RS2 - a new lease of life

[URQguy]

Head looks good. Very nice work.

<back into lurk mode> lol

[Ross]

SIMONS+ forum member had a clutch failure (slipping) with one hybrid RS2 turbo whem we were mapping the cars with our forum friend "Prj" Dmitri

we were maxing out the RS2 injectors in his car...and in the middle of the mapping we stoped in a fuel station and just after this...in the next 3rd gear launch the engine started to rev like crazy without win speed

the clutch was bough from 034 Motorsport,and it was used only around 15000kms with STOCK TURBO ¡¡¡

Simons installed it by himself,he is a very good mechanic and hi did everything perfect,with all new parts,etc... and Simons could tell us wich kind of SB clutch is... but i think he said able for 600nm....as 034Motorsport said in the adverstimentnd

and also,Prj knows a guy in the states who is a very good tuner that says SB clutchs are a piece of shi_t . we were talking with him about if we had to take care later after this failure with my Spec stage 3+ and k26/27 hybrid turbo....and he said,dont worry spec stage 3+ clutchs are very good,and up to 800nm

and luckly or not i did every mapping and at the day...it is working perfectly,and my clutch is older...with aroun 25000kms (most on motorways) but always with RS2 turbos,with 2.0bar

Very conflicting opinions, I've heard a lot of bad press about spec 3+ and almost only good about Southbend, I used Clutchnet previously with slip on one occasion but heard a few bad stories... Southbend use the Sachs racing pressure plate so I'm confident putting my money there more than any other RS2 clutch supplier...

[A80Avant]

i have been using a st4 SB on the 7a flywheel without problems so far. I have smelled it a few times as well, but no signs of slipping.

nice work on the head. Hope i get mine sorted soon!

[JP]

A lot of the time clutches slip because of contaminants imbedded in the Flywheel and polished uneven faces from previous slippage/ wear and tear. Whenever fitting a new clutch the face needs to be refaced to ensure you have a perfect clamping face.

Also they need to be driven sensibly and bedded in for the first 500 miles. We've had stage 3+ clutches hold 1/4mile launches with 900+Nm with no traction loss on R888's when mated to a brand new Flywheel. We've also seen them fail on the street at 500Nm when bolted straight up to an old flywheel without a reface.

As Ross is refacing his flywheel I don't think he has anything to worry about.

[Rocco]

I have to say that simons clutch was installed since the begining with a aluminiun fidanza flywheel.i dont know if it is important or not.


Good luck!!!

[Error404]

IIRC the fidanza flywheels warp very easily so maybe that is the problem.

anyway, enough spam on Ross's tread

[Acidburn]

I'll tell you he is some secret weapon... master in the art of cylinder head removal

Guess what I was doing friday afternoon
Clutches look good, kinda like landmines going thru a airport security scanner

Big thanks to JP for fitting this one in last-minute, Acidburn for helping me lift the head (alright so it was more like me helping him lift the head), and Laura for doing all our holiday packing whilst i was at work in the garage hours before leaving :mischeif:

The tappets are knackered - explains the tappety noise that necessitated the rebuild - so need to be replaced and then I need to pick 'n' mix with my 7A and RS2 inlet cams...

Spent around 3 hours watching jp strip your head down the other week

@Paul, Alex - will give feeback when this is fitted, I intend on doing this before refitting the head. It's a Stage 3 - Endurance, rated @ 480 ft/lb so I don't expect any slip on an RS2 set-up. Nice to know I can push it to the max though

wonder what it will be like in the urq as thats lighter, but I do give clutches some serious abuse as alex knows.

As Ross is refacing his flywheel I don't think he has anything to worry about.

How hard is it to have the flywheel refaced (3b stock fw)

[Ross]

Wot no engine?

After spending my bank holiday morning stripping the bottom end ready for removal, Acidburn popped round and removed the sump plug & all the bellhousing bolts whilst I was on the phone for 20 minutes

I am scared as hell trying to figure out how this goes back together - it's a bit more than your average lego set, and doesn't have instructions

[Ross]

The engine block is now getting checked for tolerances, bores are an issue - pretty worn on the exhaust side It's likely to need either donor block, rebore and pistons or fit liners. Whatever option it's gotta be a quick decision so parts can be finalised for balancing...

I am going with my RS2 inlet cam and 7A exhaust cam, as I couldn't find an RS2 exhaust cam. JP is going to set these up for me.

I have a set of RS2 injectors and MD147 K26/7 Hybrid turbo that came off the car. I might be refitting them for running in, but they should be replaced by the MRC Dyno Day in July (and will then be for sale). Watch this space :mischeif:

[Error404]

how worn are the bores Ross?

[Ross]

No measurement yet, I'll ask JP tomorrow, but by 'fingernail' there was quite a lip on some of the bores. Could just remove the lip and rehone, as it was only at the top of the bore on the exhaust side, but if it's close to tolerance as expected then I don't want to rebuild it knowing it'll need a rebore before covering another 100k....

[Error404]

Interested to hear the measurements as I'm doing the same on my 3B bottom end once I've cleaned it tomorrow. Think my block has covered approx 190k

[S2central.net]

@ross - isnt the lip just a layer of carbon at top of the bore where you get some deposits above the top ring ?

proper measurement is best before deciding for a hone or bore job. Audi 5-cyl engines arent known to need a rebore after 100k - more like 200k and more unless they have had a *really* hard life.

[Ross]

That's what everyone says but this is the 2nd block out at 160k I've had in need of a rebore, guess luck has never been on my side with these engines

In the earlier pics you'll see the 'rust' coloured lip and I think it's mostly build-up but if you run your finger round the bore there is a sudden pronounced lip and visible wear of the bore for a few cm on thrust side... likely the first owner, a rockerfella sales fella that covered it's first 75k in 2 years, thrashed the hell out of it.

Bores will definitely be measured properly before the fate of the block is decided, I'll update this week with facts rather than speculate any more.

[quattrostyle]

That's what everyone says but this is the 2nd block out at 160k I've had in need of a rebore, guess luck has never been on my side with these engines

I got exact the same experience with S2 engines. Never had these issues with 200K+ miles 10V non turbo engines.