Bobby Singh's Audi S2 avant project

bobby singh

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Bouncing doors - so for sometime my rear doors seem to bounce when you close them. Managed to get a used lock that's at least fixed one side:

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I also bought a B4 sunroof as parts are getting harder to find - I also used this to learn how to take it apart and then finally changed my drip tray and drip tray arms:

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Drip tray replacement:

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Roof bars

The paint shop and I was both confused on how the roof bars come off and after some invesigation and lots of wd40 they are finally off.
Im hoping to get the edge roof painted now

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Cheers
Bobby
 

B5NUT

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Can I ask where & what type of bulbs are used in the diff lock button, at least one of my bulbs have failed so may as well replace the lot
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bobby singh

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Can I ask where & what type of bulbs are used in the diff lock button, at least one of my bulbs have failed so may as well replace the lot
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I tried looking through my ebay history and could not find the listing, however Im sure I used a thread on the S2 forum - maybe this is of some help:
Cheers
 

desertstorm

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Hey Karl - correct 8374 T3, to be honest I don't have a target for power - it makes whatever it makes. I will make the bottom end a 2.5l to help spool, but off course if its too laggy I could downsize after.
I want that 5 pot sound from the group b days haha
With a 2.5L bottom end that will make it a lot better off boost and of course it will spool better than the stock 2.2L .
Those are 750bhp capable turbos so I would of thought you would be looking at around 700bhp plus crank hp with 2.2-2.3 bar boost. And those EFR turbos will deliver higher P2C ratios than the Garrett turbos so you can run more than that easily if the engine / transmission will take it.
 

bobby singh

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With a 2.5L bottom end that will make it a lot better off boost and of course it will spool better than the stock 2.2L .
Those are 750bhp capable turbos so I would of thought you would be looking at around 700bhp plus crank hp with 2.2-2.3 bar boost. And those EFR turbos will deliver higher P2C ratios than the Garrett turbos so you can run more than that easily if the engine / transmission will take it.
Indeed its very efficient https://www.borgwarner.com/go/TZ8V21
 

bobby singh

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So the car had the roof redone:

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Good news is the roof is much better now and with the roof bars out the way it made it much easier.
However, the roof trim still got in the way and it started falling apart when trying to lift it.
I've managed source one from a car being broken so this will need a revisit in the future.

In terms of tuning - I've managed to get wideband lambda going into the ECU

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I'm using the following formula:
(((X*0.007212) + 0.3125)) for the TunerPro cal

My lambda controller is set as follows:
0.5 lam @ 0.5v
2.0 lam @ 4.5v


Cheers
Bobby
 

bobby singh

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So have you found another MAF fits and will work with the stock ECU and a slight remap?
No I'm working on getting rid of the MAF and use speed density hence why wanted to get lambda logging into the ECU.
You have a broken MAF? I could flash some chips with a stage 1 tune with SD if you want?
 

B5NUT

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No it's still working. However they are rare and expensive now. So was just looking around for future options. I'm good for tuning. Someone gave me "homefries" remap chips, however I'm planning on keeping the car stock. However if you have a chips that could bypass the MAF so I could keep the car working until a replacement could be found then I would be interested. Think I'm paranoid about most of the obsolete parts on this car!
 

bobby singh

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No it's still working. However they are rare and expensive now. So was just looking around for future options. I'm good for tuning. Someone gave me "homefries" remap chips, however I'm planning on keeping the car stock. However if you have a chips that could bypass the MAF so I could keep the car working until a replacement could be found then I would be interested. Think I'm paranoid about most of the obsolete parts on this car!

This has the links for a stage 1 tune with Mafless tuning
 

LarsE

New Member
So have you found another MAF fits and will work with the stock ECU and a slight remap?

The only real MAF solution i know of is prj:s own MAF swap for a B5 RS4 one. I run this on my B2 90, but it need hardware mods as the speed density do. The maf connector needs swapping for the appropriate one, and som jumpers made into the ECU. So you are basically stuck with your MAF as long as you don't go for the speed density mod.
 

bobby singh

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Engine work

So with the help of a S2 Forum member I got my hands on a AAN block (same as a ABY but for a URs6) - It came from a car with a broken timing belt and the head had already been sold off - 100k on the clock before this happened.
Block had been sitting for 7 odd years like this:

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Done the deal and got it home for a strip down:

Don't think the water pump is usable :)
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3litres of oil came which was a good sign:

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Crank and pistons out - note the main bearings are like new with "95" stamped on all parts so its never been apart I would say

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Gave the engine a nice pressure wash and its looking a lot better already:

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With block cleaned - I wanted to get on with the grinding to clear the new rods.
In went the Diesel cranks with old pistons and new rods

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20vt cranks Vs Diesel (top)

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More to come....
 

B5NUT

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Good find on the copper washer. I never tried but is the pump easy enough to remove?

What will you be doing with the bores on that bock, as the top section appear look a bit rusty in the photo's but it could just be the light.

I would be keeping the engine as well. Do you think you would revert it back to stock if you sold the S2?
 

bobby singh

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Block work

Found some metal in the oil pick up so stripped the oil pump to check the condition and it looked mint:

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Noticed the spring was already skimmed so should have plenty oil pressure

TPS still have the oil pick up rubber and oil pump spring so ordered those new

Torque plate - nice block of alu turned up

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My cnc guy will machine this soon - I haven't seen many use a torque plate for these engine for boring which seems very strange considering its rare engine to find.

Block condition looks a lot better after a soak in vinegar

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S2 sump also landed - time to order a WELD-IN SUMP BAFFLE KIT

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bobby singh

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Good find on the copper washer. I never tried but is the pump easy enough to remove?

What will you be doing with the bores on that bock, as the top section appear look a bit rusty in the photo's but it could just be the light.

I would be keeping the engine as well. Do you think you would revert it back to stock if you sold the S2?
Good question - I bought this car to put a smile on my face when I drive it.
I understand it will be worth more stock but my objective was to extract that 80's 5 pot sound from this.
The bore rust I'm not too worried about as I'll be boring it 0.5mm+ to make way for the new pistons
 

bobby singh

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Forgot to answer your question about the pump - mine runs a 044 pump which sits inside the stock basket. However, I believe the pump should be sitting lower and you need to hack the plastic to make it sit lower.
But I failed at removing the basket so just pulled the pump up.

I've ordered this so the pump depth can be adjusted correctly - https://turbozentrum.co.uk/034Motor...Pump-Adapter-Kit-Bosch-60mm-Audi-S4-2000-2002
 

bobby singh

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So had the Air Bag light on for a while now and the error code was:

65535 - Internal Control Module Memory Error
00-10 - - - Intermittent

Its related to some bad memory or checksum issue.

I got hold of a replacement item - 8A0959655 but ended up with more errors. In the end I installed 8A0959655B from someone breaking a s2 - no more light :)

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Reverse lockout has always been broken on my car (could get reverse when going for first)
After some serious research I found the lever in Germany brand new (note the 5 speed ones are different)

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Engine parts keep coming:

Oil pick rubber boot:

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CNC guy now has the torque plate and we found the PD 8v head lines up pretty well to the 5 cylinder head gasket:

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