S2 Coupe - A never ending project

[happykriss]

Hi boys and girls!

As an S2 owner i find myself obligated to make a little project thread on my little pain in the *** S2.. I bought it from a local who had it sitting in a garage for somewhere about 4 years as it had a lot of problems.
I towed it to my garage and started fiddling with it and eventually got it working (sort of).

Back in the days. The paint looks OK, but the paint job must have been a cheap one..






The "Mechanic" who had done a useless effort to fix it had done some strange modifications to the engine.. Example is the wastegate.
Notice the missing part from the top of the piston.


a month after i got it i had a rod bearing failure. The engine were pulled out and almost everything for the bottom was ordered. Two weeks after rebuild my new oil pump decided the bypass valve should get jammed, so the engine was replaced with an AAN.




This was two years ago.. and the AAN is still there, BUT not for long!!

I recently spent some money on a S4 with a running engine. (spec at the bottom)


So i swapped it with another AAN so i could sell it as a running car.

This car came somewhat cheap as it was blowing boost in to the water channels and out the lid from where you fill coolant which i cannot remember the name of at the moment..

So i started tearing the engine apart..


An boy.. did i find some horsepowers. I thought i should go down on turbo-size as the turbo lag was way to much for a daily but found not one but two major leaks.


The other is a curved manifold. Forgot to take a picture of exhaust gasket, but you could see where it leaked..
Turbo was hold in place by 1 and a half bolt. The rest were lost somewhere along the road.

It's been running some time on 1,9 Bar boost but i think we should reach higher when it's in the S2.

Head had some cracks between valve and spark plug, but as i understood this is almost stock from factory so i'm not scared.. I believe a faulty gasket is to blame. It was a copper composite gasket, and as the great web tells me: It's great when it seals..

I sent it away for pressure testing just in case.. hope to get it back within two weeks tops.



Spec for the new engine.
Head:
RS2 Head
7a Cams
Titanium retainers
Harder springs
Portet & refurbished
ARP bolts

Bottom
H-Profil rods
JE pistons 1mm oversize
Copper head gasket (Trashed and burned)
Glyco bearings
ARP bolts

Exhause:
Furans manifold
Precission GT 6262 turbo


Filter:
HKS green filter

ECU
VEMS plug´n´play ECU.
Bosch 680cc injectors
Adjustable fuel pressure

[happykriss]

The paint job

As i said in first post. The paint had seen better days.

So i started prepping it for a quick fix.


But as always the car had other plans.. The plan was spraying both front front fenders and right rear..
Somewhere along the way i must have gone mad and before i knew it the car looked like this


So the new plan was to spray it black.. And here you could see how that went

[Error404]

Nice project. Shame about the new oil pump ruining your built engine. Some people have found grit inside the new OEM pumps (now made in Korea )
Stick with the standard MLS headgasket, it is very good quality

[happykriss]

Nice project. Shame about the new oil pump ruining your built engine. Some people have found grit inside the new OEM pumps (now made in Korea )
Stick with the standard MLS headgasket, it is very good quality

Thank you.
I bought a standard MLS gasket. I'm planning on using this HARD next summer so a "Great when it seals" gasket is not an option

I don't know where the pump was produced. I buy all my stuff from a Norwegian company (www.hansenmotorsport.no)
I opened it and lubricated all parts before fitting it. It worked a week then it started loosing oil pressure when engine was cold. Gave it a second then it came back. On hot oil it was working fine.

[simon20vq]

Wow what a lot of work you've done already! Car looks great....what is that funny shelf on the back of it now is red

[PRY4SNO]

Nice project! Looking forward to updates

What else do you plan to do before the summer?

[happykriss]

Wow what a lot of work you've done already! Car looks great....what is that funny shelf on the back of it now is red

I'm working as fast as i can. Last three years has been some hard ones for me and this is some of the best therapy there is.
It's a little slower at this point as our new garage is under construction.

You mean my dining table? A friend of me needed a place to eat

Nice project! Looking forward to updates

What else do you plan to do before the summer?

I'm currently running on stock suspension, so when our new garage is up the plan is to drop the whole front and rear, change all the bushings and suspension and weld a tiny hole in the rear left corner.

I want this to be a daily racer, so all modification has to be approved by DMW (or what you call, the guys standing along the road waving at me when i come by telling me everything is illegal..).
So hopefully i will get the new turbo approved. I need a document from Audi telling them how much power the frame could handle so i'm hoping for the best and expecting the worst. Second worst case is approved with 230bhp and larger turbo. Worst case is not approved at all..
Next in line is roll cage in the back. we're not allowed to install a full roll cage but we take what we can get.
And then there is the brakes.. i need bigger brakes.

[Greg_S]

Nice project and good write up.looks like you've suffered some bad luck along the way though

[anthonys2]

Nice project and i like your new colour choice but i always think black looks the best for a Coupe (not biased!!) Hope your luck changes as these cars are money pits but when they work they put a big smile on ya face!!!

[happykriss]

Nice project and good write up.looks like you've suffered some bad luck along the way though

Nice project and i like your new colour choice but i always think black looks the best for a Coupe (not biased!!) Hope your luck changes as these cars are money pits but when they work they put a big smile on ya face!!!

I've had some good and a lot of bad days along the way, but as long as i live to see another day i can't complain

Thank you, i'm actually considering repainting it a shade darker. It's a little to orange in daylight. I'm also a huge fan of black S2 but as i wanted this to be "mine" i changed it to something no one else in my area had.

The main problem with the car has been it's temper and mood. Monday everything is fine. Friday it misfires and cough (same symptom as fuel cut)
But whats always a standard is when you get it in the workshop everything is fine...

I've changed almost everything along the way. Some bought new, some i've had laying around. So i'm starting to think we're not meant to be.. or a bad connection somewhere.

Do anyone of you know if you can drive TFSI coil on stock ECU without any mods? Upgraded last week and it started misfiring.

[UrS4boy]

I doubt that those cracks by the sparkplugs are too significant. They need to be bigger and go deeper to be a concern.

The AAN head that you are using has the "Tuna Can" dizzy that was used in UrS4 AANs built before mid-February 1992. Any chance you can tell me what the number is on the head (AAN 001234 etc), exhaust side, front, under the cam cover vent tube.

[happykriss]

I doubt that those cracks by the sparkplugs are too significant. They need to be bigger and go deeper to be a concern.

The AAN head that you are using has the "Tuna Can" dizzy that was used in UrS4 AANs built before mid-February 1992. Any chance you can tell me what the number is on the head (AAN 001234 etc), exhaust side, front, under the cam cover vent tube.

Hi, don't got a picture of this and head is sent away at the moment. Will try to post it when i get it back

[Bowie69]

Nice project. Shame about the new oil pump ruining your built engine. Some people have found grit inside the new OEM pumps (now made in Korea )

My never-been-off oil pump had made in Korea cast into it, and a manufacturing date of '91, so they have always been made there.

My NOS one from a chap on here also had made in Korea on it.

[happykriss]

My never-been-off oil pump had made in Korea cast into it, and a manufacturing date of '91, so they have always been made there.

My NOS one from a chap on here also had made in Korea on it.

Can't remember if i ever saw any "Made in" stamps on mine. The guy who sold it to me had never heard of any issues so i guess i was just really unlucky.. I changed all the bearings in the engine and it actually ready to go. Just need the oil pan fitted. I think i'll save it for another car another day.

The stock pump had seen better days.



I booked a wheel alignment for it today. Last owner had put some bad springs on it. My guess is that they order them for a 1.8 or something. It was like a boat.. And as i live in an area where there is a lot of snow in the winter i fitted stock springs for now.

[Bowie69]

Definitely scrap, that one!