My "new" RS2.. Your input is much appreciated.

[popdemonic]

Huksa,

I think your turbo is Mitsubishi TD0X-16/18/20G? you can see this turbo on Imprezza or Evolution.

[huksa]

^^^ On the stamp it says TD-06 20G. It is in good working order, but I am not sure whether it will stay in my engine room..

[popdemonic]

wow congrats,your car is Subaru now.Kidding mate ;-)

[popdemonic]

one thing this turbo can handle 400+HP range tho,

[huksa]

The mechanic at the shop started to put away bits and pieces around the engine. the turbo is out, the intake manifold is out, and the secondary radiator and the intercooler. We would have loved to tear down the engine, but due to the budget limit I can't go that far for now.. Three to four years from now I may have a chance to open up the engine and do some more work later if needed.



We found a small leak from the secondary radiator. It's been in use for the last 17 years, so it may needs replacing..





A new radiator is fabracated with aluminium core. It's much thicker than the original, but should fit in the same place.



It's a snug fit, but it's all good.



A low quality knock-off intercooler has no place in my car. Any car, for that matter. In the Korean market, a good intercooler is hard to come by because of a knock-offs like this...




A Friend has just upgraded the intercoolers of his Porsche 996TT to 997 GT2 ones. And we decided to utilize the 996TT's intercoolers on my RS2.



What the mechanic did was essentially to put two 996TT intercoolers in tandem and weld them up.





I hope it's not too tight in there. I'm afraid we might have to trim out bumper to fit the big intercooler. Once the turbo and exhaust manifold arrive and piping is laid out, we will know..



The big intercooler also interferes with the oil cooler. And since the air filter will find a new home near the stock oil cooler's location, we decided to ditch the old one and put a new HKS oil cooler in a new place. The problem is where the new cooler should be?



Why would someone try to split a MAF wiring?



And we've made a decision on the turbo. The TD-06 will go, replaced by a GTX3071R.
It will be matched with a SportQuattro exhaust manifold and a Greddy wastegate.

Once suspension parts and the manifold arrive from 034, I expect that the hardware work will be mostly completed. Then I would have to worry about how to put all the hardware together with ECU. My mechanic has good reputation in tuning ECUs for 996TT, but I have to see how it will turn out for my RS2's inline 5.

[huksa]

Here comes a new down pipe..



The Sport Quattro manifold arrived from 034 and is mated to the new turbo and the down pipe.



A 3-inch exhaust pipe was fabricated..



The Greddy wastegate had to be mounted tilted because the hood would not close due to the size of the wastegate. For now I am going to use the wastegate, but will consider to replace it with smaller one in the future.



The intercooler is now in place. The side tank of the Porsche intercooler did a good job where a space is precious.



A Blitz blow-off valve..



Temporarily locate the boost controller and A/F guage for data gathering. My car will be driven for a few days in various conditions to collect data for ECU tuning.





I don't know what he is doing, but I am just happy watching him doing something.
He doesn't have good experience in Audi I5 engines, yet, hey, everyone has their first moment!



So.. hardware is almost completed, and ECU is done. But we realized that the intercooler is too big to be housed in the stock bumper.. And the intake pipe to the turbo interferes with the right-side headlight.. I have to do something about it otherwise my RS2 won't pass the inspection. Anyhow.. up for the dyno.



RS2 is strapped to the dyno. Again, with no bumper and no right headlight.. I am eager to see the results.



Now the result. Around 330 horsepower with 1.7 bar at the peak. But the boost could not hold the peak as much as we hoped. I might try a stiffer wastegate spring later..
Anyhow, considering what my RS2 used to be, this is a heaven!



To fit the right-side headlight correctly, the intake piping has to be modified. Now it's the final version.



A shot before max. speed run is conducted. I had to substantially trim out the inside of the bumber to fit the intercooler. The bumper opening is too small given the size of the intercooler. I might widen the opening in the future. The car has been tested with new hardware and ECU tune more than 1,000 km so far.
I was able to touch 300 km/h on the speedo that night. (Could have accelarated a little further given the traffic condition, though) Forum search suggested that 6th at 7,000 rpm is around 285? So clearly I was not able to reach 300km/h, but the sensation was phenominal! The car runs perfectly.



This is final version of the engine room. Refurbished main radiator and air-con condensor, new secondary radiator, new vacuum hoses..







A left new headlight cover is on order.. And note the each end of the intecooler peep through the bumper..

With very limited budget, this is as far as I can go for now. Fortunately major part of repair is completed and I am happy about it. It has become my daily driver, taking the duty over from my ISF.
Next up, when I have a chance and resources, a new brake system will be in the pipeline.

Although I didn't give any hand on the actual repair of my car, I really enjoyed watching the work and waiting to drive it. And it was worth the wait in the end. Now all is left is to enjoy the driving!

[UrS4boy]

Good work. Just one comment: You are limiting your horsepower by sucking hot air 2 cm from the turbo. Strongly suggest you rework in inlet piping so you are getting COLD not hot air into the cold side of the turbo. I think your original intake plumbing had the same problem.

[huksa]

Good work. Just one comment: You are limiting your horsepower by sucking hot air 2 cm from the turbo. Strongly suggest you rework in inlet piping so you are getting COLD not hot air into the cold side of the turbo. I think your original intake plumbing had the same problem.

Thanks for the comment. I've googled many engine room photos in search of an ideal intake piping solutions. Most "good" ones seems hard to replicate without altering other parts and/or sheet metal. My original plan was to locate the air filter to where the oil cooler is located. (That didn't work out for some reasons) I'll be vigilant to find better ways, though.

On the other hand, I've had an unscientific experiment on the intake temperature.
After some extended driving, I stopped and jumped out of the car and felt how hot the intercooler was by placing my hand on the intercooler.



On the turbo-side of the intercooler (marked with yellow arrow), the surface of the intercooler was very very hot (almost like radiator) - as pointed out by your comment. Yet, on the intake manifold-side of the intercooler (marked with red arrow), the intercooler is so cold that it was almost like a refrigerator (OK.. it's an exaggeration, but it was very cold)

So, I thought:
1. The intercooler is doing a great job
2. I may leave the intake piping as it is, because the air in the downstream of the intercooler should be cool enough.

But, I may be wrong.

[fish]

If i was you i would re route the inake piping aswell, and then get a chinese copy intercooler that fits and get the bumper fixed again. That bumper costs over 1 515 151,52 KRW to buy new and is hard to come buy!

[Rusty]

Check out intake setups like Jamo has, which use the inner wing as a source of cold air.

[fish]

This is how dahlbäck routed the intake on my old s2

[Sonic]

Great project!

A couple of observations -

1. The inlet looks all wrong, as other people have mentioned.
2. You already have a reverse inlet manifold which is great!
3. Lots of people (like myself) opt to remove the auxillary radiator infront of the engine for more room and easy access. It makes little or no different for most use.

Good job, and i look forward to any updates

[Sonic]

You could go for an inlet like Will's

[Jamo]

Why did you buy the manifold from 034 and not Wagner tuning directly? Would have been cheaper unless you did a bulk 034 order

[Jamo]

Unfortunately all the previous intake suggestions except rustys mtm suggestion won't work with the sq manifold puts the turbo at a awkward angle and he need to retain the maf
You have two solutions if you don't have aircon
Go through the inner wing down to the oil cooler position or towards the engine then down next to the oil filter
If you have aircon it's a whole new ball game!