My T2 build

Well I found some bolts tonight.. got home put the water pump, water pump housing on turned the engine around got the flywheel on and realized the bolts are to long.. so I used an extra washer to shim them out a touch now they seem fine EXCEPT the head sticks out to far now and the clutch disc cant sit the way it should

basically the bolts are to damn long.. back to the drawing board again!!!

They had the right size botls.. tonight I will have the flywheel on, clutch on, water pump will be tight and bolted on, thermostat will be in and the neck will be on.

the turbo will be bolted on and the lines run.

I will be spraying the engine bay out with brake clean to get things cleaned up..

I will install the release bearing

and then tomorrow after work me and my buddy are gonna drop this baby in

then I can get the upper intake all cleaned up and painted

get the electrical done

get the fuel pump installed

get the ecu in

and next week I order up my intercooler kit

I plan to have this car running by the end of the month.

that clutch wont be bad its a sprung hub.. I have drivin many 6 puk clutches before..

anywho on to the pics..

flywheel on:


clutch disc on:


pressure plate on:


Water pump pulley is on.. its smiling:



more pics




I am currently fighting with the turbo it needs to come back off and everything spun the right direction then put back on.. I was trying to angle the compressor housing but if I do that the wastegate actuator wont bolt on

Tomorrow the engine goes in.. I will prolly drop it in without the turbo so I can redue that after I get it right

The engine is in... I have to give a big thanks to both my friends Aaron and Mike... without them I would have never been able to do it...


I got the turbo off (so I can fig the problem with its location), I swapped in new engine mounts and then we got the engine on the hoist..

It was a pains since we left the tranny in... we started to get it lined up and I asked to pull it out so we can get it strait and I noticed I forgot the release bearing lol..

I got that on then we tried someone more with no luck..

I left for 5 minutes to take my nephew to work leaving them there.. I came back and they had the engine being bolted together..

I helped finish that up got the starter on and no I just need to finish the rest...

anywho onto pics..








More to come

ok its a bit cold today so I did not spend much time (as of now out there) I mannaged to do the following

connect the front oil cooler line
connect the wire to the oil pressure sensor
connect the wire to the oil pressure sender box
put in the spark plugs
put on the new slave cylinder and SS braided line and bleed
put the inspection cover on over the flywheel

I will need:
new banjo bolt for the rear oil cooler line

I still need to reclock the turbo corectly, clean and paint the uim, get my injectors back, change the fuel filter, get new fuel hose, get that all mounted and then get the intercooler mounted and plumbed (once it arrives)

then I can start on the inside with installing the ecu, fuel pump, get the battery charged and give it a try!

Here is a few pics.

I got the oil filter pedestal on
got the turbo clocked and all bolted on
got the outer coolant line hooked up to the lim

what a pain to bolt the turbo to the manifold with the manifold in the car

on to pics

last night I went out and bleed the slave cylinder completely through with some elf dot 4. tonight I am going to go pickup an end for the turbo feed to the front iron. The injectors should be here today and if so I will install those and then get the upper intake cleaned, ports blocked, outer lower plates removed, and painted

this weekend if everything goes well I plan to have the intercooler being installed, the engine done, the ecu swapped in, and the only thing left will be the fuel pump...

I hope this all works out and I get it done in the next week or so.

Start up is getting real close.

Here are some pics from tonight

Got the injectors in and the fuel rails on.. I have 2 of the 3 fuel lines on.. and the wire harness ran and lots of plugs hooked up..





Tomorrow I need to put a new end on the wire for my coolant temp sensor (on back of rear iron)

tonight I plan to clean up the uim and if I have paint down stairs I will paint it up..

Hopefully I can get a new fuel filter come thursday.. install that and the fuel line to it and then put the uim on...

Nothing to eventful today...

I got my rear oil cooler line on, got the upper intake painted (got something special for you) when I get pics of that.

sprayed the engine bay down with brake clean... tomorrow I will clean it with engine degreaser then more brake clean and hopefully it will be decent..

I got to order up a few items but I should have the upper plenum on by Saturday (wont get much time tomorrow or friday to do any work on it)

Plan to get the intercooler on or close to on this weekend..

A bit closer I am !

[djmtsu]

Quick question.

Why keep the S4 turbo? All that goodness, and then that!

[stylEmon]

Is it really that much different from the S5? Basically, S5 has a slightly larger turbine and no twin scroll, right?

because I have the S4 turbo, and manifold and because I am running the stock ecu for now sine I will be on the stock n/a drivetrain so I want to get the engine broken in, enjoy it this year then swap the drivetrain then upgrade the turbo and manifold...

Just the way I work.. first rotary build.. since I did it all I am still scared to turn the key.. no need to make it even harder on me for the first one..

[stylEmon]

great logic... why make things more complicated then they already are (na to turbo swap)

[Nutsid]

I'll have to finish this read tonight, but wow. Great build thread for sure.

Ok so the intercooler arrived today and WOW it is HUGE...

I got the bumper off tonight and noticed that I will be doing alot of cutting and hammering in the front to get this to fit...

Anyways onto the pics

The intercooler


The piping, couplers, clamps


the bumper had to come off


the intercooler next to the car



The intercooler in front of the opening.


the thickness of the intercooler (3" thick)


The dimensions are

31" long x 21" tall x 3" thick with 3" in and outs

Oh and from last night I got the uim all painted.. here is what I did..








What do u guys think?