RS2 engine into UR quattro

[DamoM]

Rather than spend a fortune taking 20v up to 350ish bhp and given that I wish to revert the car to std if I wanted to sell it as original, I decided that the easiest thing to do would be to buy a complete RS2 engine - which I did today, including RCU, engine loom, turbo etc etc

I already have the gearbox, diff and subframes from an S2 for a 6 speed conversion (which I have undertaken previoulsy on my 10v WR quattro) and I am hoping that the installation should not be too problematic. However, these things are never as easy as you imagine they will be and I was posting to see if anybody had any previous experience of such a conversion and whether there are any obstacles that I really need to be aware of!

Other points that I have considered are:

Need a higher flow fuel pump
Intercooler size and siting
engine loom interface problems with the existing dash
Cooling

Any help or advice much appreicated!!!

[Acidburn]

Rather than spend a fortune taking 20v up to 350ish bhp and given then I wish to revert the car to std if I wanted to sell it as original, I decided that the easiest thing to do would be to buy a complete RS2 engine - which I did today, including RCU, engine loom, turbo etc etc

I already have the gearbox, diff and subframes from an S2 for a 6 speed conversion (which I have undertaken previoulsy on my 10v WR quattro) and I am hoping that the installation should not be too problematic. However, these things are never as easy as you imagine they will be and I was posting to see if anybody had any previous experience of such a conversion and whether there are any obstacles that I really need to be aware of!

Other points that I have considered are:

Need a higher flow fuel pump
Intercooler size and siting
engine loom interface problems with the existing dash
Cooling

Any help or advice much appreicated!!!

Just out of interest was the engine from the one being broken on ebay?

High flow fuel pump, is it possible to get a 044 pump for in the tank on yours? might be worthwhile checking out djones's thread on here for info as his ur now has a 20v with more power than an rs2.

Intercooler, theres a few options, one is what djones has done with two intercoolers, it is possible to fit a bigger ic behind the front bumper.

[DamoM]

Just out of interest was the engine from the one being broken on ebay?

High flow fuel pump, is it possible to get a 044 pump for in the tank on yours? might be worthwhile checking out djones's thread on here for info as his ur now has a 20v with more power than an rs2.

Intercooler, theres a few options, one is what djones has done with two intercoolers, it is possible to fit a bigger ic behind the front bumper.

Yes it was! Collected it yesterday. It was way over priced on a buy it now so put in a cheeky (what it was worth really) offer and they accepted. Really nice people if you want any parts form them btw.

Have just spent ages reading his 2 main threads. I also get PPC mag and saw it in there2 turbo. MRC remappd it and it has exactly 350 bhp but not getting full boost til 3000 rpm is tedious. I also have a 10v ur with about 350 bhp running a Gt3071r and am wondering whether this turbo might suit that application too (I track that car so lag = time!).

On the fuel pump, I remember now (easy to forget these things!) that I fitted an RS2 fuel pump when I fitted Motronic and had to change the fuel return pipes etc for the 20v parts so I am guessing that it should just be a simple swap. The pump is external.

Intercooler-wise. I run a very similar setup to djones on my 10v but it is a charge cooler (where the std intercooler fits) which then runs to a molified Dialynx intercooler that fits in front of the rad. Had some cooling issues on track and so fitted a sport quattro replica bonnet with extra vents etc and that has sorted it. The inlet temps are very low - circa 20 degrees above ambient at 1.6 bar as read off of the inlet temp gauge.

Thing is, as djones has the Wagner type inlet manifold he has a better pipe routing option than I would have so was considering a custom intercooler which was much larger than the 1st one that he has but fitted in the same place but at an angle that is almost flat (this is what treser used to do). Obvioulsy airflow is compromised but I was thinking about some ducting and also a fan mounted on it that activated at WOT. I have never seen this done before so there may be a reason why it hasn't been!!!

[Acidburn]

I think Gnutz is doing a chargecooler style setup on his s2/golf using a fan on it as space is restricted on his one so might be worthwhile checking that out.

[DJones]

I think Gnutz is doing a chargecooler style setup on his s2/golf using a fan on it as space is restricted on his one so might be worthwhile checking that out.

Happy to help in anyway i can....!

[DamoM]

I think Gnutz is doing a chargecooler style setup on his s2/golf using a fan on it as space is restricted on his one so might be worthwhile checking that out.

Yeah I saw those pics! Looks a hell of a project. I did consider the chargecooler option but I would need a big one and locating it in the tight engine bay is the problem. Reaslistically there is not enough room for it where the std intercooler is and whilst it could sit near to the throttle inlet, there is the issue of the heat from the exhaust and engine that the chargecooler rad would not be able to deal with. I did then consider putting it on the other side of the bulkhead as there is space there but that would entail chopping into the bulkhead to allow access for the pipes...all 4 of them! I didn't really want ot have to chop into the car in anyway incase I ever wanted to return it to std to sell on.

[DamoM]

Happy to help in anyway i can....!

Thanks mate, really appreciate that. Nice write up in PPC by the way! Have you seen the intercooler that is going on Will Holman's car?! That is not going to be subtle!!!

[DamoM]

Happy to help in anyway i can....!

By the way, fascinated by that turbo that you are running. What exactly are the characteristics on your car? i.e. when does it start to spool, when do you get full boost. I have a GT3071 (on an 034 tubular manifold) on my 10v UR and that starts spooling at 2k and has full boost by 3k. My RS2 runs a garret bb hybrid of some kind (fitted by the previous owner) but that reaches full boost (1.6 bar courtesy of an mrc remap) only 200 rpm earlier. Neither are particularly satisfactory, especially when with my RS4 the boost comes on so much earlier so when you drive a laggy car they feel so different. However, you trubo seems like a different prospect all together but I'm not sure if it will suit any of my 3 applications as your car is of a much higher spec?