Shane's Project Mayhem

[s2_wot]

I'm going about a complete refresh of the engine in my coupe with a view to being on the road in the new year.

I had the bumper off but today got the aux rad, intercooler, crossmember, airbox, wastegate, air con pump, alternator, & all the rest of the aux belts removed. EM bolts to the head are all loosened.

Getting the turbo off is proving to be a pain but I'll get there tomorrow hopefully.

The plan is engine out, top and bottom end off and change anything that looks like it's needed. The last time it was started (too long ago) there was a knocking noise down low do I'm assuming I'll have a few bearings to do down there.

I plan to lift the head off with the engine in situ and also to open the crank bolt. I might clean & paint the block.





1st broken part discovered... Add to shopping list.









Could anybody tell me what the bolt at the top of the exhaust flange is shown here. The EGT sensor doesn't want to come away from the downpipe. Any tips anyone.





I would also like to identify this sensor at the bottom of the engine.



All going well I'll get myself a hibrid turbo before this lot goes back together.

I've priced a bunch of parts from Audi. The oil pump is bloody expensive, are there any alternatives.

[sam80quattro]

bottom pic looks to be the oil temperature sender for the gauge in front of the gearstick

[repo]

You stole my project headline.

Although, I admit, Your's look more like mayhem. In the other way, though..

[driftin jo]

the sensor in the downpipe is a lambda sensor not an EGT sensor .

[Error404]

sensor on the oil pump is the oil temp sensor for the aux gauge

[turbodriver63]

Nice project Shane
Will you be sending the head away?
If so, will it be Donnelons or treacys?
Also, Do you have a navy/Dark blue s2? Seen one on the n4 on way to dublin around 10ish last saturday.

[s2_wot]

bottom pic looks to be the oil temperature sender for the gauge in front of the gearstick

sensor on the oil pump is the oil temp sensor for the aux gauge

Thanks, I still have not got my head around a lot of the sensors / wires.

You stole my project headline.
Although, I admit, Your's look more like mayhem. In the other way, though..

Sorry Repo, you are quite right.

the sensor in the downpipe is a lambda sensor not an EGT sensor .

That explains the 3 wires, I'll have to get the downpipe out to remove it.

Nice project Shane
Will you be sending the head away?
If so, will it be Donnelons or treacys?
Also, Do you have a navy/Dark blue s2? Seen one on the n4 on way to dublin around 10ish last saturday.

I'll have to wait and see what it's like when I get it off and stripped. I'll let you know either way.
Wasn't my s2 it's red, "david in dublin" has a navy avant, I don't know of any other blue s2. Was it on irish plates?

[s2_wot]

A small bit of progress today, I borrowed a crank locking tool earlier in the week to open the crank bolt. Thanks David . I could have used the BF air gun but wanted to see the condition of the crank pulley.

Before slackening off the cam belt I cranked the engine around a few times by hand. I could feel varying degrees of resistance at different points of the rotation. Looking forward to finding out why.

Those 2 bolts holding on the lower timing belt cover were a complete PITA. They're off now but replacements will be needed.



Good to see the key is where it's meant to be.



Hopefully I'll get a few more hours at it tomorrow.

[s2_bo]

Engine resistance is just cylinder compression and is supposed to happen.
Keep us posted on the progress

[s2_wot]

, based on that I've a headgasket that's leaking on 3 of the cylinders!!

[s2_bo]

How many points of resistance did you find on two full turns of the crank?
I wouldn't worry about it anyway. You wouldnt be able to spot a leaking headgasket like this as even with a tiny leak it would still make compression.

I cant remember exactly - but when i did this on one of mine i found that the 'pockets of resistance' sometimes merged together, guess it all depends on piston and valve movement.

[s2_wot]

bo I think it was 2 places of heavy resistance in 2 full turns, head off tomorrow if I get a run at it. Any pics of the s8 BTW? don't tell me I missed that thread too.

[s2_bo]

Cool good luck with that. i have been flat out on the s2/s4 braking the last fortnight so no time yet for pics of the s8, besides it needs a good coat of wax first.... ill get my girlfriend to do that though as she seams to be driving it more then me....(im still paying for the fuel though )
Sorry off-topic.

[s2_wot]

Finally got my C type 15mm spanner delivered today to release the downpipe from the turbo. Had to modify it with an angle grinder so it'd do the job. I'd have been better off if I just cut a 15mm ring spanner in the 1st place. Anyway I have a little spanner for that job if anybody ever needs one.

Just need to get a junior hacksaw at bolts joining the DP to the cats and it'll be free.

[Phil Payne]

Finally got my C type 15mm spanner delivered today to release the downpipe from the turbo.

?

Socket on long extension from the back.

The bolt in the flange blocks a drilled hole used on some cars for a gas probe pipe that goes up past the turbo so exhaust gases can be sniffed upstream of the cats.

See 'adapter for CO test', 035 129 703Q in ETKA A10Q illustration 27-35.