S2 Avant -93

[Antsa]

It does not hit the rail, it's pretty close but doesn't touch. Maybe I will add a couple of shims under the right engine mount to raise it just a little bit.

It's a precision 5558 turbo with a 55mm compressor inducer and it's advertised horsepower rating is 650hp. We will see how this turbo works once everything is ready for tuning.

[Antsa]

I have an adjustable Tommi's Billet cam pulley. However it was not a direct fit. I had to grind it from several places so that it doesn't interfere with the cam sensor.

This steel ring holding down the cam sensor wheel was too thick. I used an angle grinder to make it a little thinner. Also the bolts had to be shortened.


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Dremel and a sanding drum used here.


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Now it's better. I used a 0,2mm feeler gauge between the sensor and the wheel and it fits. I take it's enough clearance.



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New flywheel came. It weighs under 6 kilos.



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Installed


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Bolted the engine and gearbox together to make sure no rubbing of anykind is present anymore.




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The new flywheel does not have the TDC marking on the outer circumference. With the aid of a dial indicator and a degree wheel I set cyl 1 to TDC.


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Red marking pen and a scribe was used to make a new marking. Now it should be fairly easy to find TDC when I need to.


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Tomorrow will be a day to install the box and engine in the car!

[Antsa]

The engine and gearbox are in! It took a few tries make it go in nicely but got there in the end. It would have been easier with left side engine mount removed but I thought of that after everything was installed.

But now I have another problem to solve. The shifter linkage doesn't want to bolt on to the gearstick. It is also hitting the transmission tunnel. This might be because I renew the linkage ball bushing and I had to put a couple of washers under the right engine mount to give clearance for turbo.

I will probably have to take out the engine and box, remove the turbo and put the engine and box back in without the washers under the engine mount to see if that is my issue. If that's the case, I will have to think of other measures to give clearance between turbo and chassis rail. I currently have a 10mm spacer between turbo and exhaust manifold, making it a 5mm might help.



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[Jaswan]

Looking good!

If it were me I'd try it without the spacer between the turbo and manifold. That said, if there is no issue against the chassis when you remove the shim from the engine mount just leave it in.

Well done on the work so far.

Jase.

[Antsa]

I will have to do some testing to see what works best. A little spacer between turbo and manifold has to be left. Without the spacer the compressor housing is too close exhaust manifold, about 1mm between them.

I thougt that I will just throw the gearbox and engine in and evyrything just would work Of course I should have known that changing one thing will have an effect on others. I guess I will have to do some more trial and error and remove and install the engine couple more times