Another s2 => rs2 project

[valjo]

No it's not, RS2 turbo say K24-7200 on the blue plate

damm!!!
what kind of turbo is it then ?!

[Jamo]

What's the full plate number? looks like a K26 variant, what for sale thread did you buy it from?

[bad8008]

milltek exhaust

Hi all!

About year ago i decided that i will upgrade my s2 with rs2 parts.
Goal is to get about 370-380 hp and to use original rs2 parts so engine bay will still look almost stock !

List of parts i planed to change :
-rs2 airbox
-rs2 chamshafts with cam pulley
-rs2 exhoust mainfold
-rs2 turbo
-rs2 intake mainfold ( i know it is the same as aby but it is powered by porsche )
-rs2 downpipe
-rs2 injectors
-complete milltek exhoust 2.75"
-rs2 timing belt and wather pump

Until now i have bought almost all parts.

Rs2 vs S2 airbox:




Milltek:




MANY THANKS TO RUSTY for helping me getting one of the last aby milltek exhoust available for salle

about the milltek exhaust system, how many bhp will it increase? still available to get?

[valjo]

Good morning

i wrote down numbers from blue plate on turbo. Numbers are:
034145703D
HL50091089 0004
k24 72000

There is also number on compresor housing: 53261015160

i guess it is original rs2 turbo

[Jamo]

Phew! Why does it show K26 in the pic?

[valjo]

it is not. very poor photos

[Jamo]

it is not. very poor photos

ah o.k sorry for the heartattack

[valjo]

First we changed s2 camshafts with rs2 chamshafts.







Rs2 camshafts with pulley and s2 chamsfats:



Fitting camshaft pulley (special homemade tool required )

[valjo]

Because it is more that 5 years since cambellt was changed we have changed it too.
Because i am going for rs2 setup i used rs2 cambelt and wather pump.
List of pats i have changed:
-cambelt
-wather pump
-cambelt tensioner
-all bolts for crankpulley
-crank pulley

Parts:


Left rs2 wather pump, right s2 pump






Crank pulley changed. I hardly recommended to change it every time timing belt is being changed... You could imagine what happened if it fails....



As you may already know timing marks on rs2 dont line up perfectly so i have to put timing belt one toth to the left. Thanks god we have s2forum with alot informations !

Fitted and tested:

[H_man]

Looks awesome!!!

[valjo]

Project continue....

Turbo, wastegate and exhoust mainfold removed:


Downpipe removed:


Collection of new gaskets, nuts , screws, washers....


Rs2 exhoust mainfold fitted !

[valjo]

Rs2 turbo was renewed, but they fitted turbo and compresor housing wrong, so i have to undo both housings and refit it in order to fit perfectly to wather and oil lines, downpipe and turbo boost hose.



Tool for fitting turbo:


Plug&play:


Downpipe fitted:


It is pleasure fitting rs2 parts to s2 aby, because you dont have to customize anything, al parts are plug&play

[valjo]

Because wastegates have tendency to have leaking diaphragma, cracked housing and worn valve, i have decided to rebuild one from perfect parts.
I have three doner wastegates:


WG dismembered:








New diaphragma installed...


Ready for installation:


WG and downpipe installed:

[dkw_dude]

Looks good! did you find a WG with little valve/valve guide wear? The WG's I have opened had a good amount of wear, the valve was quite loose in the guide.

[valjo]

Looks good! did you find a WG with little valve/valve guide wear? The WG's I have opened had a good amount of wear, the valve was quite loose in the guide.

HI!

well all valves have some wear, so i use the best one with almost no wear ....