My silver RS2 Project

[Tractor Dave]

I started re fitting a few bits in the engine bay yesterday. I made a new short piece for the coolant hose and got it fitted with new Norma stainless clips.


Then I went to get the next hose and remembered that the RS2 uses a different hose. Doh!


So before I tighten this up, could someone with an RS2 confirm the route this hose takes to the bottom of the coolant reservoir?
Also did a few other little jobs like tightening up the crank bolt to 450nm. Big boys toys required for that.








Then I went to fit my nice new shiny oil cooler. I however hit another problem. I don't seem to have the shroud. They normally rot out so I'm not surprised. Has anyone either got a good one for sale or one they could take measurements from so I can re make one?


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[Pitcaig]

I think TRW are a good choice.

Just checked the ones I taken off which are marked with the VW AUDI logo on them and TRW. So looks like TRW made some genuine ones also.

[K Simmonds]

The original discs i have here have steel bells. Unfortunately, one is cracked so I'm not able to re use. I did some research on the forum and I'm 99% sure the new ones I got will fit. Dimensions appear the same. The replacements are single piece but appear good quality and are made in Germany.

That's great news! As separate rotors and bells are prone to cracking, especially if they're cross drilled, a single piece steel disc really is a better job for a road car.

I expect you will already know to paint the un-swept area with VHT, I'd go for black or silver.

[Tractor Dave]

The original discs i have here have steel bells. Unfortunately, one is cracked so I'm not able to re use. I did some research on the forum and I'm 99% sure the new ones I got will fit. Dimensions appear the same. The replacements are single piece but appear good quality and are made in Germany.

[K Simmonds]

I have the latter spec larger diameter front brakes and they're rotors on alloy bells if I recall, can check in the morning as I'm spending this week in the workshop,

[Rikki Kitto]

Look like the Jones I got from German eBay about £400 with tax I think

[Tractor Dave]

I've been hunting for new front discs for a while. They aren't that easy to find as I have big reds.
I found these in Germany for about £100 cheaper than UK price. Unfortunately, I got stung for import duty which was, you guessed, £100!
I hope they are the right size.





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[Tractor Dave]

My boy gave me a hand and we got the engine in.
First fitted starter motor


And the bell housing sensors.


Double checked the timing and I'm good.



Rs2 timing is slightly different!

Just goes to show you can't rely on the timing mark on the damper which is well off!


Then I got things lined up.



The turbo is the awkward bit but is easier than fitting it afterwards.



Then the gearbox jacked up and the subframe fitted.







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[Tractor Dave]

It was hammerite Kurst. It wont last very long. It will flash rust after the first hot run but makes me feel better.

[Timo]

Hi,
which rust converter did you use for the exhaust manifold. Looks amazing.

Thanks Timo

[Tractor Dave]

So the gearbox and engine are ready to be re united.


And my friend (who is also called Dave) came over to give me a hand.


It's far easier with two people when the engine is on the crane.


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[Tractor Dave]

I finished cleaning the flywheel.


It appears to be from 2007


There are a few heat marks but nothing major. All the old oil has been removed using brake cleaner.

Then it was time for the engine to come off the stand.

And fit the flywheel.

These bolts are the same size as original ones which appear to be nla. Apparently they fit a Volvo.


I bought this little gem from Alex a few years back. It's very handy for locking the flywheel and torquing up the bolts.

30nm plus 90 degrees.

Then it's clutch time. My cheap alignment tool in action.

New cover bolts plus thread lock.

And 25nm



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[Tractor Dave]

Coming together nicely.

I haven't fully tightened the crank bolt yet. I need to fit the flywheel and double check the timing marks before I can do that and also it's difficult to do 450nm on the stand.
The flywheel is getting a tidy up and that all important mark highlighted.





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[Tractor Dave]

New heat shield made.


I've tied back the loom ready for the engine to go back in.
The vibration damper has had a clean. I have one of James billet sprockets and new bolts.

I also have a new oe crank bolt.

Next job is to fit the belt and check the timing.


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[Tractor Dave]

Ok, I've fitted the aircon pipe where it seems to want to go. Let me know if you think something isn't right. A couple of the purple seals were missing but fortunately I happened to have a few good spares.




Next job on the list is to make a new heat shield to replace this one which is past its best.



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