My silver RS2 Project

[Tractor Dave]

There was quite a bit left!


I cleaned the last bit out with an old towel.


The basket got a really good wash


And dry


I'm changing the cap seal.


These are the lugs that slot into the basket holder. There is a mark on the basket that needs to line up with a mark on the basket holder. Rotate clockwise to re install.


I put some Vaseline on the slots to aid fitting. Once you get the basket in the right position it's just a matter of giving it a whack in the right place.


My boy is 3d printing me a tool but it's in development.
Just waiting for a pair of new crush washers for the outlet on the tank cap then I can finish the job and test the car.


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[GT500]

I'm just on with getting my ur running after a 15 year sleep. Petrol side of the operation is definitely a pain. I'm nearly there. The banjo on the pump had rotted through! Made for smelly garage!

[Tractor Dave]

So this morning I investigated further.
I drained some petrol from the tank as it was almost full.


My tank cap is a little ropey if anyone has a good spare.


Bingo! What's this crud?


The bottom of the fuel pump filter is almost completely blocked!


And some old silicone sealant. Never ever use this to seal your tank cap!


So I need to remove the basket to clean it and fully drain and clean the tank. Yes, I know, I should have done this before fitting the new pump. Doh! What a #### I am sometimes.
Anyway, getting the basket out is easy when you have done it a few times. The right size length of timber, placed in the right place and a couple of gentle blows with a large rubber mallet is all that's required. Remember that you want to turn the basked anti clockwise.



The basket is also quite dirty.


And underneath even worse.


The difference between Rs2 (left) and S2 Avant basket.


So now I need to drain the rest of the fuel, clean everything up and put it all back together. Phew.


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[Tractor Dave]

Unfortunately boost is still being cut.
I ran the fuel delivery test again and I'm still not getting the volume I should be.


I've had a good look in the tank and everything is connected fine with no kinks in the pipes or anything loose.
Has the pump gone faulty after just a few hundred miles or am I missing something.



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[Tractor Dave]

One thing i forgot to mention is that doing this mod makes it really easy to fit a hidden immobiliser. Just a simple switch in the trigger wire or battery feed is all you need

[Tractor Dave]

Ok. A small update. I was reading up on this fault code at S2 Central. I think I have eliminated boost leaks, vac leaks and ignition system. So this is fuel related. Either delivery or monitoring (MAF or oxygen sensor).
So I thought I would check fuel delivery.
I have a copy of the RS2 manual and this is what I should be seeing at the fuel rail.


So I disconnected the feed pipe and ran it into 1 litre bottle. I then jumped the fuel pump relay for 15 seconds.
I got approximately 400ml. That's not good.
So I did a little digging and found this!


This is the connector for the fuel pump. Just about hanging in there!
So, whilst fixing this I decided it was a good time to do the relay modification. Not difficult. I've done this on all my previous projects and it was on my jobs list.
An old vac pipe helps running wires in awkward places.


I've included an extra fuse on the live connection.


Avant fuel pump and sender wires run through here under the back seats.


A mess.


And after some Tessa tape and a tidy up.



I need to make a mount for the relay which is temporarily wrapped in some foam.
I've tested everything and car runs and fuel gauge works.
Road test tomorrow. Fingers crossed this has fixed the issue.


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[Tractor Dave]

Ok, thats useful to know. I fitted the new one which arrived this morning. I took her for a drive and I'm still getting boost cut. So might be the maf pins.

[GT500]

I think mine was at 4.1 on tick over. Not much higher but enough to upset it. It did take a few hundred miles to get to no codes after the new reg.

[Tractor Dave]

RS2 one is 0.2 bar lower. Are both of yours the same part number?

Hi, yes. Aware of that. I have a new 3.8bar on order. Was just trying another I knew was working. I didn't think it would make much difference. I will test again when the proper one is fitted. Thanks for advice. Always learning with these cars.

[GT500]

RS2 one is 0.2 bar lower. Are both of yours the same part number?

[GT500]

Aby is different.

[Tractor Dave]

Thanks for the tip.
Did a boost leak test. Nothing major at all. Tiny weep from the n75 which I nipped up.



I had an ABY fpr spare so swapped it over.


Still the same.
Tried swapping out the coils. Made no difference. Swapped the MAF. No difference. Cleaned the MAF pins. Still no good.
Read the codes again.


Have I got a faulty oxygen sensor? It's brand new. Humm


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[GT500]

When mine was throwing 561 it was the fuel pressure regulator. Worth testing what it's doing.

[Tractor Dave]

Yes, they just press onto the metal tab thats welded to the sunroof and the lever dowel clips into the round part of the clip.

[andyg plym]

They sit at the bottom of the lever which pushes the flap down when you move the roof forwards. See the parts diagram on previous page.

dave not sure if I’m missing more than I realised, your prints - do they just clip in?