Fitting my RS2 parts to my ABY S2 shortly

[orsum]

I will be removing my existing S2 stuff and installing the following shortly.

RS2 Exhaust manifold
RS2 Turbocharger
440cc Injectors
Replacement ECU that has been upgraded

Do I need to change any pipes or are the diameters the same on the S2 and RS2?

I am aware that there are three manifold studs that need to be made shorter.

Anything else that I should look out for?

Also about how long should this take? start to finish.

I will be upgrading the DP and the Intercooler at a later stage.

All advise welcome

orsum

[Rikki Kitto]

Buy new gaskets for everything you are changing, would probably get new nuts and washers too sure all the pipes are the same just doing mine at the moment

[Rikki Kitto]

Tell me more about the studs I didn't realise this

[andy10v]

Tell me more about the studs I didn't realise this

RS2 has a few of 27mm studs as the 35mm studs on an ABY would hit the RS2 manifold. I just fitted replaced all the studs with short ones, but you only need to replace or shorten 4 or so.

[andy10v]

I will be removing my existing S2 stuff and installing the following shortly.

RS2 Exhaust manifold
RS2 Turbocharger
440cc Injectors
Replacement ECU that has been upgraded

Do I need to change any pipes or are the diameters the same on the S2 and RS2?

I am aware that there are three manifold studs that need to be made shorter.

Anything else that I should look out for?

Also about how long should this take? start to finish.

I will be upgrading the DP and the Intercooler at a later stage.

All advise welcome

orsum

I take it your ECU is for 440cc injectors?

Do you have new gaskets/hardware?

RS2 turbo bolts right on, you need to bend the wastegate flexi to line up as the RS2 manifold moves the turbo 5mm or so.

If everything goes to plan its an eay afternoon job, if studs start snapping/nuts rounding off etc then......

Do you have a bent spanner for the downpipe nut?

Something like this (heated and bent to match the curve of the downpipe.



Airbox out, take the intake pipe that goes along the cam cover, you can also pop off the front bumper/cross member if you want more access.

[orsum]

New gasket
Nut
Bent spanner

Aware of and will be arranging


Studs not sure if I should replace. If the nuts come off ok then I would be tempted to use the old ones.

Moving WG did not know thanks.

440cc and ECU software being matched.

orsum

[martinjs]

I wouldn't bother replacing the studs, even if the nuts come off ok.
It's a whole world of pain if you snap a few, btdt had to take the head off.

[Rikki Kitto]

RS2 has a few of 27mm studs as the 35mm studs on an ABY would hit the RS2 manifold. I just fitted replaced all the studs with short ones, but you only need to replace or shorten 4 or so.

[andy10v]

These ones (probably a pic from Dave I suspect)

[orsum]

Thanks gents

orsum

[UrS4boy]

3B AAN ABY ADU Exhaust stud info

These ones (probably a pic from Dave I suspect)

Yup. Thanks. I just got up (we're 8 hours behind you here in Vancouver).

As for NOT changing the exhaust studs because they might snap on removal that is a fool's errand. If you think they are going to snap on removal, one of them is going to snap during the RS2 manifold installation.

They are not expensive (about $2.00/each or less than a pound) and should be replaced when installing a new (or used) exhaust manifold. They are PN N90188902 which my online source, GVAP, shows as MSRP = $2.00 Core = $0.00 Sale = $1.24 each. Item 9 here (you need 16):



What you want is a properly sized stud removal socket:





More 20VT exhaust info here: http://forums.quattroworld.com/s4s6/msgs/196904.phtml

Specific head stud info here: http://forums.quattroworld.com/s4s6/msgs/150069.phtml

[martinjs]

lol they still snap even with those proper extractors.

[Dift]

Orsum, keep us updated on how you get on.

I'm conducting the same procedure on an S4 in a week or so.

[Error404]

:Iagree: Heat them up really hot first they normally come out ok

[UrS4boy]

lol they still snap even with those proper extractors.

As per Error404's comment, you need to do some prep work, i.e. extra heat, perhaps a liquid corrosion removal spray (NOT COMBINED WITH THE HEAT), etc.

The story I use as the example of the pain of not replacing the studs was a local UrS club member who was doing his RS2 EM install without replacing the studs, as he was tightening the last unreplaced stud, it snapped. Had to take the car to a shop where they used their skills and tools to extract the snapped stud. $$$

People can do what they want. Replacing ALL 16 studs is my personal recommendation.