S2 ABY 400cv Project

[javispa]

Hi all you guys.
First of all, let me introduce myself: I am Javier, from Spain, and I have a S2 3B Coupe, with 125.000 miles (more or less). My plan is to upgrade my engine to RS2 specifications, but I will start my project probably in half a year or so.
I have decided to open this thread to show you what has been done to my friend Kilian's ABY Coupe. This project started probably a couple of years ago, but now, when it was nearly finished, it has appeared some internal damage to some parts of the engine, which makes us doubt of what to do. But I will tell you about this later... now, let's talk about what has been done to the car.
I will talk only about mechanical modification (things relating to the rims, or mph and rpm watches will not be explained, unless somebody asks so), and excuse me if the quality of some pictures is not good... they were taken using a mobile phone.

So... let me introduce you the car. It is a 100.000 miled S2 Coupe ABY. It gave (stock) 257hp on a dyno run before the project started. Here is the result of the dyno run and also a picture of the engine, before everything started .

[javispa]

Kilian was very happy with the car, but wanted more (seeking about 400hp). So some friends from the spanish Audi forum (audisport-iberica) started to talk about what could be done (there's another project from Ferni308, another friend of the spanish forum, a 3b with RS2 specs which is nearly finished and with good results) to the car.
Kilian decided to base his project on a KKK K27 turbo, and he also bought some other pieces.

Picture of the engine showing the camshafts. Ready to fit the new set up:



The turbo and the 5 to 1 exhaust manifold:



The turbo comes from a BMW 745 i. This BMW mounts a 3,2 liter 6 cylinder engine with turbo, with 252hp, but I assume that the turbo is able to produce much more power.



When my friend bought the turbo, he did not know which car it came from. At first he was a bit disappointed when he discovered the car the turbo came from had only 252hp, but when we saw the size difference between the K27 and the stock K24, we realised that this turbo could surelly produce a big ammount of power.



Obviously, RS2 camshafts and injectors were also bought.



Once most of the pieces were bought (a bigger intercooler will also be bought, but we prefered to make it work and then change the intercooler) and were ready to be mounted on the car, the project started.

Picture of the RS2 camshafts, already fitted:



The 5 to 1 exhaust manifold ready to receive the new turbo:

[javispa]

The displacement produced by the use of this exhaust manifold, and the different turbo, made necessary to built new turbo oil lines (artesanal). This turbo is not water cooled, so the water lines were not a problem . A picture of the oil lines:



Once the turbo was fitted to the exhaust manifold (a new holes had to be made to the hot part of the turbo because the original ones did not fit on the exhaust manifold), and before fitting the oil lines, the downpipe was built. On this picture our friend Ferni308 is designing the new downpipe.



Finally, after the design of the downpipe, this was the result:



It fitted perfectly:



Using the 5 to 1 exhaust manifold and a big turbo such as the K27, supposed that there was no room for the air filter and the MAF, so some invention had to be done:



The MAF is located just beside the blow-off valve:



The first idea was to mount the air filter just next to the MAF, but it was not a good idea, as it would be too close to the floor and would be easily damaged by any bump of the road. So Ferni308 decided to move it to the other side, just in front of the water radiator:

[s2_bo]

Wow! I think thats a first, haven't seen that much pipework for a air intake before. Did it go well?

Welcome tot he forum btw, Im sure you'll enjoy your stay?

[javispa]

Once everything finished (except for the mapping, that was going to be done next), everything seemed to work fine, but unfortunatelly not for a long time. A couple of months ago, when Kilian was going to drive the car from Girona (the city where the garage is) to Barcelona (where he lives), he suddenly heard some clak clak coming from the engine. Back to the garage, once we checked that compressions were ok, we opened the engine and we saw this:







Excuse me, as my knowledge of English is limited, and I do not know the exact translation of some words.
The clak noise was caused because a damage on the 3rd rod. The thing is that to make it work well, a nearly whole restoration of the engine is required... and now here it comes the question I wanted to make you:
Would it be very difficult to use a 2,5 TDI 5 cylinder block? I have heard that on big projects this block is used. The thing is that we have one of those, and if it is not difficult to mount, we would rather use it instead of restoring Kilian's engine.
I would appreciate very much any information you guys could give us, specially if it's a good idea to use this block. If so, we would also like to know which pistons and rods we should use, and also if the head would fit with no modifications to the block.

So at the moment, this is all. We just wait for your help, specially Kilian who now is very sad. We all our group of friends really want to see this ABY running again.

Cheers from Spain!

[javispa]

Wow! I think thats a first, haven't seen that much pipework for a air intake before. Did it go well?

Welcome tot he forum btw, Im sure you'll enjoy your stay?

HI s2_bo, thanks for the answer and for the welcome. I have to get used to the forum and to the language xD.
About the pipework, my friend Ferni308 decided to do it this way because otherwise the air filter would be too close to the floor and could get damaged (and also the MAF sensor). Unfortunatelly we didn't have much time to drive the car, but it seemed to work fine. We hope to mend the problem with the rod and the crank and see the car run again.
Cheers!

[terrybullwon]

To the forum,

I was in Girona last month and i got a parking ticket
The car lives in france so i did not bother to pay it.......

Good luck with the car it looks good.... Who does the mapping? and the block of choice is a AAT, if you do a searxh on it

Cheers James

[volcano rs]

welcome to the forum .
you need a reverse inlet manifold from aan engine or a custom one to get rid of all that pipework. diesel block few people are doing that on here at the moment can be done but its not just bolt on job a few modifications required .

[shark_S2]

Hello! I am Kilian, the owner of the car jeje, good so(then) like well Javispa has said we have the option to put the block of cylinders of 2,5 TDI, I put a photo a photo of the exterior in order that one sees that alone him(her) haveis dress the guts xD
Regards

http://www.audisport-iberica.com/foro/uploads/monthly_01_2008/post-5541-1199570324.jpg

oficial post:

http://www.audisport-iberica.com/foro/index.php?showtopic=129421

[javispa]

Hi forum members, after a year and a half, I have decided to rescue this thread as the car, we hope, will run again soon.
After the rod bearing broke, we started to search for a complete engine and found a 70k milles 3B but, unfortunatelly, we couldn't get it. We also considered the option to build a stroker, but it could get a little bit more complicated and expensive. So, we decided to rebuild Kilian's engine.
Starting the extraction .

[javispa]

Engine out and view of the engine bay with the custom downpipe.

[javispa]

We knew that a rod bearing broke but we did not know exactly how damaged the engine was. So, it was opened.
It was'nt too bad. The piston hit on two intake valves but, appart from this and the broken rod bearing, everything seemed fine.

[javispa]

At this moment we had two options:

- Restore (sorry, but I do not know the technical word in English) Kilian's crank, which got damaged.
- Buy another one.

We decided to search for another one and, in case of not finding anything interesting, restore Kilian's one. This would mean to use oversized rod bearings and Ferni308 (the project builder) didn't like this idea very much.
The solution came thanks to this great forum. Spink contacted me and sent us a crank from the UK.

[Bram]

Good that you solved it. Another engine saved from the scrap yard

[javispa]

Good that you solved it. Another engine saved from the scrap yard

Yes... saved from the scrap yard, and living a new youth. In fact, the whole car is saved from the scrap yard... many people told the owner that the best was to brake it.
We hope that once the car is finished, will be worth all the time spent.
Cheers!