1992 AUDI S2 Project - Keep it British with a twist.

[Wizard-of-OD]

Going to place an order tomorrow for (4) Compbrake units. Anyone in North America interested to save on shipping?

As usual could never leave good enough alone. Swapped in a MTM ECU I had and took it out for a spirited drive last night.
- Get in, brakes feel a little off , start it and the Brake Pad light comes in. Turn off ignition turn it back on . Light goes away
- Pull onto the highway and engine won't go above 4000 rpm's. Pull over open the hood to look for a boost leak (, couldn't find anything. Turn it back on drives normal , then as I am pulling into the shop it starts acting up again.
Could be the wastegate , could be the MAF (allthough it is brand new) or could be a torn hose somewhere.

Might be a good excuse on the tilting scale for SEM vs Motronic and the built motor.

[quattrostyle]

MAF connector?

[Wizard-of-OD]

MAF connector?

Doubtful as it would be completely dead if that were the case or it would idle like garbage.
Update : Torn "Michelin Man" hose from Samco. Makes you wonder why overpay for something when a Taiwanese version is 1/10 the cost and does the same job.

[Error404]

No brake pad warning on these mate, its probably the low hydraulic pressure warning or sticky PAS fluid cap sensor

[Wizard-of-OD]

No brake pad warning on these mate, its probably the low hydraulic pressure warning or sticky PAS fluid cap sensor

Sorry that is what I called it.
B5+ guy
Going to take a look at it later on. Speaking with JP now about plans for the motor.

[ralleyquattro]

Going to place an order tomorrow for (4) Compbrake units. Anyone in North America interested to save on shipping?

Put me down for 4 units as well, need some for the Ur-q.

No codes from the ECU??

[Wizard-of-OD]

Put me down for 4 units as well, need some for the Ur-q.
No codes from the ECU??

Going to run a diagnostic on it over the weekend when I have time.

Ok
Wizard-of-OD = 4
ralleyquattro = 4

anyone else?

[PRY4SNO]

Not sure if you sourced your hubs yet, but found a good deal on eBay.

I've sent it via PM

[Wizard-of-OD]

Not sure if you sourced your hubs yet, but found a good deal on eBay.

I've sent it via PM

[Wizard-of-OD]

Started building the spare suspension up.
Ordered yesterday from wavetrac the following:
A4/S4 (B5/B6) 01E 6MT FRONT - 18.309.170WK = $1395 USD
80/90/UrS4 QUATTRO REAR - 18.309.160WK = $1395 USD
(helps being a wavetrac distributor).

Going to make subframe bushings with serated sections to actually lock it into the body. Going to call ARP on Monday and see if they have metric hardware wide enough to replace the bolts.

Has anyone made a chromoly subframe (K-frame) as yet?

[andy10v]

Wavetracs should be nice! I fancy a rear one if I grenade my rear v8 torsen.

Do they do a centre as well?

Are the serrations going to "bite" into the body, or lock into serrations fitted to the body?

Terrybullwon has one made by puglife IIRC

http://www.s2forum.com/forum/showthr...=50050&page=39

[Wizard-of-OD]

Wavetracs should be nice! I fancy a rear one if I grenade my rear v8 torsen.

Do they do a centre as well?

Are the serrations going to "bite" into the body, or lock into serrations fitted to the body?

Terrybullwon has one made by puglife IIRC

http://www.s2forum.com/forum/showthr...=50050&page=39

They do not do a centre one but you can get bias shims for it to set the bias. As for the serrations , they are just going to lock. I found that the 034 units on my last car had way too much play. Like throwing a hot dog down a hallway...

Is James commercially making them now? I will sign up for one if so.

Side track.
How many of you would be interested if I got the thermostat housing replicated in cast aluminum again?

[PRY4SNO]

Another custom subframe option, closer to home, is worth investigating.

My2000apb has redone everything in quite a tidy manner,

His build thread with some details follows. When I asked, he was up to build some for others at a reasonable price. Just didnt fit for my timeline. I'll try again on v2.

http://www.theprojectpad.com/viewtopic.php?f=11&t=193

[Wizard-of-OD]

DECEMBER 5TH 2014:

Like everything in life , most projects tend to change through out the course. I am breaking down the project into various stages.From the start I have always stated this will be an OEM+ theme car. I do not have the desire to "ruin" it by trying to make 600+whp. I want to build it the way it should have come from Audi.
- Bigger brakes (Front & Rear)
- Decent Suspension upgrades
- Recaro interior
- BBS wheels
- 400whp
- OEM management.
- OEM wire harness

Stage 0 - current state.
Stage 1 - EFR7163 Turbo kit
Stage 2 - EFR7670 Turbo kit w/ full suspension redo.

Stage 1:
After conversing with Hank (Iroz Motorsport) , he needs a decent test pilot for his turbo kit in the small chassis and I just so happen to know a guy . For my short term goals and time line it fits the bill as the entry price point is extremely reasonable and it allows for something to happen within the Stage 0 ---> Stage 2 gap while JP@JNL gets all his ducks in a row.

Motronic Tuning:
EFIExpress (Marc Swanson) will be handling the tuning for Iroz's kits and Marc has managed to come up with an amazing product. We will dyno the S2 with everything being bone stock (aside from the 6 speed conversion) see what it does in the numbers department and then install the plug and play EFR7163 kit from Hank. Considering a chip is not yet available for the EFR7163 in a 3B , I am going with the VEMS plug and play ECU box from Marc to get it initially dialed in and then hopefully after a few trial and error runs , we are able to create a chip that will somewhat mimic what the VEMS is able to do.
Link to the EFIExpress Motronic replacement ECU:


Stage 2:
The bodywork & paint shop I feel extremely comfortable with will not be able to fit me in until the middle of March. Considering I want the vehicle ready for the 1st week of June , that gives me May to build it up and December ---> February to "test" the 7163 kit hopefully on days where the roads will have 0 salt/snow.

This is the list for the motor build which needs to be done by the middle of April 2015.

• Audi AAT 2.5 TDI Block
• Audi 2.5 TDI 95.5mm Forged crankshaft
• Mahle Motorsport 82mm bore x 95.5mm stroke w/9:1 CR pistons
• DM Forged 160/21mm Connecting Rods w/ Rifle drill through the centre
• Mahle Clevite Connecting Rod bearings
• I5 Sputter Main bearings - Calico Coated
• ARP Main Studs
• ARP M12 x 1.75 Head studs
• Audi 7A Oil filter Housing
• Mocal SPIT Sandwhich plate
• Mocal A1910 19 row oil cooler
• INA baffled & kicked out oil pan (never seen a racing oil pan for the 3B to date)
• /
• Audi AAN Cylinder Head
• JNL Racing - Cylinder Head port work
• Custom CAT Cams
• Supertech +2mm Intake Valves
• Supertech +1mm Exhaust Valves
• Supertech Valve Springs & Ti Retainers
• (20) AZG VW MK4 2.0 8V lightweight lifters
• AAN Valve cover
• INA CNC'ed Coil Pack holder
• INA 10-AN Fuel Rail
• ID1300cc injectors
• MTM Replica intake manifold - opened to 75mm
• INA 75mm throttle body
• /
• Radiumauto FPR & Fueling components
• Fluidampr Harmonic Dampner w/INA machined ring
• INA Accessory bracket
• AAA VR6 Alternator - 120A
• AWP MK4 1.8T KYB Power Steering Pump
• Cast T3 turbo Manifold
• EFR7670 Turbocharger
• INA Oil & Coolant lines (not like the garbage others sell that don't fit)
• TiAL MVS 38mm Wastegate (water cooled on separate circuit)

So what have I been up to? Aside from buying various bits and pieces as Christmas gifts (don't tell the misses) I have been busy designing components that I deem necessary for my end goal. Two of which I think most here will appreciate:
1. 75mm Throttle body that will work with OEM everything
2. Accessory bracket that will clearance a forward facing intake manifold.

Last week I posted in this thread
http://www.s2forum.com/forum/showthr...t=49192&page=2


I usually find myself constantly redoing designs and this was the latest Revision (REV_06)


Which then became this:




which will eventually get chewed out of Aluminum on Monday while I do a trial fitment over the weekend. Thought about long term what some users would not want to do i.e. wanting something plug and play without porting so I did make a 66mm ID to 75mm ID adapter plate 8mm thick.



Topic of Throttle Position Sensors.
There seems to be ALOT of conflicting information with respect to TPS.
I have the following 2 TPS:
Audi 200 20VT - 3B - OEM # - 034133154F / BOSCH #: 0 280 120 410
Audi URS4 20VT - AAN - OEM # 078 133 154 / BOSCH # : 0 280 120 431

Threads of reference that I came across that had information relating to the matter:
http://forums.quattroworld.com/s4s6/msgs/21009.phtml
http://forums.quattroworld.com/s4s6/msgs/20405.phtml
http://www.audiworld.com/forums/audi...meter-2833936/

The common theme across the threads was the TPS's have different readings , however , my findings were the opposite. I have been looking at new Bosch TPS's and the cheapest I found was from the Audi A8 3.6. Everything I can see points that it is interchangeable with the AAN.

So , does anyone here know (not what the Bentley or other books say because they are different part #'s) what the difference is between the Bosch 6-PIN Throttle Position Sensors found on the following vehicles:
- 3B Audi 200 20VT
- 3B Audi S2
- AAN - Audi URS4
- ADU - Audi RS2
- Audi A4 B5 2.8 12V V6
- Audi A8 3.6 32V V8
and pretty much all the vehicles I came across that had a Bosch 6-PIN TPS (including Porsche).

Thanks,
Issam

[Greg_S]

Nice work on the throttle body. Im not sure on the part numbers for the TPS, I can take measurements from mine if it helps?