3b s2 coupe resurrection

[andy10v]

Slide hammer, didnt think of that

Yup, I was just going to ditch the splash guard, my dad did ask me how often I removed the oil filler cap with the engine running

I had not tried to fit the seals yet, dont want to do it wrong. I will try tapping it in.

You can get kits like this on ebay, are they any good though? I think it will still go squint and you will just end up tapping it in evenly anyway?



Hopefully get a good amount done over Christmas, all the gaskets are here now, so would like to get the engine buttoned up.

Yup, I used a small magnet stick, and a little screwdriver.

Thanks Kit

[simon20vq]

Great work Andy. The only down side is I am planning a top end rebuild and think it may turn into something else after following yours!

[andy10v]

What all are you planning on doing in the rebuild?

Rear main housing off



Mcguyver would be proud



New gasket, you can see the groove worn by the old seal



New seal and fitted



Front housing off





Oil pump opened up, needed to make sure no crud had fallen in, and check over, all good.





New seal and back on

[andy10v]

Windage tray, oil pickup and new gaskets



Sump on, cordless drill on low torque makes doing all the allen key bolts a lot faster.



Headgasket and headstuds



Waiting on one bit from Audi to get the head on.

[andy10v]

Ghetto stud removal



Had a play with the replica RS2 exhaust manifold, I bought it unused, second hand on here.

One of the reasons they are cheap (I have spent a good bit of time removing the random lumps (and loose balls that could just be knocked off, and casting lines from the inside), Ports not round, stud holes not in the right place





Marked up



Lined up (get to misuse my christmas present from my girlfriend )



In progress



Done



I have modified 4, there are still still another few out of line

I am not sure whether to continue with modifying this manifold, or try porting the stock one, JP modified one and made 420bhp.

Both manifolds had 2 tight holes, I assume to locate the manifold, and the rest larger. I think as long as I get still get a tight fit on the studs, and match everything to the gasket using those alignment studs the manifold will line up.

Something someone has to remember about flowbench work is that it can be achieved in various means. Where you look at the figures of the stock AAN vs RS2 mani for example and go hold on not much difference yet we can make 420 on an RS2 mani and not on the AAN I tweaked an AAN mani and made 420hp. The restriction was not on the individual runners comparatively it was the design of the collector.

Quite correctly when you flow on a flow bench the easiest testing method is on a single runner at a time basis. Whilst functioning on a vehicle this will not happen and one has to look at the turbulence created by the cross over paths and the volume that has to pass through the joining runners into the collector. . The restriction on the AAN manifold was that multiple runners where trying to squeeze through a space half the cross section of a single exhaust port. Open these up to allow for less turbulence and free flow and now it is capable of the same power as an RS2 manifold which has got a lesser restriction around the collector from stock

Stock collector

[K Simmonds]

Making good progress there mate, I like the CV joint drift, good thinking

Not sure what I'd do with that 'RS2' EM either, I guess if you can get it to fit properly and clean the casting up it will be worth a try. The one I got fitted straight on with no alteration required and the casting was very clean, not sure to this day if it's genuine or not.

Nice Christmas present

[andy10v]

After waiting for this to arrive (there is one in my garage somewhere )



ARPs in and torqued down



Cams and dizzy in



Metal gear



And after a clean up, a little bit of paint.



Still to order injector inserts, timing belt idler, fpr, and exhaust studs to get the engine buttoned up. Billet pulley is on order.

Then into the engine bay for

Battery tray
clutch slave and flexi
steering rack gaitor
mfts plug
fuel lines

check wiring
check brake hardlines
check for rust

Any other essentials before the engine goes back in?

[andy10v]

Cleaned up and new gasket



And on



Battery tray out, soo much space!





Nitrous out, I think I would be pushing my luck running it on the next turbo without mapping to suit.



Tried a wheel on the front with the 255s on 17x8 et 35, as predicted it rubs

[andy10v]

Fitted a new rack gaiter.



Shiny for now





Going to fit this to the firewall, and just run a cable from the new battery location to the old. Gives a jump point in the engine bay.



Started to try and put the loom back And still faffing about with fuel lines, I am not very good at this

[newsh]

Watch out with the length of the exhaust studs, IIRC some of them need to be shorter with an RS2 IM

[andy10v]

Yup, thanks for the heads up. I am leaning towards just running a heavily ported stock manifold. I am done throwing money at this, so just going to get it on the road again with parts I have, and I am not happy with the RS2 replica manifold.

[martinws]

Looking really good man. Do you already have an uprated clutch? This thread makes me want to go play in the garage!

[andy10v]

I have the stock clutch I removed, (was working ok), and a clutchnet? disc



So it will be the stock pressure plate, and stock or uprated disc

Where are you at just now?

[martinws]

The 90 is sitting with interior removed to find a water walk that let 12litres into the foot well and glovebox.Haha. my clutch is slipping so need to get another one but think I'll put my 7a flywheel on with uprated 3B pressure plate and a UR disc to match my gearbox. Probably go for helix paddle or similar so when I swap engines over I don't have to worry. Been so busy with fixing up another house that I haven't thought much about it.

[geryS2]

hell of a job done here, nice !