My silver RS2 Project

[newsh]

I've checked and double checked but unfortunately the last owner got these fittings the wrong way around when replacing the fuel pipes.

I confirmed it by blowing air down the return line.

As my flaring tool can't be used on the car I had to cut each pipe, swap the pipe nuts over and add a flared section.


The joys of restoration.


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Good save though Dave, if you hadn't spotted that it would have been a serious head scratcher!

[Tractor Dave]

Yes, It was fortunate. I'm not sure if the ends should be straight mind. My Avant has them bending towards the braided fittings. I guess i will find out when the engine is back in.

[Tractor Dave]

Anyone have a good clear pic of the engine bay without the engine in but with the aircon pipes fitted. Needs to by aby or RS2 and right hand drive. Thanks

[Rikki Kitto]

My lines were fitted wrong way round after I had my fuel pipes done it was a bit scary watching the fuel bubble out of the filler cap when the pressure built up too much

[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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[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]

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]

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]

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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[Timo]

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

Thanks Timo

[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.

[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]

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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[Rikki Kitto]

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

[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,