420+bhp project

[S2central.net]

Doug - Remind me the trick with the fuel pump if you can...

I recall that MarkH (Monster #1) had to get a different pump housing to accomodate the larger Bosch competition pump - think it came from another Audi 80 application which magically has the same pump diameter.

Cheers,

Paul

[Doug_RS2]

Originally posted by S2central.net
Doug - Remind me the trick with the fuel pump if you can...

You need to get the fuel pump housing from an older Audi as they had 60mm diameter pumps - the S2 is 40mm. Luckily the housing clips straight in.

The Bosch fuel pump has a lip about a fifth of the way down it so it doesn't slide all the way into the housing. All I did was put 3 slots on the top of the plastic housing, opened up and it could slide all the way down. Luckily there is plastic band round were the slots are, that opens up and still holds it all in place.

If you get the banjo connection off the same old Audi this connects straight upto the fuel tank internal hose.

I had to make a tool to get the fuel pump housing out and in but it's just a few bits of wood screwed together - not pretty but really easy.

The pressure damper off the same old Audi has a different thread and Mark is going to have a look at that at the weekend.

Reservoir(pump mount): W895 201 779H
Strainer: 895 201 531A
Pressure Damper: 895 906 095
Sealing Washer N 902 832 01
Sealing Washer N 013 812 8
Adapter (Banjo) N 903 307 01

One of those washers is wrong - I'll check later and update the list. Just under £70 for those parts from vagparts

Might not need the £47 damper if we can't mod it to fit though - that's when you need the M12,1.5mm thread pitch dome nut.

[SteveH]

Doug,

I look forward to seeing this installation in the flesh. If the new hybrid turbo is a good upgrade I'll be looking at something along these lines early next year.

What fuel pressure reg are you using, the original ABY or a motorsport version like Mark H?

See you Friday, if you get the car up and running

cheers
Steve

[Doug_RS2]

Originally posted by SteveH
What fuel pressure reg are you using, the original ABY or a motorsport version like Mark H?

You can modify the FPR upto 5 bar - Mihnea has given me instructions on how to do this and Kim Collins told me how to do it when I asked for a motorsport FPR.

Marks FPR is coming in at £130 minimum for everywhere I could find that could get it - and 3 to 4 week leadtime.

We are going to see how we get on with the standard one and maybe stick in some bigger injsectors.

[Doug_RS2]

Fuel pump now fitted:

The wooden block is what I used to get the pump in and out - it locks in place.

[Doug_RS2]

While everything is in bits I thought I would try and get some more air into the air filter.

I've cut up the oil cooler ducting and the original airbox inlet tube:

[Doug_RS2]

And it bonded together

[Doug_RS2]

And the ducting in the car

[Greg_S]

jeeezz that filter is HUGE!

ducting is definetly a good plan,

[Dutch_RsBlueS2]

Very Nais!!!!

i`m very interested in the results! Keep us informed

[PhilS2R]

very very very interesting and nice ..... up up up for the next evo...

[S2central.net]

@Doug - Full marks for the ducting from the oil cooler duct. Very reminiscent of a certain mod featured in Autospeed for a UrS4 but damn worthwhile I reckon. If time ever permits I would look to do similar with the standard airbox.

Paul

[Doug_RS2]

I now have the turbo in my hands

Trial fit - see what is wrong?

[Doug_RS2]

And now I have the turbo I can get the intake hoses sorted. This setup is sort of going over the top of the turbo - I'm going to go with this just now until it is all fitted and then try and route it a bit better.

[Doug_RS2]

I can confirm that you definitely need the oil feed spacer as the oil feed line on the ABY does NOT fit over the K27 housing.

And the water feed to the turbo needs to be modified to fit as it doesn't quite fit over the housing - I'm not sure how much to modify it as I don't have the turbo to water line adapters on the turbo Tom - how did you modify yours?

That black metal intake pipe that bolts onto the turbo inlet is designed to use the standard rubber ribbed intake pipe but cut up. I am tempted to get another metal adapter pipe made as the turbo inlet is 70mm(a guess), the Maf outlet is 80mm but the metal pipe is reduced to 60mm to fit the standard ribbed thing.

More tomorrow - day today.