing caps number (1-6) facing the exhaust side. Nr 1 closest to pulley side:
45764-a301e74c27a22a705cdc09e61bbed1a8.jpg Conrods all lubed up and ready for install with new piston rings. Rings installed with 120 degrees gap between the ring openings. New bolts and nuts as manual says they have to be renewed when dismantled.
Torqued 30Nm+90 degrees according to manual, oil the surface between nut and conrod:
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Conrods installed with "lugs" pointing towards pulley end as manual.
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Pistons installed, valve pockets facing intake side. Hopfully i will not have to see them ever again after i put the head on
45764-600c2aaf6c15d839c4d895724a43164f.jpg Not to forget, install the check valve! Installed with loctite according to maual and 6Nm:
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The ADU head nr 002094 , it should be just PNP as it is overhauled by the last owner. New valve guides, sealings, grinded seats, valves and resurfaced. The lifters is as far as i know the olde one's. But i will take my "new" lifters from the AAN head that i had for one summer on the Urs4. It would be stupid to run it without changing them. I hate noisy lifters
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That's all for today. On monday i will leave the aluminium parts that i glasblasted to the painter. Can't wait to get them back so i can continue with the assembly.. Then it will start to look like an engine again!Last edited by s0_big; 8 June 2019, 21:47.
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Bra jobbat! Skƶnt nƤr folk rƤddar klassiker =)
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Parts delivered to the painter yesterday. After some thinking and looking at colours I choose to go with a colour from Porsche called GT-Silber effect. On their cars it will be with shiny clearcoat. I don't want "shiny" so I went with a matt clear coat. Hopefully it will look good. Don't want to blast everything again
Today I sorted out some bolts and brackets thats going on refurbish. Will be yellow/gold galvanized as it was from the factory. The "aluminium" colored bolts is harder to get refurbished around here. So i think those will be stainless instead. Maybe I manage to leave them this week.
Picture of bolts/brackets:
20190108_151102.jpg
āāāāāāāLast edited by s0_big; 8 January 2019, 18:58.
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Todays "funny" work... Will leave it for refurbish tomorrow.
45764-343aad6ed0cedfb18224cb4b9e01f757.jpg Also got my sump baffle from Thuppu today. Thought it would be good later on track days!
45764-a53cbd1754791206ab116530a1e80ee6.jpg
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Yesterday i got some time in the garage for the RS2. Like i said earlier the head was refurbished by the last owner (newer) mounted. The lifters they didn't change though. As the car has about 240 000km on it it thought it was very stupid not to change them. I did have a spare head from the URS4 that i had brand new lifters in, so i dissasembled the head and took my new lifters to the ADU-head. I can' stand noisy lifters
Happy i changed them, there was some old burnt/lose oil particles under the lifters, the company that refurbished the head didn't clean them at all.
Head without cams/lifters:
45764-249d83047e554775930c909c9de4910d.jpg The old lifters, lots of dirt underneath. And it was loose to, happy i changed them:
45764-0094f695f4f7cd19479cf16724f5a399.jpg The new lifters in place, lubed up with lots of oil:
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Camshafts in place and alligned, caps tightend to 15Nm, waiting to get mounted, will clean the outside of the head a bit more:
45764-8d45740728fb2700ec80eb9bd662d1c7.jpg
Last edited by s0_big; 13 January 2019, 18:37.
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Little bit of christmas for me today! The painter called an told me to pick up my alumium engine parts! Said and done
Really happy with my choice of colour and clear coat. Porsche's own colour GT-Silber effect with the matte clear coat.
Here is some pictures of the stuff, hard to get the colour right, but this is what it looks like.
45764-a7c28d348043be5b4a876222e3176f19.jpg45764-e2796bb61a1ef49da3c11132a2df0e32.jpg45764-6c4b7bf8f480e944a2098e818f1ceb6b.jpg
Now i have to clean the oil filter house and theoil pump so there is no glas left from the blasting. Otherwise it's just a time of waiting until i get my bolts back so i can start assemble the parts!
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Today i had some time to burn in the garage. I had to clean the oil pump and oilfilter/temostat housing from the glasblasting. I halso had time to take away the masking from the painted parts.
Started with the oilpump, here it is totally in parts, cleaned and ready to assemble:
45764-e76f857104b954522e2fc148bd25271d.jpg
Assembled with new crankshaft seal:
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The oilfilter/thermostat housing in parts, cleanead and with new fittings to oil cooler:
45764-c9388c4ed8da3dcfb525da7614ed3590.jpg Assembled again.. :
45764-8e43ec23f6c62cc2bf4e0b023e2e6525.jpg
The idling motor also got some refurbish:
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I have lots of stuff to do, but it's coming together as fast as i can. All cleaning and looking over stuff takes time. I'm still waiting for my nuts/bolts then i can speed things up. Will fit my new injector seats next time i do a visit to the garage, and maybe fit the oil pump. Thats all from todays workLast edited by s0_big; 22 January 2019, 17:52.
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Today the company that electro galvanized my bolts/fasteners called and said they were ready for pickup. Glavanized yellowish like the original. All good besides the bolt that holds the oil filter housing, i will leave more stuff so i will ask them to remake that one later. Otherwise all looking very good i think.
45764-f05f747fa19d9a0eb96cabe9b88c7de5.jpgLast edited by s0_big; 23 January 2019, 21:42.
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The whole project is very nice. Only downside of making everything shiny like new is that you don't dare to drive the car anymore.
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Originally posted by Thuppu View PostThe whole project is very nice. Only downside of making everything shiny like new is that you don't dare to drive the car anymore.
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Garage time again, installed the sump baffle from PKKM (Thuppu). Will maybe help in the future at trackdays. I also mounted my new injector seats in the intake. Really nice pieces. As the screws/fasteners turned out so good in my opinion, i left the rest of my stuff for the same treatment. It matches the Porsche paint really good i think..
Sump with baffle plate:
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"Extra pocket" installed with refurbished bolts:
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Injector seats installed in the intake manifold, used loctite 148 for gas,oil:
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Fasteners and stuff going to be electro galvanized yellowish:
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Today i got my bearings for the generator. So tomorrow i hopfully have time to assemble it
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