Audi S2 Coupe Project-Getting to the Engine

More catching up…this time with some engine building…

Let’s get to the pics…

The bay has been mostly cleaned up. I still need to get in there and do some more cleanup around the rack and tranny tunnel. Those were the last things to come out and I haven’t cleaned the bay for a few years, lol.

I also had my rack sent back to Jorgen for a rebuilt unit. I had considered doing it myself, but I’ve got to draw lines somewhere. It was kind of nice that I didn’t have to clean it either, and it came freshly painted, even if it is a crappy paint job (no primer, probably not prepped great), but as long as it doesn’t leak and does its job, that’s all I was paying for.

Just for reference, this oil pan is a good indication of the ‘protective coating’ that the 7A was under. The 3B was much cleaner, but not so well preserved in the lack of 1/4in grease layer.

I stripped down the both the 3B and the 7A engines so I could kind of cherry pick things that were interchangeable and also figuring that the parts that don’t make it into the first engine, may end up being used for a subsequent built motor. The block was painted with grey engine enamel. Hopefully it will show the leaks, or hopefully the lack thereof better.

I installed ARP head studs and Reinz MLS headgasket…

I wanted to mock up the motor and accessories because I knew that there would be issues with getting everything to play nicely together. It is a combination of 3B 200TQ, ABY S2, and 7A CQ, so there is going to be some fitment issues. I’ve left the 3B head as it was for this stage. No cracks around plug holes. I may run 7A exhaust cam at a later date.

The first issue was a result of the ABY intake manifold being used with a distributor engine like the 3B. The ABY was direct fire and did not have a distributor. At first I didn’t think it was going to work and did a little research here and s2forum and found that it was indeed an issue, but one I hadn’t come across or considered. Where is hybrid_hatch when you need him to keep you straight?

So I’m also using the phenolic spacer and 2nd gasket that adds about .40” of offset. This turns out to be just enough.

Here you can see the alignment problem between the ABY intake and 3B pressure pipe. This is compounded by the phenolic spacer. I plan on fabbing up an intake tube out of 2.5” aluminum to go from the throttle to the crossmember link pipe.

Around this time I was looking through all of my stock hoses and realizing I didn’t want to use many them in their condition and really didn’t want to clean any of them. I will likely have to use some and pieces of some but this box of snakes should get the job mostly taken care of. Thanks 034!

One other thing that I forgot to mention above about fitting the STR manifold was the tight clearance for the oil supply line and the log on the manifold. I was able to tweak the hardline and get about 1/2in of clearance. Hopefully that is enough and I may put a little ‘shield’ that clips on the hose to block the heat. Things are looking nice and clean.

I had to take the wastegate completely apart to enlarge the mounting holes. I tried drilling them by hand at first but after going through a few drill bits, it looked like the milling machine was required to finish the job. It made easy work of it. So while it was all apart, I cleaned it up and explored around a bit. I installed the 034 1.9bar spring that’s been sitting around for a few years. It is the shorter one on the right in the picture. Stock 3B is on the left

With the turbo and wastegate finally able to be mounted, I test fit the 034 3” downpipe. I have the full 3” system and will need to v band a race catalyst in there. Notice: a few welding tasks identified thus far, and I am a poor welder. The downpipe looks good but we’ll really have to see when its all in the car and there is a bit more to interfere with.

Then, here is where the engine currently sits. I am trying to work through everything I can on the stand and will then mount up the Fidanza aluminum flywheel and Spec Stage 3 clutch. I will be putting the engine and tranny back in together with as much mounted to the engine as possible.

I am now trying to consolidate a few of my lists into one that I can work off of, but it is coming along slowly.