Bobby Singh's Audi S2 avant project

 
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Head parts are finally here:


View: https://drive.google.com/open?id=1nq3CS7OoKh0VFsFeCOZVyFcPttkZHvBq&usp=drive_fs

Door card cloth

So the doorcard on the S2 have been degrading over time and the backing has been breaking away:


View: https://drive.google.com/open?id=1ppRxi-5paS_gLFm7fX6PHAu4t5B_Lt7x&usp=drive_fs


View: https://drive.google.com/open?id=1ggyLvMaM4Iac8zPDhYKQKhOGPoUQZVWr&usp=drive_fs

As you see above I managed to get hold of the origional material from Audi Tradition

Next task was to drill off the plastic welding for the door pockets


View: https://drive.google.com/open?id=1gNjWHziIQJ0B6WdXAFtVSvt12lhIIXX_&usp=drive_fs


View: https://drive.google.com/open?id=1gfBFrspNFiYVLZKdEGt25HFn0tTeASAM&usp=drive_fs

(wonder how long that gum has been there)

Ready for action:


View: https://drive.google.com/open?id=1j9oYjB4hz72A_Fg4cE-XM__8KjC1-h7G&usp=drive_fs

Final result:


View: https://drive.google.com/open?id=1JnAU2TJTnbB6SycG0-YrJoTWd1_31EyU&usp=drive_fs

Used cable tie as welding rod and plastic welded the pockets back on:


View: https://drive.google.com/open?id=1LNjBEFkZ6ezQDBtWGXa4QeYFffqNYAp1&usp=drive_fs

Cheers
Bobby
 
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New exhaust cam - managed to get hold of a brand new ABY exhaust cam


View: https://drive.google.com/open?id=1J_4sHAeFtIKaWpAI479y947YL4NnmlIV&usp=drive_fs


View: https://drive.google.com/open?id=1mGe8_UCyl69ZyJktUkOJ-Je5YbFt2Enj&usp=drive_fs


New s2 boot badge


View: https://drive.google.com/open?id=17-5xsJJ2irFYK1z7MTOCZD1FMT3SQHuB&usp=drive_fs


B5 fuel tank shield (apparently with minor modification it can be used on the b4). Mine was totally rusted through so removed it sometime ago.


View: https://drive.google.com/open?id=1dXXH7lobJGJdJhg-xxd1gv5dawo0TnLa&usp=drive_fs


Boot wiring repair kit


View: https://drive.google.com/open?id=1uk6S6aSBtKuzjU_X7S--eXaoprr1d-7W&usp=drive_fs

Found this on ebay - have no use for it but old new stock is always nice


View: https://drive.google.com/open?id=1xYlkQ35jVAq1pb_gNFI0JgL1YCXYm3R2&usp=drive_fs
 
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There's been a lot going on with the S2 in the background and its finally back from a full paint job.
Yes it was done last year however I wasn't happy with the colour match so best way to get around that is to have the whole lot done.
It come out very good and I'm impressed by the Bodyshop I used - they get my recommendation.

Nice to see the car is still solid under the body kit.

Here is a video:




Cheers
Bobby
 
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Car has been detailed by https://www.instagram.com/reflective.detail/ after the paint. Results are just mind blowing:


View: https://drive.google.com/open?id=1zgFtQ-4VO6nsDgfVSlw421xyQiT3d3B-&usp=drive_fs


View: https://drive.google.com/open?id=1WFxkcHsmF9aDXUdIwwNV0f9caRqIgiHp&usp=drive_fs


View: https://drive.google.com/open?id=1Li03Pi1bodYRKzWoSjbV-ejtWqufBJLK&usp=drive_fs


View: https://drive.google.com/open?id=1kO66ueKEpJGEfEAWO9lb4REvHPP4Jtup&usp=drive_fs


View: https://drive.google.com/open?id=1Ag3E-a4RQEP4eQSmpJpOR00iznP6CAE5&usp=drive_fs


View: https://drive.google.com/open?id=1HqmAs0Z9HvjJdnzOhpUtQcEv3htN9hiu&usp=drive_fs


View: https://drive.google.com/open?id=14CAkQW3jqv9ayCKIR80xo7WiSRw8hFFJ&usp=drive_fs


View: https://drive.google.com/open?id=1h9MzHRmDOQw9Spuormj_PHaXdSStY45y&usp=drive_fs


View: https://drive.google.com/open?id=12D4rHg_1fyWnnSn-l4Y5pPXVBlk7C5B5&usp=drive_fs


View: https://drive.google.com/open?id=1RGbYxwjshDZZrjNUZCSIQkRzE9BMqTGs&usp=drive_fs
 
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Stunning mate
 
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Maxx ecu mounted in the OEM position


View: https://drive.google.com/open?id=1pB2mB1dm9wv4e_eFL-a5vRlxZ2H2Xeap&usp=drive_fs


View: https://drive.google.com/open?id=1S2the3c9WZMhbYMLsZeaxY-QiF6lRIyg&usp=drive_fs

3 x 0-5v inputs
6 x egt
Wideband


View: https://drive.google.com/open?id=1HID32PdM0hWhztTjurqV1pd4pSCHzhpv&usp=drive_fs


View: https://drive.google.com/open?id=1On6nmMDnFXIOc5n97mVZglfVjdfSgl_8&usp=drive_fs

6 bar back pressure sensor wired in


View: https://drive.google.com/open?id=1VAS8mpVol_K-RpU5Q2qnQjobDfaBXcnV&usp=drive_fs


View: https://drive.google.com/open?id=169BIYFcK16mGz9wGqbBOqHMF1MLoEqKm&usp=drive_fs

Cylinder head -
I bought another 7a head and had it converted to ABY spec (the other head had a tight cam bearing which will get fixed and kept spare) with new guides, all high points machined down, valves lapped in and skimmed


View: https://drive.google.com/open?id=14z6z1ooN5G_6w8CN3n7TEvgztBSynTK4&usp=drive_fs


View: https://drive.google.com/open?id=1164KLBAvJVpFV_EFW-JcwoTIYqpJt9nq&usp=drive_fs

I will install the new inlet ABY cam (purchased from AT) with a 7a exhaust cam

Cheers
 
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Maxx datastream

So the Maxx ecu has a nice feature whereby it can datastream over bluetooth.
Bought an 8" tablet and made it removal by installing Neodymium magnets behind switch blanks


View: https://drive.google.com/open?id=1gRqddP3k_ogGG6Oiaev3-BaPxaa__n4Z&usp=drive_fs


View: https://drive.google.com/open?id=1swFsdBQdDfS7-VcEk6Qmi_88I_1LaO0-&usp=drive_fs

RS2 spec on Maxx ecu:

To get a base line of the current spec with the maxx I went back to the dyno:

Running 1.75bar (previously 1.85) and now making 370hp / 515nm (wouldn't want anymore than this on stock rods)


View: https://drive.google.com/open?id=1Kvw2-8_AfMhFka6d1XAcCWyL786TyquW&usp=drive_fs


View: https://drive.google.com/open?id=1zSqA8VT0v1lJKVLDay14CnkLSG3wgA-t&usp=drive_fs


View: https://drive.google.com/open?id=1Z-UvQlxQHZIjSroiWH94tYkM4bPX9eaJ&usp=drive_fs


View: https://drive.google.com/open?id=1N2ZtFdXDMJSzNp6YCFTMITPgB5xVWHg6&usp=drive_fs
 
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Heat protection by http://www.thermomet.co.uk/


View: https://drive.google.com/open?id=1CFsHvPZWzF-VcRdUo0w0jIx5qgrYQLev&usp=drive_fs


View: https://drive.google.com/open?id=1Tw41m5Qg_s0RzIEQCv6p0ofy_FnyUQ6O&usp=drive_fs


View: https://drive.google.com/open?id=1pD2mVmTi14L1cereeeqy2VPaeiVYI_1l&usp=drive_fs


View: https://drive.google.com/open?id=13MR0ihKsrEEtn5rg9d3ZESAhH1SEBrNX&usp=drive_fs


View: https://drive.google.com/open?id=1iMMcxQx3WF6OnWV6BL0F7NQzTzDuK4mW&usp=drive_fs

Head mounted:


View: https://drive.google.com/open?id=193i4AbwIirj677DOG6acZ71jB03aZ4aa&usp=drive_fs


View: https://drive.google.com/open?id=173A19HokS5tp8wBdQV3LpxK-HUaUM5ze&usp=drive_fs


View: https://drive.google.com/open?id=1YBT9xhYdhsXyKPeQrKFEgsM032vcFxD7&usp=drive_fs

Random pic with the coil cover on


View: https://drive.google.com/open?id=1wTXNbsXfKc5joCgaAWz8dGAnt7DatgP9&usp=drive_fs
 
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Replacement Cam belt cover (back) - Previous one was cracked and not suitable for turbo coolant return


View: https://drive.google.com/open?id=1PKca4yzW30g0ttzYlyv5pwijRXnob4mk&usp=drive_fs

New EVAP unit


View: https://drive.google.com/open?id=1dTo7Zs46OcceYd7R7C9Mvghp1wppZ5Og&usp=drive_fs

Some AN fittings for the turbo oil & coolant


View: https://drive.google.com/open?id=1QV1z1peRQRKLLgu7AmnNQ064SJhNK44r&usp=drive_fs


Cam cover has been Cerakote (Thin ceramic coating) - Sprayed on with advantages being:
stable against UV
Chemical can not touch it (even acetone)


View: https://drive.google.com/open?id=11Mdu2ozJugNN7gCYK2RAQnb8WOU1_AFj&usp=drive_fs

High grade turbo studs and bolts


View: https://drive.google.com/open?id=18xP2aKkosei4vFUChOl0yX3U9eJFK2pA&usp=drive_fs
 
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Been having problems with hosting pictues

So I had water coming into the boot area and at first I thought it was the rear lights and the rear number plate panel


View: https://drive.google.com/open?id=1lgVEhjHB8fehbkbMdwYYPa3uIHJkK9xC&usp=drive_fs

Roll of sealant


View: https://drive.google.com/open?id=1Yo3J2vXer6ozjcG-_K4dkOnwveekkYs-&usp=drive_fs

Lights cleaned


View: https://drive.google.com/open?id=1AaMBlqM_Bw8YG-xbYW0_XkGob8lDPxAE&usp=drive_fs


View: https://drive.google.com/open?id=1qGW_SAVQ5BbbnwRY_Dlnv7OlUy6sXRnq&usp=drive_fs

This did not fix the issue so I ended up in the boot to track down two holes which are meant to be covered at factory. I can only assume the OEM tape was removed during the repaint:


View: https://drive.google.com/open?id=1RI8gSM56wjVa3fiwilgK9csatP6MYSvK&usp=drive_fs

Sealed


View: https://drive.google.com/open?id=1h1Y7lJPCI93iWiy9rpnYemKTfVnatl2K&usp=drive_fs

During hunting the leak I found some rust (drain hole)


View: https://drive.google.com/open?id=1OE4mX1Gs9KfC2-TrA4fLEl2v7XrBHgUA&usp=drive_fs


View: https://drive.google.com/open?id=1XIu_uZAInEVHWrTsN0LuZ8uAC0OOCQ4M&usp=drive_fs

Cut out


View: https://drive.google.com/open?id=1E3ZwOb5r6jLfNaNlw7bKiWE-ubpCwe-G&usp=drive_fs

Plate made and treated the area


View: https://drive.google.com/open?id=1v1sTAcc8n6nOOYoZZ9YG6w5PZ1BewGz7&usp=drive_fs


View: https://drive.google.com/open?id=1-mUWN8ehFQ34pSDFaP0r7TzmZD9aEeCa&usp=drive_fs

While at it I waxed sealed the both sills


View: https://drive.google.com/open?id=1moQOvuGYTsS4a25I40q-btjqkTqmByPf&usp=drive_fs

Being a summer car its often on trickle charge and I wanted a more easier way of doing this.

Used the OEM gromment under the battery (so no extra holes)


View: https://drive.google.com/open?id=1QRWarDqiDl23urNqUVZlnEITd3TfMijm&usp=drive_fs


View: https://drive.google.com/open?id=10zohOt8JL0NQA0VP9KgdADSswhTCPtkT&usp=drive_fs


View: https://drive.google.com/open?id=1ZpFh5pHZj5W62uNKS3uOuLUPX_USsWvB&usp=drive_fs


View: https://drive.google.com/open?id=1sOMU1mgstPnsPKH3pW-mawDQqC4V8MZ_&usp=drive_fs
 
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Rear axle rebuild

This has been on the to do list for a while
Every bush has been changed (some very hard to find), sub frame powder coated, diff seals and oil changed, cv boots replaced, KW v3 suspension etc etc


View: https://drive.google.com/open?id=1CB1vLAL3fjlwgd2mHeH3ENLiqSiNLkYq&usp=drive_fs


View: https://drive.google.com/open?id=1Lbp4XYcfHv6rmlKKAHn9ZDZuFX4uBuDU&usp=drive_fs


View: https://drive.google.com/open?id=11B0GDrXSoiQeRPD3KWFed3R8aXcE6Sng&usp=drive_fs


View: https://drive.google.com/open?id=11YnFOpKGjcpUYjpmcCpsjE_sdUZA4CUf&usp=drive_fs


View: https://drive.google.com/open?id=10abDGy9NnRjsHztdCu3Wd04HYd40y1Ne&usp=drive_fs


View: https://drive.google.com/open?id=1rBLAhQ1V74pqXT5PFJtzXy71QEuy8KAO&usp=drive_fs


View: https://drive.google.com/open?id=1W982plNiEo9MdV-PVVpB9lG2S9jGkYAa&usp=drive_fs


View: https://drive.google.com/open?id=1laY8Z77LFSlhsZUW3WaiuVfVKVi9GurZ&usp=drive_fs


View: https://drive.google.com/open?id=1VjkvYG4Ykf1uFk17v2ce-yieYBUywfyi&usp=drive_fs


View: https://drive.google.com/open?id=1B3VftvIXjCeex-5ilKvtmCCAyCaGd3SC&usp=drive_fs


View: https://drive.google.com/open?id=1wTWbv06kAxktolmSlZDuOSGxAQ5OefeJ&usp=drive_fs


View: https://drive.google.com/open?id=1pPkEm7mG_3lJx2plEfwFCpHX5_JX8laL&usp=drive_fs


View: https://drive.google.com/open?id=1tbWxamuh8kZzF0XkEXjF0VbYOb4s-sOy&usp=drive_fs


View: https://drive.google.com/open?id=1AwN0fCiwUylKpVu0_AvsFjj8g6V7ffft&usp=drive_fs


View: https://drive.google.com/open?id=1NZ_cr1VfDrNXAcJjAV7DqH3dujtdbf6k&usp=drive_fs


View: https://drive.google.com/open?id=1kqGUUkiwQKbcN5dBcZxf6UHRjk1U0yXo&usp=drive_fs


View: https://drive.google.com/open?id=16V6hTXBtpu0PZMFV28Ar--EHiFUigiYj&usp=drive_fs


View: https://drive.google.com/open?id=1Z8vOQFQQxDQJ6XER8GRUBINE6mEJilt1&usp=drive_fs


View: https://drive.google.com/open?id=1Eids8-4zcEXeyxX-LgAzlcDoEOveiT21&usp=drive_fs


View: https://drive.google.com/open?id=171IMQL6KEv8owYxX1zWo05oYzTxeJpkM&usp=drive_fs


View: https://drive.google.com/open?id=191R4kZT0T5khmtdcAjmUQB6VQ4Bki3B8&usp=drive_fs


View: https://drive.google.com/open?id=1OUal-N5_KWDEOMisNFucfi_fa6HvQ089&usp=drive_fs


View: https://drive.google.com/open?id=1Iyf4Q6akqggRV_2cW7aLUdaFA10g-TUD&usp=drive_fs


View: https://drive.google.com/open?id=1Z9QcKcEBHRktRvDh293lb0H6tMgwJldW&usp=drive_fs


View: https://drive.google.com/open?id=1Uow8dHH8krtq04ut-T2h0XrKOHNnzvNQ&usp=drive_fs


View: https://drive.google.com/open?id=1WVY4uMNL4D4J_1F7S0ZfSj657nbGZzlJ&usp=drive_fs


View: https://drive.google.com/open?id=1nR7Ie6vR8380B0QOoL3kcdwzouabRFCn&usp=drive_fs

So far these KW v3's are very nice and comfortable which was my main concern.
 
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Rear abs sensors

Since doing all this work to the rear axle I had notice the abs would kick in at low speeds so decided to change the rear sensors:

They put up a good fight:


View: https://drive.google.com/open?id=1aKhH8xO4XJZMHIPITc0IuoHZ6bs0BM7o&usp=drive_fs


View: https://drive.google.com/open?id=18hjwGV_RtgaHZ0no3gzg9GkhYZtMfvfT&usp=drive_fs


View: https://drive.google.com/open?id=1BrOTJWAuGYU_59aeLqXI957aRLopxMom&usp=drive_fs


View: https://drive.google.com/open?id=1UBiVoT_leGdWFv_ddpYB9w0Hc9rLywt9&usp=drive_fs

Unpinned the plug to get the rubbers into the correct location


View: https://drive.google.com/open?id=1prG3FwNgORD-nqGjU3Wmf7uyGro4wDOZ&usp=drive_fs

Done the trick and now abs was behaving as it should

Next task bigger front brakes

Decided on:

Porsche GT3 996 caliper (larger than the C4s)
Ultra performance brackets
Merc ML350 discs - 330mm x 32
Brembo HP2000 pads

Also got my hands on cast front suspension arms


View: https://drive.google.com/open?id=1XPHJUrpL93Cp0q08CXHOXGaq4cshrnJo&usp=drive_fs

Replaced all the seals


View: https://drive.google.com/open?id=1MbWq16g4OMv5-icRNP941UOjYekYK8Jm&usp=drive_fs

Freshly powder coated:


View: https://drive.google.com/open?id=1Aky4UUN5cdBjJVAjIv7vRdl8CIr442xD&usp=drive_fs


View: https://drive.google.com/open?id=1zDtDyCHWR6l1zAN26j33_fzj_eYhtN98&usp=drive_fs

Old Vs New


View: https://drive.google.com/open?id=1Hd4I51okCJ5mbawqAygxI1DaDGaJ6C3c&usp=drive_fs

Brackets


View: https://drive.google.com/open?id=1_1ZevwqN8vDGKnPO2EjCa5U5z5xk3BUv&usp=drive_fs


View: https://drive.google.com/open?id=1Dp_ufoGcE1tzoKA-GEjUFn1Ott_muYRl&usp=drive_fs

Discs


View: https://drive.google.com/open?id=1-MQV2bUMK6fdVL4W9As9nMtGii4CpTsN&usp=drive_fs


View: https://drive.google.com/open?id=14oXoKEkKeTKt1m5i7r6xmtx3EOlYH4wb&usp=drive_fs

Pads


View: https://drive.google.com/open?id=14wDcWDaaABbarideLEwP3UcSXDzlESRF&usp=drive_fs


View: https://drive.google.com/open?id=1kvY5eo4CFEdaHYixqer7KS7FQR7DbBoM&usp=drive_fs


View: https://drive.google.com/open?id=1a0THAytunjEurLrxeT2TFrpc4WvlA2np&usp=drive_fs


View: https://drive.google.com/open?id=1LYpQAN1zFil6G8QCHkBygfIk4sSB2I0V&usp=drive_fs

All fits under the 17" wheels


View: https://drive.google.com/open?id=1TqXSsknztAmOw0-VG0oR7dTWSSELbzXK&usp=drive_fs
 
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In preparation for servo assisted braking rather than hydro I'm currently preparing a single stage power steering pump. The dual stage pump currently supplies pressure to the brakes and steering rack. The safe pressure for the steering rack is around 110bar so using a 100bar unit is totally.

For those that are interested Back side of the pump is from a 050145155A (100bar) & Front from a 048145155F
Servo, MC etc - 4f0612105F


View: https://drive.google.com/open?id=1gOgXbBJm3sImBkTZkLXQYvcI2T4pVOxc&usp=drive_fs


View: https://drive.google.com/open?id=15TKtQcr-rVJIQ8_xgqLoA-XnhbtNqlfq&usp=drive_fs


View: https://drive.google.com/open?id=13SjNxZMU1pJOx2k2e-Gh1rvvFZOG3XDD&usp=drive_fs


View: https://drive.google.com/open?id=1lmliVUVRyIW4Hvfqqn6pf9x6kGijg2b4&usp=drive_fs

Bought this seal kit:


Next install the kit and paint the unit.
 
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PWM & Walbro 525

Finally got around to setting up the R8 PWM unit


View: https://drive.google.com/open?id=1SrXovZLhQCfx0Uql0_yMauCJIx-_RcnP&usp=drive_fs

Pin out:


View: https://drive.google.com/open?id=1VprD9spLST7z3PRWh7w8b3biJIS-f0V4&usp=drive_fs

Used 6mm2 cable for all load terminals


View: https://drive.google.com/open?id=1RH3eL9MRWvKk-Kk4bw7DpiXIZRcNqE2P&usp=drive_fs

Perfect location next to the ABS unit


View: https://drive.google.com/open?id=12xrK9vAzpvJHmtTiskSCS-uFfzt_lquj&usp=drive_fs

Stock pump wiring was end of life


View: https://drive.google.com/open?id=1KmSMyit9o8D-ri3hVd6X_-Lk85Dy55IR&usp=drive_fs

Stock wiring Vs 6mm2


View: https://drive.google.com/open?id=1_pDhj4qiCqDzU12NJyz4xCmc8JZ2ttYn&usp=drive_fs

Stock connector re pinned


View: https://drive.google.com/open?id=14l47pid6MaeSAZujLsqIOuvF4_cwUScy&usp=drive_fs


View: https://drive.google.com/open?id=1Xxr-5wOofKD1EINLeXOY7_H2UdO0klCt&usp=drive_fs

Level sensor wires renewed


View: https://drive.google.com/open?id=1Y-E6qHereubbLS0rcbLP2SG62MM6hg2E&usp=drive_fs

After testing it I found the controller would power the pump even with the key out for around 15s
Looking at the wiring diagram on a R8 it turns out the controller is powered via relay.
So looking through some old diesel wiring looms I found a 40amp OEM relay with a holder which I repined with 6mm2 wire (used the oem fuel pump wire as the trigger)
Another great location for the relay under the PWM controller


View: https://drive.google.com/open?id=1vXEfco--BFaln1b7-vLojHuJ8OiOfRQS&usp=drive_fs

Walbro 525 pump install

The fuel pump basket was a pain to remove


View: https://drive.google.com/open?id=1u3c4LWg8LiaKCZJM9aC64STsE3yUHlvW&usp=drive_fs


View: https://drive.google.com/open?id=1KxmqNDrIQ4bUk5ZiB7CRwYKczORjMRtx&usp=drive_fs

Pump installed using a 034 adapter


View: https://drive.google.com/open?id=1GMu-a2wFE6aGzXdX3dxncARbn1S9gBx4&usp=drive_fs


View: https://drive.google.com/open?id=1HCXxS5N7FydyF5-TeqLjBDrKBtsV_dPr&usp=drive_fs

Basket installed and mapped in

The unit uses a 20hz works from 11% to 93% duty cycle
Works great and now the car can idle with just 3.4v with 35% duty cycle


View: https://drive.google.com/open?id=1sZoEb4ucZJ076ZSP0uevqeNCV23VUzAU&usp=drive_fs
 
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Here is a full parts lists for the PWM set up:

PWM - 4F1906093B
Plug - 6N0973755
Terminals:
963709-1 AUTOMOTIVE CONTACT, SOCKET, CRIMP, 11AWG
927833-2 CONTACT, SOCKET, CRIMP, 40A

Fuel level repair wires
000-979-135 E

Repining walbro fuel pump to oem connector 000979212E (2.5mm2)

The OEM 4 pin relay I used also used the 927833-2 terminals so buying these in bulk paid off.

One thing I would say is buy from a good source and not cheap ebay terminals.

I used https://uk.farnell.com/ & TPS
 
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Nice crimping btw, which tool?

More great work.

Surprised the OEM wires melted like that tbh.
 
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NHN said:
Surprised the OEM wires melted like that tbh.
Click to expand...
I've seen it a few times, including when I put a Walbro in one of my older machines. R8 had it in one of REperformance recent vids.

What surprises me is more cars don't go bang but I guess lack of air saves most of them :astonished:

@bobby singh Epic work mate :icon thumright:
 
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NHN said:
Nice crimping btw, which tool?

More great work.

Surprised the OEM wires melted like that tbh.
Click to expand...
Thanks mate - I use Toolaid 18650 kit, its not the best but does correct crimping

The OEM pump wire is now over 30 years old and the car has been running a Bosch 044 pump for the last 10 years or so.
I was reading some of the posts on the S2 forum and you would not believe some run the stock wiring with a walbro 450 at 600hp.

I've gone over the top with 6mm2 wire but its not something I need to worry about again.
 
While running the cable for the PWM unit I noticed the front insulation was damp.
I started digging and found the water was coming via the pollen filter housing:


View: https://drive.google.com/open?id=1c_3RU42iFpW9LktuiIs6_YZF6jz7TLoS&usp=drive_fs

Cleaned up the whole area


View: https://drive.google.com/open?id=1--Uwt9n5WSDRReYWDpYO5G-9RzBV8cCq&usp=drive_fs


View: https://drive.google.com/open?id=1oLUcuaWXlsOdlMUW55fkyMxkUKsKJbTc&usp=drive_fs

The seal itself had been overlapped on one side and off course its no longer available
So used 3M sealant


View: https://drive.google.com/open?id=1l4PY7tVtJoj87Pw68UiD9HQtSHLDd0F3&usp=drive_fs


View: https://drive.google.com/open?id=1Nb09sW0BHqthU_esgg8X3XZacOLbNDas&usp=drive_fs


View: https://drive.google.com/open?id=1zdlmUAsoF89DnIHXzTqwOSm7kzTExPIO&usp=drive_fs

Whole area was then sealed with Dynax-UC clear wax
 
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Fuel Rail pressure sensor

Next task was to install a fuel rail sensor to enable fuel tracking:

Fuel pressure sensor X

Fuel pressure sensor Fuel pressure reference Atmospheric pressure Manifold pressure (MAP) - Must be used to be able to use the fuel pressure deviation tracking features below.
maxxecu.com maxxecu.com

Had mount machined out of stainless steel and I used a Mercedes M10 x 1 fuel pressure sensor from their diesel application - rated to 11.5bar


View: https://drive.google.com/open?id=127dOmBKIHQYegvoCENlKJbnoqUeypPju&usp=drive_fs


View: https://drive.google.com/open?id=1AOEbLrZgdVxLEfiLM_hQ6SXDNnwBAyPu&usp=drive_fs


View: https://drive.google.com/open?id=1BSWalvUo9S7jiypYcxGqKgAa5nzr-3vG&usp=drive_fs

Powder coated


View: https://drive.google.com/open?id=1aozcBaWfSq4iFSufFPPGQZJcrAxMgKWy&usp=drive_fs


View: https://drive.google.com/open?id=1RUg2C62Ib9vFztUGwNdcE5mpkHGxKaCh&usp=drive_fs

Perfect fit:


View: https://drive.google.com/open?id=1RW6dZrTSbCGo3G8dC8oOYs0WWff9RPcb&usp=drive_fs


View: https://drive.google.com/open?id=1q3RDIy_x4p6CPUEdAwOIpOIlgvaH97f9&usp=drive_fs


View: https://drive.google.com/open?id=1Wtv_uhdivmlwGhgi8kV712JtG9NIYsEI&usp=drive_fs

Got exhaust manifold pressure sensor mounted from a PSA rated to 6 bar - used the psa bracket into brace


View: https://drive.google.com/open?id=1p7Z1PNv0u0SkLXczMMGqh8VWcjaxG3fS&usp=drive_fs

Managed to get my hands on new oil cooler - might not be man enough for the new engine but for short weekend blasts hopefully its ok.
 
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Engine work has finally started - Old engine removal:


View: https://drive.google.com/open?id=1Z7OAHwTAOlgu1luJQLYxz0_W_ASTYt0P&usp=drive_fs


View: https://drive.google.com/open?id=1OuJglNIYf-3Y_ygEmuQELe6MqFt0BW-2&usp=drive_fs


View: https://drive.google.com/open?id=1bh4wWrTN5ZgUMmKgqHfpRrSET_3Q9eJb&usp=drive_fs


View: https://drive.google.com/open?id=1BT9XHRwml6_kHcXD48OUmXBjY0p2hEoN&usp=drive_fs


View: https://drive.google.com/open?id=1KN5xVzYt2IQKs3l1DjLg2gLS7yzX23rO&usp=drive_fs


View: https://drive.google.com/open?id=18afiubSMjP2gGpeXhYSvY29JBvGfoOsb&usp=drive_fs

Engine bay washed and detailed:


View: https://drive.google.com/open?id=1DkTPf5GTmyrP9sfImpwgXdhdyYErZKoh&usp=drive_fs

Sub frame


View: https://drive.google.com/open?id=1ilkxMYj6boAkviUw9cBR_n_rdq6Jw1Nh&usp=drive_fs


View: https://drive.google.com/open?id=10Arj_7TUIIwAUWwpjVyrMXsqARLSeE9T&usp=drive_fs

Oil cooler duct powder coated


View: https://drive.google.com/open?id=1duuF7L1B8Eq2j5INJB4td4lzz5wtXUj6&usp=drive_fs


Replacement engine mounts


View: https://drive.google.com/open?id=1QIJ2GfEh_SFnIFxSZWoGlNEIaz8Ul9QU&usp=drive_fs

Metal face clutch release bearing


View: https://drive.google.com/open?id=1XRzQ-_u-osxrL75fv9oSXPYLIoRrZ7EL&usp=drive_fs

Old clutch line remade


View: https://drive.google.com/open?id=1YSfjlN9LoEyawCi_w87yfHW0F5Hy-__D&usp=drive_fs


View: https://drive.google.com/open?id=1BI5bbrN3AqwQldfsx0AoD7j1vu9PaIl7&usp=drive_fs

Water manifold:


View: https://drive.google.com/open?id=1-t5mPMTGu4MKO0vCXHuk_hHnr0b04YpF&usp=drive_fs


View: https://drive.google.com/open?id=11EmnKnHMF6Y1yOVAeI23m9kgUk-zn0Xi&usp=drive_fs


View: https://drive.google.com/open?id=1E5_xzBgoAsBk0d1-Iz7wULH1hAAbmFu_&usp=drive_fs

Track rod arms


View: https://drive.google.com/open?id=14uThNeKslWOmOcIcU4vzo7wAXStjPg8C&usp=drive_fs


View: https://drive.google.com/open?id=1E2E8-F2JiIgl-wcIGYhvB4J1VOxzwBmd&usp=drive_fs

Adjusters with 17mm hex compared with the 14mm stock


View: https://drive.google.com/open?id=1H1fLFctQLxpl5_5xGZZBBs_s1fRTHO0G&usp=drive_fs

Aux loom recondition


View: https://drive.google.com/open?id=1WV2JveWVS6y3fOEmWbrgDngJbCyiL2jP&usp=drive_fs


View: https://drive.google.com/open?id=1r1XQt5Pd1yebDOj9HFdxUNvs6bxBLNBS&usp=drive_fs

Steering rack rebuilt


View: https://drive.google.com/open?id=1AIx8u933WMEvNhystZb47gCi-QJ_s2vm&usp=drive_fs

Front hubs, dust shield, brackets etc all powder coated


View: https://drive.google.com/open?id=1ED0NXzbWvxgYrZ4wALCwUWlJpasuji1b&usp=drive_fs

SKF bearings installed


View: https://drive.google.com/open?id=1xWNRP3kCQFL5XUxt6AJRZmhh37-NqR2d&usp=drive_fs

Gearbox oil changed and cleaned up


View: https://drive.google.com/open?id=1U3PEeG8_icxq742OvGGqBV6HmUEZ4x5A&usp=drive_fs


View: https://drive.google.com/open?id=1ocIGgSxs1hGFcXnY6N5fkr1JyeLalvy1&usp=drive_fs

Flywheel with 60/2 trigger built in


View: https://drive.google.com/open?id=1o7hwNpQGJUUnP4oSqPWlvHpXnDJLuchm&usp=drive_fs


View: https://drive.google.com/open?id=18Euxc8CYQLQH-IYB5FvKQJzaKOi9jhEh&usp=drive_fs


All new suspension bolts:


View: https://drive.google.com/open?id=13hicuUUzs6fKfeNxzccRvmI_UI4aZr7R&usp=drive_fs


For the last few weeks I've wire been brushing, cleaning etc etc all the small parts of this engine but the task continues.....
 
Last edited:
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Excellent work as always Bobby
 
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From hydro to Vac servo
I wanted to get rid of the hydro servo as parts are hard to come by and its a complex system to maintain.
I used kit from https://www.ultraperformance.co.uk and used a servo from a Audi C6:


View: https://drive.google.com/open?id=1fHPhxgihgQJgg9RVxfV9nuMI83phCV7q&usp=drive_fs

(Got it wet painted)

Stock set up

View: https://drive.google.com/open?id=17C3uTK9hrDlR-ki-uChdfyh80k9EDYu_&usp=drive_fs


View: https://drive.google.com/open?id=1y37NjCYI1MRZU2EPWL2bt5K--GSp7pjL&usp=drive_fs


View: https://drive.google.com/open?id=1_nj3Uo8mqdYW1zbLiwLBO3LErL3i5hFv&usp=drive_fs

Adapter plate mounted - noticed the cross brace needs cutting off as well as the fuel line holder


View: https://drive.google.com/open?id=1WsiG1nZj_0l-lDPgTNuked55Hf5pk5KR&usp=drive_fs


View: https://drive.google.com/open?id=1jenNZDVq31dcLLEFnnRvk8rnBedgCkZY&usp=drive_fs

Cuts made and painted


View: https://drive.google.com/open?id=1xeJed4FKPafEo-58gGKICt6zWTfpp-zN&usp=drive_fs

Servo fits but the fuel lines are in the way


View: https://drive.google.com/open?id=1dYa9_Se0PuOZJdUK9mDlcVwZJms6P-Tl&usp=drive_fs

Cut the fuel lines behind the heat shield under the firewall


View: https://drive.google.com/open?id=1dYa9_Se0PuOZJdUK9mDlcVwZJms6P-Tl&usp=drive_fs

New fuel lines (an6 from BMRS)


View: https://drive.google.com/open?id=1sWomMhBpRB3QFDCfBncuEk6VJf1UuFo9&usp=drive_fs

Wiring bracket needed cutting short too (was coated afer)


View: https://drive.google.com/open?id=16OZVK5uuEMFRTGoLM2JmZVs2vljwQxzd&usp=drive_fs

Next AC line needed modifying to clear the servo


View: https://drive.google.com/open?id=1YXkOUXwrWGSkk70BR9lS51I58k0btWjw&usp=drive_fs

40mm cut out where the G clamp is

View: https://drive.google.com/open?id=1N3SzgDyGcNLZPZa6Zsgfk-K-a02afE4m&usp=drive_fs

And then the bolt in front of the servo needed 60mm extending


View: https://drive.google.com/open?id=1BJ1pq9tQKrSb2yRKUdsuPsxDLPKJ3m7j&usp=drive_fs


View: https://drive.google.com/open?id=1bkW-3eSWP75y_Gs6M0QKIDRX0knKwzAJ&usp=drive_fs


View: https://drive.google.com/open?id=1a44uSdEbX1LfbBHtHAGxYKZTa7rpCCFE&usp=drive_fs


View: https://drive.google.com/open?id=1ybtA3MLtamBgB9Ytr3xW8KYlTToZpLJe&usp=drive_fs

Ac line complete with all new seals


View: https://drive.google.com/open?id=18-RBcXDtQ5x2KqMti8-zoy2MPDieZ6oK&usp=drive_fs

Brake lines extended for the new master cylinder & heat protected


View: https://drive.google.com/open?id=1t0EXB74NaQpQeNLLpQsiDq5Bpv9DWfV4&usp=drive_fs

Heat shielding made:


View: https://drive.google.com/open?id=1IEGNPeR44FtAzNHW3oItzaAh-whVSMmP&usp=drive_fs


View: https://drive.google.com/open?id=18R71UHOTiYIg1bEIBJ4LDfM7nhJHj6R3&usp=drive_fs


View: https://drive.google.com/open?id=1PT2_ppvYm8f59-SdWHoB7yzvvW9ZYGOx&usp=drive_fs


View: https://drive.google.com/open?id=1Jlq80O0A9e7mIZDc2vcgg2jfZKYPKxYO&usp=drive_fs

Extra wires ran into the engine bay via ecu loom


View: https://drive.google.com/open?id=1r8IwYrtDHYD7ANRAcVotA7L1t_-wJAO9&usp=drive_fs
 
Last edited:
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Man this cars epic, the work & atd is great bud.
 
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Last edited:
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bobby singh said:
Thanks - its getting there slowly
Finding time to do my own car is always challenge as customers cars have to come first.
Click to expand...
Do you run your own place for clients also, as be good to know when I'm asked by my clients if there's anyone out there.

Edit, found your yt channel lol
 
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bobby singh said:
New heat shield nuts

a1AmDwS.jpg


All air con lines redone with fresh hoses

IsEbpIi.jpg



Alternator seen better days

cPJ20lX.jpg


Rebuilt

f2ONRie.jpg


Cheers
Bobby
Click to expand...
Those shield nuts look much better quality than the ones of today that corrode to feck very quickly.
 
The BST inlet manifold didn't want to accept the stock rail so needed some work

Flattened around the fuel pressure reg


View: https://drive.google.com/open?id=1wtptsEk96Ru6DkYWafnDTnL9U3XuMJBk&usp=drive_fs

Leaving space to tighten the hose etc


View: https://drive.google.com/open?id=1UkLgeOoQD0fquIFmCtCfi1ayh4_p_dMH&usp=drive_fs


View: https://drive.google.com/open?id=11X2rj-6fWlZC9YlYpdHgOQlG3XBnP8Bf&usp=drive_fs

Then the stock injector were hitting he head casting:


View: https://drive.google.com/open?id=10JyayhFIsrXPuxbmNBgpeoAA_Zk814Uy&usp=drive_fs

More shaving


View: https://drive.google.com/open?id=1bIKvBzkQ37Jh1AbGS9EmbHuYluNW14bP&usp=drive_fs

Quick test with the 1000cc injectors (the rail mounting holes will need increasing


View: https://drive.google.com/open?id=1fQNIEsUiDhBENm55yzPh95a9HtsKjnQb&usp=drive_fs
 
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