My S2 coupe

[ranz]

Some news, old cars needs after time to time some repairing so I'm not going to list what I have changed, I am going to list the special things what I have done.
2 weeks ago I ordered new key for my car and fitted my aftermarket alarm remote in to that key:



Also I changed gear switch system with short shifter version:



And today I replaced cheap FPR to Mallory 4305M regulator, also fitted new fuel lines, now is pressure at both sides of fuel line not only at one:



Also I made some changes in the car:











The car is lot more silent now

[Greg_S]

How do the plastic trims on the boot lid come off?

[ranz]

How do the plastic trims on the boot lid come off?

You just have to pull them by starting at the smallest one (the lowest one when the boot is open), then the side ones ant then the biggest one.

[Greg_S]

Will have a try, always worried about breaking those bits of trim. Need to fix the wiring for boot light switch

[frazz]

I like what your doing with the interior mate nice touch, what sort of material is it your using.

[ranz]

what sort of material is it your using.

It's leather.

[ranz]

Some news, I desided to change the original exhaust manifold with RS2 manifold. The manifold is almost brand new (used less than half a year) and it's ported, also it has place for EGT sensor:





Also I installed the fuel pressure regulator, now is the fuel pressure at both ends of fuel rail because the fuel return is in the regulator:



To listen detonation at test runs I installed in the car 6mm hose whats one end is under the intake manifold and the other one under steering wheel:



And these are home made listening devices



To get the EGT down I decided to try one wery simple "tuning". The wastegate is now breathing to atmosphere not to downpipe:



Regardless the EGT stayed almost the same.

Also I have installed some extra switches left of the steering wheel:



The upper one is for after run pump and cooling fan, basically it is the same as original system but I can swich it on whenever I want to.
The lower switches are for blink fault codes, one activates the MIL lamp in the instrument cluster and the red one is for shorting cabels to get the lamp blinking:
The lower left lamp is for the codes:



Many thanks to S2central for that

One day I found from Estonian audiclub wery cheap driverer side seat, I decided to make the deal and thats what came from it:





I installed into the seats heater and also 2 cooler ventilators

Now it was time to make something with sound system. I selled my becker head unit and in plase of it did go blaupunkt one:



In my previous car I installed tweeters to A pillar, didn't like it and in that car I made it so:



I used original speaker grille, drilled an hole in it, put in tweeter housing and covered it with carbon.

In to the doors I installed 8" midbass speakers:





The speakers get power from NXS amplifier what has built in sound processor, I like the time alignment

Now yesterday I started to make my own revers intake manifold, I took one original manifold:



Cut it in two pieces:



And weld the first piece to it:



Now I have to make some cuts here-there, make the runner holes, also I try to sand down all of the cast steel.

[Jamo]

Love the 8" midbass! haven't seen any ICE bling in a long time on here

[ranz]

Love the 8" midbass! haven't seen any ICE bling in a long time on here

They sound really good also

[Tom_]

nice project mate,

[ranz]

Also I forgot to mention that I viseted local dyno bench. I wanted to test 4 different ECU chips.
First run was made with original S2 soft:



Result from wheels where: 126,5kw and 238,3Nm. When we make allowances for transmission loss 25% then these number are a little bit higher than factory given numbers 168,6KW and 317,7NM from the engine.

Second run was with J.K.Motorsport chip (boost same as original):



Result: 143,9kw and 271,1Nm.

Third run with one noname soft and 250kPa MAP, highest boost point raised to 1,3BAR:



Result: 147,8KW and 331,6Nm
And last run with soft that is made for engines with RS2 stuff on it, 300kPa MAP and highest boost point 1,6BAR:



Result: 141,8KW and 351,3Nm

I expected a little higher HP numbers, but after I examined VEMS round log files (it shows me AFR, EGT, boost and RPM) I saw that the AFR is from 5000p 10.2 (lambda 0,69). After I canged the fuel lines, it's a lot better now, around 11,7 (lambda 0,79).

[ranz]

Some update:
Intake manifold









Some "tuning" made also with distributor rotor
7A rotor:



7A VS 3B



and modified 7A rotor:



And home made coilovers

[Rocco]

great custom work

you are making all with your hands


about your AFR values around 5000rpm.... they were richer just after change the old fuel lines to the new ones?? without any tune mod in Vems??

[ranz]

about your AFR values around 5000rpm.... they were richer just after change the old fuel lines to the new ones?? without any tune mod in Vems??

I can not make any changes on vems round because it is not an ECU, it´s only read only unit, I´m still using motronic ecu.
Yes, ofcource my main goal is to replace motronic with programmable unit (vems or tatech - depends of available money )

[ranz]

And now finally the IM is ready, just got it back from powder coating and there was nothing else to do then install it on to the car.

Old one:



And the new one:





Nothing really much did not change (according to butt dyno), maybe the soolup is little faster, but right now I did not have the equipment to measure it before and after.