Another 3B walking the RS2 path

[VladaS2]

As you can see from the title I have decided to upgrade my S2 into RS2 beast. I think the availability of parts, ease of upgrade and everyday driveability makes this path the optimum one. I have done fair amount of resarch on the forum to come up with the list of neccessary items for this.

Basic Items:
RS2 Turbo obviously
RS2 Exhaust Manifold
RS2 Intercooler
RS2 Injectors (though some sources say 3B injectors with 7A FPR@4.2 bar can do?)
RS2 Headgasket
RS2 Rod Bearings

Are there some hoses or lines that I have to get too in order to mount these?

I am not sure about following:
7A or RS2 exhuast cam
7A Fuel pressure regulator
Uprated fuel pump (RS2 or Bosch 044)

I would need help getting part numbers for these things as well as recommendations for where to get them cheap (if not from VAG).

My goal would be around 360hp and 550 Nm. I considered using RS2 rods but some soruces say they are the same or even worse then 3B and are not good for above 550 Nm.

Obviously I would need remap of ECU as well (who can do this I have learned that Minhea is guru for this)

My car has around 115K Miles on it, should I consider changing some other engine parts as I do not want it to be blown to pieces? I want car for everyday, and periodic drag racing.

Things that I already have in car:
- Decat pipes
- Uprated MAP sensor (2.5 bar but do not know if that is enough)
- Stiffer wategate spring
- Uprated clutch

That is good but not good enough.


What I also want to do:

- Upgrade the brakes. I plan on keeping 16" wheels
- Upgrade the suspension
- RS2 Front and Whiteline Rear ARB
- Powerflex rear diff bush
- Maybe rear torsen diff from V8. Sounds tempting and I can get it cheap
- Aluminium flywheel (what is the actual gain with it?)

I want to start collecting those parts too so recommendations and where to get these cheap are welcome!

I want to add all the part numbers and recommendatios to this post so that somebody else can use them later!

[VladaS2]

I have got some part numbers and prices quoted directly from dealer. All prices in euro.

RS2 Turbo - 034 145 703 D :: 1600
RS2 Intercooler :: 530
RS2 Injectors :: 700 (set of 5)
RS2 Exhaust manifold - 034 253 031 A :: 970
RS2 Head gasket 034 103 383 AD :: 70
RS2 Rod Bearings - 034 105 701, 034 105 701 B :: 70
RS2 Turbo gasket - 035 129 589 D :: 18
RS2 Manifold gasket - 034 129 589 A :: 61
RS2 Exhaust manifold studs N 906 483 01 :: 10

7A Exhaust cam - 054 109 022 :: 680 (RS2 Exhaust cam 034 109 022 G :: 1047!!)
7A Fuel pressure regulator :: 67 (RS2 FPR :: 100)
RS2 Fuel Pump :: 330

Total 5106 euro ! (not including the remap )

[VladaS2]

Did I miss something? Did I include something I do not need?

[s2dude]

Did I miss something? Did I include something I do not need?

OK. Well forget the main dealer!!

http://www.034motorsport.com/index.php?cPath=28_63

can supply a lot of great bits that are either as good or better than RS2 spec

http://www.wotan-ag.de/deu/index_us.htm

and here sells manifolds really cheap!!

and here for full info on parts needed etc

http://www.s2forum.com/forum/showthread.php?t=2346&highlight=aby+adu

[VladaS2]

Little update on the project.

I have found new very nice exhaust manifold sold here for 420 euro:

http://cgi.ebay.com/ws/eBayISAPI.dll...MEWA%3AIT&rd=1

They say it could be used for much bigger hp applications then those what I need.

Turbo I am trying to buy from an certain s2forum member right now

Thanks for that 034motorsport link! They certainly have a lots of interesting stuff.

I have just a couple of more small questions:

1. What is the difference between 7A cam and RS2 cam. Can either be used for this application?
2. Do I need uprated downpipe and exhaust if I want 360hp/550Nm? I currently only have decat pipes on my exhaust system. If I change only to rs2 downpipe will it make a difference?
3. I will buy Bosch 044 fuel pump. Do I need also new fuel pressure regulator (7a or RS2?)

[s2dude]

Little update on the project.

I have found new very nice exhaust manifold sold here for 420 euro:

http://cgi.ebay.com/ws/eBayISAPI.dll...MEWA%3AIT&rd=1

They say it could be used for much bigger hp applications then those what I need.

Turbo I am trying to buy from an certain s2forum member right now

Thanks for that 034motorsport link! They certainly have a lots of interesting stuff.

I have just a couple of more small questions:

1. What is the difference between 7A cam and RS2 cam. Can either be used for this application?
2. Do I need uprated downpipe and exhaust if I want 360hp/550Nm? I currently only have decat pipes on my exhaust system. If I change only to rs2 downpipe will it make a difference?
3. I will buy Bosch 044 fuel pump. Do I need also new fuel pressure regulator (7a or RS2?)

be warned!! those manifolds are shlte
Can often crack due to poor metal used as its very thin walled so Ive been told.
Also, the beauty of an RS2 (or the 034 one) manifold is that it fits in the stock location with no modifications.....

That tubular one does not.

[Ross]

Wow another turns to the dark side...

I'd say source alot of the parts used, and cut that bill in half. Then it's suddenly alot more affordable, and leaves a bit extra for all those other things that will inevitably need doing... deffo get the brakes and suspension done too! Fuel pump and injectors should be done for reliablility, may as well as tehre's not much extra cost involved.

Just don't get stuck in my shoes, have everything done except no budget left for a turbo and re-map

For that power, the exhaust would be a restriction too. I think 2.75" would be enough (same as RS2).

[VladaS2]

Dark side is sooo appealing

I found the Intercooler too. It is 600x300x75 for 220 euro. Can this it fit inside 3B bumper? They have 600x300x100 too for 250 euro.

[s2dude]

Dark side is sooo appealing

I found the Intercooler too. It is 600x300x75 for 220 euro. Can this it fit inside 3B bumper? They have 600x300x100 too for 250 euro.

600 x 300 x 75 is the MAXIMUM that can be made to fit behind the S2 bumper iirc
Even that takes a fair bit of hacking and fabrication to fit...

You also dont need any bigger than that size!

[Jamo]

I have got some part numbers and prices quoted directly from dealer. All prices in euro.

RS2 Turbo - 034 145 703 D :: 1600
RS2 Intercooler :: 530
RS2 Injectors :: 700 (set of 5)
RS2 Exhaust manifold - 034 253 031 A :: 970
RS2 Head gasket 034 103 383 AD :: 70
RS2 Rod Bearings - 034 105 701, 034 105 701 B :: 70
RS2 Turbo gasket - 035 129 589 D :: 18
RS2 Manifold gasket - 034 129 589 A :: 61
RS2 Exhaust manifold studs N 906 483 01 :: 10

7A Exhaust cam - 054 109 022 :: 680 (RS2 Exhaust cam 034 109 022 G :: 1047!!)
7A Fuel pressure regulator :: 67 (RS2 FPR :: 100)
RS2 Fuel Pump :: 330

Total 5106 euro ! (not including the remap )

I'm sitting on a gold mine with all my bits then

[VladaS2]

While it may fit I have found out that the intercooler can be too big. I do not need such a monster (for now

What about this one. It is near RS2 Spec size and I believe 2.25" inlets will fit my hoses?

http://cgi.ebay.com/JJR-550x180x65-I...QQcmdZViewItem

[Jamo]

While it may fit I have found out that the intercooler can be too big. I do not need such a monster (for now

What about this one. It is near RS2 Spec size and I believe 2.25" inlets will fit my hoses?

http://cgi.ebay.com/JJR-550x180x65-I...QQcmdZViewItem

Whilst technically yes you are right on you can have too big an intercooler, the intercooler posted is a good size for an RS2 conversion with futureproof overhead.

MartinJS ran it on a RS2 setup with no problems whatsoever, the one in the link is too small.

[Jucca]

I want this IC from 034, but it's too expensive for me:

http://www.034motorsport.com/product_info.php?cPath=25_66_69&products_id=218

[VladaS2]

Whilst technically yes you are right on you can have too big an intercooler, the intercooler posted is a good size for an RS2 conversion with futureproof overhead.

MartinJS ran it on a RS2 setup with no problems whatsoever, the one in the link is too small.

Can you elaborate too small? It's core is 550x180x65 while RS2 unit is 500x185x63 - that should mean it is 10% larger?

I'd gladly have the big bad one, but I am afraid I do not have technical expertise of Martin in order to fit it

Btw. What size are RS2 intercooler inlet and outlet pipes?

[martinjs]

I'd gladly have the big bad one, but I am afraid I do not have technical expertise of Martin in order to fit it

Its not that hard to do, all the info you should need is in the thread i posted about it, loads of other people have fitted one also.