My silver RS2 Project

[Tractor Dave]

Old seal out and in with the new.





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[K Simmonds]

Good news from the machine shop. My block has measured within tolerance and just needs a hone. The crank is also good and just needs a light polish.

So I'm after a couple of standard size pistons in good condition if anyone has any for sale?
Also after recommendations for main crank bearings and where to source plus piston rings and big end bearings?

I'd try and get the bearings and rings from TPS if they still stock them and aren't too expensive. There's so many knock off parts on the market now that I don't mind paying a small premium for the genuine article. My trade account is still active and I could try pricing them up for you.

Good news on the crank and block, things can start getting expensive if there's machine work and oversize parts required. All the various S2/4/6 pistons are the same which you probably already knew, it shouldn't be too hard to find a couple but good luck non the less!

If I had to guess I'd say the bearings are probably Glyco and the rings Victor Reniz but I'm far from 100% sure. I do know the RS2 uses sputter bearings for the upper big end shell's as they take the most stick.

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[K Simmonds]

My cave may hold what you need Dave

If John can't help I've got most the parts to build a stock RS2 turbo knocking about as well as a billet wheel K24 7200 K26 hybrid ready to go I'd be prepared to part with.

[Tractor Dave]

Cheers Kit. I will try TPS first but searching the forum suggests CS parts in Germany are a good supplier.
I have a seemingly good original Rs2 turbo here and John's EM has my name on it

[K Simmonds]

Cool, having a serviceable OE turbo is a bonus even if it needs a rebuild, though as long as it's been stored in the dry, spins smoothly and has zero end float it should be okay to use as is. I'd suggest popping the the turbine housing off to check for cracks before you fit it, be a good opertunity to check the condition of the turbine wheel itself as well, though it should fine. Those old KKK journal bearing turbos are really remarkably tough units.

Finding a good OE RS2 EM is ideal, John to the rescue yet again, has to be the most helpful guy on here! Don't worry about a few hairline cracks around the flange for the turbo, they almost always have a couple.

I've got an extremely good copy as my spare EM, it looks OE aside from being missing the Audi logo after the part number on the underside otherwise the casting is identical. Had one from the same batch on my S2 and actually thought it was genuine, didn't crack in 30K miles of abuse so the material must be pretty good.

If you don't get any joy with TPS Alex might worth a try for bearings and ring's, didn't occur to me last night, he'll know where to get them at least I'd have thought.

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[Tractor Dave]

Busy day in the garage.
The RS2 water pump is nla, even at Tradition. The only difference from an ABY pump is the pulley. Chef here was doing a billet rs2 pulley but I can't seem to get hold of him. Anyway, I have a new SKF ABY pump here and it was really easy to swap the pulley over.





I've been cleaning down bits under the car that haven't been done and painting.



I'm missing the oblong grommet here if anyone has one?


It was an unusually warm day here today and ideal for topping up the cavity wax.



Can anyone tell me where this wire enters the car? It's for the number plate lights in the bumper. Obviously rs2 specific.




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[K Simmonds]

That body work looks to be in pretty exceptional condition underneath, a bit of rust here and there is to be expected, you've dealt with much worse. Good to know the water pump pullys can be swapped, it's a bit of a pain having a unique belt etc. Not sure why Porsche decided the water pump needs to spin slightly faster, the stock ABY ones can easily manage to handle just as much heat.

I can have a look in my boot tomorrow, I need to get in there regardless, I really should reinstall my boot handle. It's currently easier to open from the inside and full of parts.

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[Scarecrow]

I can’t express how much joy is kindled when I see you’ve posted an update Dave, I always enjoy reading your project threads

[Tractor Dave]

Thanks Kit and thanks Scarecrow. I'm enjoying doing the work while the weather is nice.

[Tractor Dave]

So after removing the bumper it was quite obvious where the wire enters the car.



Whilst checking the fuel filter I found that it was held in with a cable tie. It was doing a good job but not quite up to my standards.



The little Allen bolt was seized solid and I had cut it out.


Some stainless bits and we are good. The filter is a new Mann one.


Whilst the tank is dropped down I cleaned and painted the strap bolts.


Whilst rummaging in the boot I found these. Nice. The hall sender box was empty and has already been fitted. I knew this as they cut the old one out but left the plug in the holder.



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[John.]

Not sure why Porsche decided the water pump needs to spin slightly faster, the stock ABY ones can easily manage to handle just as much heat.

So the pulley has less teeth, they must know that cavitation won't be an issue so must be to circulate the coolant better at idle then ?

[K Simmonds]

Yeah the pulley is either one or two teeth smaller, would have check that. I have to wonder if a design engineer at Porsche got bored one afternoon and did it just for the sake of it. There must be a good reason but given the amount of 400+bhp ABY S2’s that have no issues with cooling I can’t think of one.

[Tractor Dave]

I have no idea why either but want to keep it oe as far as possible. A very expensive oe belt is on its way from Germany.
Another little job that needed doing.
The brake pipe front to rear is copper and would be fine to keep but it's a little squashed in places so I made up a new one. Don't forget the fitting!



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[K Simmonds]

The timing belt on an RS2 is a little tricky to fit as you'll find when the bottom pulley is on it's mark the one on the camshaft pulley will be half a tooth to left of the mark on the cam cover. There is quite a detailed post on here regard the subject but it was many years ago I read it.

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[Tractor Dave]

Cheers Kit. Read that a while ago and ready for it when i re build the engine