Diy S2

[Ruffiano]

I've been around here for a short while, but never made a formal introduction, thought now would be a good time.

So here is the start, As most of you know the S2 didn't make it to the American shores, guess the gestapo didn't want that... now that the war is over I'm trying to piece one together.

This is the car the day I bought it, Notice the DREADFUL USDM Bumpers!!





Other than a few small bits here and there, it was in Excellent shape, the paint work is very good and that is really what was most important to me

Here is Phase 1:



Just a step up in the looks department.

Now as it sits this morning:

new to me V6 (s2 style)bumper


you can see my new daily driver s-car in the backround of this shot


Still have the USDM rear bumper, but have a S2 rear on its way...


My goal for this project is actually to finish the swap in a relatively short time. The reason for the rush is that me and a friend want to compete this year at the Bonneville World of Speed, which takes place this September. As many of you know last year the Top Gear crew were out there running some cars. Our goal is to be part of the 130 club, basically you have 1 mile to get your car from nil to 130 miles, on the salt.

To complete our goal we are going to be using mostly OEM parts for ease of swap reasons, here is the shopping list:

AAN Engine (will be sourced from our parts car)

ABY Wiring Harness (thanks Steffen)
ABY Oil feed and Return lines (thanks Steffen)
ABY Oil Pan extension with return hole (found on one of my 7a motors)
ABY Cross Member and Intercooler (thanks Sonic)
ABY Intake Manifold and Charge Pipes (thanks Sonic)
3B Downpipe (thanks Jonas)
Strebro Exhaust (thanks Darin)
Spec 3+ Clutch and Pressure Plate (still need to buy)
S2 Hubs (thanks Anton)
Avus 16" wheels (there are some local)
034 Alu Subframe Mounts (purchased for a different car and never used them)
034 Silicone Hose Set (still need to buy)
034 Motor Mounts (still need to buy)


Right now I still have the chassis of a 90q20v sitting in the garage, that is mostly stripped, it needs to go to the breakers this week then I can pull in the Donor URS4 and get to work. I also plan on converting my Auto climate control to the Manual style, there is a lot of work to be done on my Coupe to get it ready for the new engine.

[Acidburn]

What climate do you have in yours? i've got all my manual stuff sitting spare due to putting climate in my s2 in the next couple of weeks.

[Ruffiano]

I have this Hideous one



However since I'm LHD, I don't believe the HVAC boxes are interchangeable.

[S2central.net]

Why not delete the hideous vacuum one you have and go straight for digital climate system - should be easy to rip from V6 engined Audi 80/90 from that side of the pond. It was an LHD only option and you can source a suitable head unit from other cars as well.

Nice project. Not easy !

[Acidburn]

ah yeah thats the early version, i'm going for the later version. Should be getting everything tuesday.

[Ruffiano]

Why not delete the hideous vacuum one you have and go straight for digital climate system - should be easy to rip from V6 engined Audi 80/90 from that side of the pond. It was an LHD only option and you can source a suitable head unit from other cars as well.

Nice project. Not easy !

There is actually a pretty nice write up on how to swap from my current CC to the later B4 V6 style here. However if you look at that thread, I actually like the second posters look better, just simple and clean. Besides, I have more than a handful just trying to get the wiring sorted out for the engine swap.

[S2central.net]

I for one am not a fan of the 'oven controls' used on the manual aircon. We got a raw deal in the RHD territories... Its only a fluke that we can upgrade to the digital climate system.

@ Mr Burns - what weekend are you attempting this fine task and what part of the world are you in - I'm trying to organise myself to get over there for quick trip this month and I'd be glad to help with this one - and reduce the fear factor for removing the dashboard on my own car ! I've got all the schematics and knowhow for coding the head-unit. Plus I'm hopeful of extracting some underfelt from one of your fine dry vehicles. Pls let me know what works for you.

[speeding-g60]

hi Dave. carry on

[saltinot]

Nice start to a fun project. Glad to see you've found Anton out in Washington. I guess I'll just keep toughing it out here in GA by myself.

I think you mean DOT bumpers not USDM.

[Ruffiano]

Nice start to a fun project. Glad to see you've found Anton out in Washington. I guess I'll just keep toughing it out here in GA by myself.

I think you mean DOT bumpers not USDM.

Yeah DOT, I'm used to distinguishing between US Domestic Market, and JDM (Japanese Domestic Market). DOT is probably more accurate. I also have Ben out here, the previous owner of the pearl s4 you recently parted. He came by and got some parts from my parts car...

[saltinot]

When I saw the USDM I figured you must have bee hangin' with the NASIOC crowd Glad you're here.

Ah yes, ol Ben. How's he getting along? Tell him I said hello. Pursuing any Audi projects?

[Ruffiano]

Got another package, here are some of the things collected.

S2 (3b style) downpipe:



S2 ABY Harness (no cuts, I'm happy and impressed):


S2 ABY Oil feed and return lines (the style that feeds back to the oil pan extension):


And a model of my car that I thought the scale was larger... oh well still cool and it is pearl!



unfortunately it has the current engine, not the future one


and to show the scale:



Something I noticed about the ABY Harness is that it doesn't have the power running through it like the stock 7A does, Obviously because the ABY had the battery under the back seat. My question to you is regarding the power cable on the ABY, I know it splits, I'm assuming that it runs from the battery to the fuse box, and then the second part that splits goes into the engine bay and gives power to the starter, and probably has a line that runs back from the alternator.... Since I have never seen an ABY in person and don't have access to one here in the USA, I was hoping you guys could fill me in on the diagram for that power cable. Thanks!

[Ruffiano]

oh, I just actually had a thought, does it just run to the Battery post that is under the hood? like on the S4? then from there it goes to the alternator/starter?

[mcandmar]

I've had both looms side by side and the obvious difference is the starter wiring is a part of the engine loom. On my S2 the starter loom is routed through the chassis rails separately from the engine loom. Battery and alternator wiring also seem to be separate from the engine looms, i assume they all meet up via the fusebox regardless of where the battery is located.

I haven't studied the two wiring diagrams yet but from looking at the looms it seems a simple job of unwrapping the 7A loom and re-using the starter wiring from it. Battery and alternator wiring is used same as before. The one thing i dont know is if there is any difference between the radiator fan circuits, and does it matter which you use as S2's have a different fan and regulator thingy.

[Acidburn]

Hmmm i'll have to compare the looms, i've currently got both a 3b/aby out the cars and soon a 7a