My silver RS2 Project

[johne]

Looks like mould to me.

[Tractor Dave]

Yes. Was some kind of fungal growth.

[Tractor Dave]

I got a few jobs done today.
Rear end is coming together nicely.
I used a tap to clean up the threads before re fitting the shock housings. They have quite a bit of paint in them.


Then everything bolted up nicely.



I only have one good rear abs sensor. I did however have a new A4 TQS one spare (as you do). So I did a little surgery to splice in a sensor from a good S2 front one. Sensor back is identical to S2 Avant and Rs2.


I made the join where the wire is plated down so it's well protected. A length of old vac line is perfect for getting the wire in.





Thanks to 'The Spanish' for sending me a pic of the handbrake cable route and some clip ideas.




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[Tractor Dave]

I'm ready for my rear driveshafts but they aren't ready for me.


So I set about removing the joints.


Rear outer have the horrible locking circlips which are a pain to release.

Got there in the end. Ready for the wire wheel.



Got them cleaned nicely and first coat of primer on.
Joints next on the list for a clean and paint.
I was surprised to find that RS2 rear driveshafts are equal lengths and have identical part numbers.




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[Nuvo]

I was surprised to find that RS2 rear driveshafts are equal lengths and have identical part numbers.
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Exactly the same part number for the S2 Avant too. Progessing nicely.

[Tractor Dave]

It's so long since i did my Avant and too many Coupes since then

[Tractor Dave]

I spent the morning cleaning cv joints. What a pain.




Then this afternoon collected my block and head from the engineer.
I haven't had a chance to check things over yet but apparently everything came out lovely.


The only exception being the bill of course.


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[K Simmonds]

All looking great Dave, am guessing you had the block lightly honed by the looks of it, are you doing the full engine rebuild yourself from this stage?

The S2 Avant and RS2 share a surprising amount of parts, I know the dampers have a different part No but I'm pretty sure the springs are the same, mine is fitted with stock S2 Avant air-con springs which look identical to RS2 items and feel the same to drive. Much better than the lowering ones that were fitted when I got the car.

VAG outer CV joint's can be a bit of a sod to knock off, I've got a heavy copper faced dead blow hammer I use to whack them with, I can normally manage to get them to pop with one good sharp blow, but I've probably removed 100's... However, if the hub bolt threads all the way through the CV joint it can be used as a puller against the end of the driveshaft to pop them over the clip which is how I do it given that option.

[Tractor Dave]

Yes, it just needed a light hone. I will be rebuilding with some assistance from my mechanic friend. I have some pistons coming in the post (hopefully tomorrow) then can make a start over the weekend. The front outer cv joints were the hammer off type and came off easily. The rear outer had the circlip thing which must be opened out before being tapped off.

[K Simmonds]

Ahh, yep, those type of outer CV joints are indeed a bit of a sod.

Building up a stock engine isn't that difficult and the end result is highly rewarding, it's time consuming making sure everything is spotless and you need the right tools, a good piston ring compressor is a must which I'm sure your mechanic friend has.

[Tractor Dave]

I made a **** up. Doh.
This part of the loom needs to run up inside the brake pipes. And there wasn't enough space to pass the loom back up so I had to remove the pipes again to make access.





We got there in the end.

Drive shafts ready.



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[Tractor Dave]

So the drive shaft paint was dry enough to assemble. I discovered an issue with one of the rear inner cv joints. It had a significant wear ring.

And the balls were all dull.
Fortunately, I have a few spares from the S2 Avant I broke a few years ago that are good.

Nice bright balls!



And we re assembled one shaft. Insulation tape helps get the new boot on.


And the best place to store an assembled shaft………on the car of course.



I shall get the other back one done tomorrow.


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[ottawa coupe]

Cv joints are one of the more annoying jobs imo. Probably because traditionally i have done them in the dead of winter in unheated garages lol.

Looks great though!

[Tractor Dave]

I'm still trying to source a good standard piston so just doing a few small jobs before I re build the engine.
The pistons have been soaking in heating oil which is a great solvent.

The oil squirters are also getting a clean.

And a blow through with the airline.

Pistons scrubbed with an old firm toothbrush. Before.


And after.


The pistons are all in excellent condition apart from the damaged one.
Then the oil squirters got installed with a healthy drop of loctite 243 on the bolt threads.
Magnet tool useful here.


Little Allen bolts were cleaned in brake cleaner before being re fitted and torqued to 10nm.



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[Tractor Dave]

Today the oil pump got a strip and clean.

Screws are tight.

Very clean inside and minimal wear.



The casing got a good clean.



And the inners.


These little pipe cleaners are very handy for the little oil ways.


I used some assembly grease on the gears.

And a little thread lock on the screws. Torqued to 10nm.


And new seal fitted with just a light smear of rtv on the outer surface.



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