Monday, August 29, 2011

Exhaust manifold

Installing the exhaust manifold was pretty simple, Just screw in the studs first using high temperature anti-seize paste and then put the gasket and manifold on the studs and bolt it all together, it kinda was a pain because there was a whole bunch of stuff in my way so had like no room to bolt it all together, would have been easier to attach to the head before mounting the head to the long block. This is a Rs2 exhaust header replica.
Waste gate attached to the top flange and turbo to the bottom one.

Tuesday, August 23, 2011

Master cylinder

This is the vacuum booster where the mastercylinder on the brake system goes. When you press down the brake pedal, a rod goes inside the master cylinder and compresses the brake fluid.
This gasket is old, was not able to locate a new one so i will just be putting gasket sealer on it to be sure, it has to hold a vacuum.

put the sealer on both sides and insert into the booster and bolt it down,
after the reservoir is installed

Axle install


Ok, first take any lithium based grease and lob it in the flange, making sure no big air bubbles, and a lot is needed.
then after that it will look like this. and then just stick the axle on it and bolt it together.
then it is installed. repeat for all other axles as well.

Thursday, August 11, 2011

Fuel rail install

Take your fuel injectors and the fuel rail.
then just squeeze the injectors into the rail making sure not to pinch the O-rings or you will have a gas leak
will be hard to do.
After they're in the rail, just insert it onto the intake manifold and lightly hammer down with a rubber mallet making sure not the pinch the other O-ring as well.

The fuel injectors and rail have just been installed, simple, the rail is built by 034 for the 20v head of the Audi Inline 5 motor.

Intake manifold

So I installed the Intake manifold, pretty simple to do. I installed a Wagner tuning high output intake manifold with a 034 intake manifold gasket/spacer.
On this intake manifold it puts the throttle body near the front of the radiator. I'll be using an electric power steering pump, so I don't have to worry about fitting of the stock belt driven pump. However out of shear curiosity I'm still going to try to get the old broken pump in there just to see if it would fit.
The stock S2 and Rs2 intake manifolds are built quite a bit like this one however the throttle body is located behind the cylinder head and therefore have no problem with the stock power steering pump.

Sunday, August 7, 2011

getting the engine in.

So first off I lubed up the plastic tab and the metal rod the throwout bearing goes on, be gentle on the lube making sure none gets on the clutch/flywheel.
I removed this guide dowel, its to big, common when installing different transmissions into cars, this tranny from a Audi 2000 S4.
Line everything up, the transmission should just slide into the pilot bearing.. do "NOT" force anything, you will break your car.
Bolt it all together, then hoist it up onto the engine hoist, you will need an engine balancer as well.

Now the engine is in the car with the transmission, in retrospect it would have been easier to put the transmission into the car first then the transmission onto that, however its all together now.
This is the stock engine block with an upgrade to a 20 valve head gotten from a 1990 coupe quattro, stock was 10 valve, the Long block was built to withstand over 1000 horsepower by 034.