Since I first saw Audi S2 Coupe as a child in early '90s I fell in love in it. My dreams of having one finally came true fifteen years and several other Quattros later as I bought my S2 Coupe in 2007. It was supposed to be a basis for something much faster then the RS4 I owned those days. The truth was cruel- stock 2.2T Audi was not only much much slower than 2.7biT, but also slower than my other car- 2005 Ibiza Cupra TDI with mods on 230HP... However, I was extremely happy with my new buy as I knew its potential.
S2 Coupe is a rare, facelift version with ABY engine and all extras belonging to the 1994 MY, such as "ellipsoid-type" headlamps, 6 gears, blue-carbon decors, beige nappa leather and intriguing dark blue (Indigo-Perleffect) lack.
Stock one looked like this (three German quattros):
And has healthy stock parameters:
And remained stock not for long. First I installed a BOV, free-flow stainless steel exhaust, K26 turbo instead of K24, 7A cam and some extra meters:
I also removed the old OBD1 from below the bonnet and installed it as OBD2 inside:
And I remapped the ECU, of course. Now it was fun! I don't remember the exact figures, but I should have been ca. 300HP. Satisfying? Not at all. Now I couldn't proceed without help of 5 cylinder turbo specialists and a big bunch of new parts. The goal was to overstep the 500HP level. So almost all engine parts were changed or at least improved.
The engine displacement was raised from 2225ccm to ~2380ccm with bigger bore, cast pistons and rods. All mods were made to make the engine sustain high boost and stay healthy in everyday use: from stock 0.9/1.1bar to nowaday 2.0/2.2bar.
The cylinder head:
- ported, polished (where needed- not intake)
- shortened valve guides
- bigger, lighter inconnel valves- 034 Motorsport
- lighter titan valve discs- 034 Motorsport
- stronger valve springs- 034 Motorsport
- camshafts- 7A&ADU
- ARP bolts- custom-made
- camshaft belt wheel, wide- Dahlback Racing
- cylinder head gasket- metal, custom-made in France
- good look: polished from the outside, powdercoated upper cover, inscription '20V Turbo' polished
- oil cap from Lamborghini Avantador
Shortblock:
- stronger one from diesel
- maximum bore
- Pauter rods, the ultimate strong ones
- Wiseco pistons
- Sputter rod bearings
- oil jets improved
- oil pump OE Audi, oiling improved
- oil sump improved- APmotorsport
- steel crankshaft wheel- PK Motorsport
- crankcase breather system, catch-can- APmotorsport
- engine supports polished
- engine mounts (a bit extreme)- 034 Motorsport
Intake:
- 'reversed' intake manifold- PK Motosport
- phenolic spacer- 034 Motorsport
- HKS air filter
- turbocharger KKK K27/28/29, rallye-origins, with anti-surge- custom-made
- dual FMIC based on intercoolers from RS2 ADU i and reversed S2 ABY- APmotorsport
- turbo-blanket
- MAC industrial valve instead of N75
- BOV- custom-made APmotorsport
Exhaust:
- exhaust manifold OE Audi Sport Quattro (that's a rare!), bought brand new by me!
- stainless steel exhaust 4"/3,5"- APmotorsport
- stainless muffler OE-style
- separate exhaust for wastegate
- wastegate OE Audi improved
- thermoshield-bandages
Fuel and ignition systems:
- Bosch 044 fuel pump in stock bracket
- Siemens 780ccm injectors
- steel fuel lines
- 5 SMD ignition coils + heavy-duty igniton cables- 034 Motorsport
- NGK iridium spark plugs- improved
Electronics:
- VEMS ECU
- 5-channel EGT gauge, up to 12 probes real-time view- PARTZ Motorsport
Cooling:
- extremely efficient Ron Davis radiator- custom-made
- 80deg.C regulator- APmotorsport
- additional cooling electric water pump- Mercedes
- oil cooler- OE Audi improved, APMotorsport
Drive system:
- SPEC clutch improved and strenghten by 50%
- flywheel- single mass, reduced weight, from 7A
- steel faced bearing- JPGroup
- mounts- 034 Motorsport
Suspension:
- H&R lowering springs
- Bilstein B8 shocks
- poliurethane bushings
- uniball McPherson mounts
Brakes:
- whole kit from Porsche 993 Turbo/ Audi RS2
- Zimmerman 323mm discs
- PAGID pads
Wheels:
- BBS RC 18"
Interior:
- Sparco seats on original rails, modified by me
- additional gauges
- Sparco seatbelts
After three years of adventures and modifying the setup I can say that all plans are fulfilled. I reached all I have planned, the Audi runs smoothly and flawlessly and it runs like hell. There is almost nothing modified to be seen from the outside, no cheap leds, giant China intercoolers, no blue Samco hoses etc.
How it runs? You can find some clips on Youtube. Here is the speedo: http://www.youtube.com/watch?v=Ov9_X__afo0
And here's duel between S2 and RS5: http://www.youtube.com/watch?v=Q8egDuhceTs
That's how works went:
Custom KKK turbocharger:
My KKK in comparison to a stock 1.8t KKK K03 :
Siemens injectors, Bosch 044 pump:
034 igniton system capable to generate spark up to 3.5bar:
Phenolic thermo spacer:
Dahlback camshaft wheel:
PKM billet crank wheel:
Hardcore engine and tranny mounts:
Facelift of the key (by me):
Sport clutch improved even more:
Big brake kit:
H&R spring, quite comfortable:
Working on the seat mounts, the goal was to leave the stock adjustments:
Ron Davis (former NASCAR star) radiator, now the temperature NEVER exceeds 80deg.C:
Cylinder head after porting:
Shortblock:
How are intercoolers made. This was inspired by B-Group rallye Audis and also some Dahlback solutions. Nothing to be seen from the outside:
EGT probes installation:
Sport Quattro exhaust manifold:
And gauge:
Here are some figures:
Now pictures of the whole Audi:
S2 Coupe is a rare, facelift version with ABY engine and all extras belonging to the 1994 MY, such as "ellipsoid-type" headlamps, 6 gears, blue-carbon decors, beige nappa leather and intriguing dark blue (Indigo-Perleffect) lack.
Stock one looked like this (three German quattros):
And has healthy stock parameters:
And remained stock not for long. First I installed a BOV, free-flow stainless steel exhaust, K26 turbo instead of K24, 7A cam and some extra meters:
I also removed the old OBD1 from below the bonnet and installed it as OBD2 inside:
And I remapped the ECU, of course. Now it was fun! I don't remember the exact figures, but I should have been ca. 300HP. Satisfying? Not at all. Now I couldn't proceed without help of 5 cylinder turbo specialists and a big bunch of new parts. The goal was to overstep the 500HP level. So almost all engine parts were changed or at least improved.
The engine displacement was raised from 2225ccm to ~2380ccm with bigger bore, cast pistons and rods. All mods were made to make the engine sustain high boost and stay healthy in everyday use: from stock 0.9/1.1bar to nowaday 2.0/2.2bar.
The cylinder head:
- ported, polished (where needed- not intake)
- shortened valve guides
- bigger, lighter inconnel valves- 034 Motorsport
- lighter titan valve discs- 034 Motorsport
- stronger valve springs- 034 Motorsport
- camshafts- 7A&ADU
- ARP bolts- custom-made
- camshaft belt wheel, wide- Dahlback Racing
- cylinder head gasket- metal, custom-made in France
- good look: polished from the outside, powdercoated upper cover, inscription '20V Turbo' polished
- oil cap from Lamborghini Avantador
Shortblock:
- stronger one from diesel
- maximum bore
- Pauter rods, the ultimate strong ones
- Wiseco pistons
- Sputter rod bearings
- oil jets improved
- oil pump OE Audi, oiling improved
- oil sump improved- APmotorsport
- steel crankshaft wheel- PK Motorsport
- crankcase breather system, catch-can- APmotorsport
- engine supports polished
- engine mounts (a bit extreme)- 034 Motorsport
Intake:
- 'reversed' intake manifold- PK Motosport
- phenolic spacer- 034 Motorsport
- HKS air filter
- turbocharger KKK K27/28/29, rallye-origins, with anti-surge- custom-made
- dual FMIC based on intercoolers from RS2 ADU i and reversed S2 ABY- APmotorsport
- turbo-blanket
- MAC industrial valve instead of N75
- BOV- custom-made APmotorsport
Exhaust:
- exhaust manifold OE Audi Sport Quattro (that's a rare!), bought brand new by me!
- stainless steel exhaust 4"/3,5"- APmotorsport
- stainless muffler OE-style
- separate exhaust for wastegate
- wastegate OE Audi improved
- thermoshield-bandages
Fuel and ignition systems:
- Bosch 044 fuel pump in stock bracket
- Siemens 780ccm injectors
- steel fuel lines
- 5 SMD ignition coils + heavy-duty igniton cables- 034 Motorsport
- NGK iridium spark plugs- improved
Electronics:
- VEMS ECU
- 5-channel EGT gauge, up to 12 probes real-time view- PARTZ Motorsport
Cooling:
- extremely efficient Ron Davis radiator- custom-made
- 80deg.C regulator- APmotorsport
- additional cooling electric water pump- Mercedes
- oil cooler- OE Audi improved, APMotorsport
Drive system:
- SPEC clutch improved and strenghten by 50%
- flywheel- single mass, reduced weight, from 7A
- steel faced bearing- JPGroup
- mounts- 034 Motorsport
Suspension:
- H&R lowering springs
- Bilstein B8 shocks
- poliurethane bushings
- uniball McPherson mounts
Brakes:
- whole kit from Porsche 993 Turbo/ Audi RS2
- Zimmerman 323mm discs
- PAGID pads
Wheels:
- BBS RC 18"
Interior:
- Sparco seats on original rails, modified by me
- additional gauges
- Sparco seatbelts
After three years of adventures and modifying the setup I can say that all plans are fulfilled. I reached all I have planned, the Audi runs smoothly and flawlessly and it runs like hell. There is almost nothing modified to be seen from the outside, no cheap leds, giant China intercoolers, no blue Samco hoses etc.
How it runs? You can find some clips on Youtube. Here is the speedo: http://www.youtube.com/watch?v=Ov9_X__afo0
And here's duel between S2 and RS5: http://www.youtube.com/watch?v=Q8egDuhceTs
That's how works went:
Custom KKK turbocharger:
My KKK in comparison to a stock 1.8t KKK K03
:Siemens injectors, Bosch 044 pump:
034 igniton system capable to generate spark up to 3.5bar:
Phenolic thermo spacer:
Dahlback camshaft wheel:
PKM billet crank wheel:
Hardcore engine and tranny mounts:
Facelift of the key (by me):
Sport clutch improved even more:
Big brake kit:
H&R spring, quite comfortable:
Working on the seat mounts, the goal was to leave the stock adjustments:
Ron Davis (former NASCAR star) radiator, now the temperature NEVER exceeds 80deg.C:
Cylinder head after porting:
Shortblock:
How are intercoolers made. This was inspired by B-Group rallye Audis and also some Dahlback solutions. Nothing to be seen from the outside:
EGT probes installation:
Sport Quattro exhaust manifold:
And gauge:
Here are some figures:
Now pictures of the whole Audi:
0-200km/h 9sec
Comment