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

[Wizard-of-OD]

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?

If that helps sure but I got the TPS off the S2 (another 3B) and it had the 410 part #.

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-original-s-cars-25/throttle-potentiometer-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.

Values checked out to be the same so I am wondering who or why it was posted that the 3B and AAN or any 6-PIN tps for that matter has different values when they do not.

Water manifold thermostat down by the water pump?

Yes , the plastic ones seem to follow the same issues as the later vehicles so would like to recreate them in aluminum. Should we start a GB?

Nice development with the TB Issam - is it a restriction at 500hp though? Don't get me wrong if I had the resources to do stuff like that I would regardless of whether its necessary or not... but I would be surprised if many will pay the price it would cost for such a pimp item
That is some list of upgrades there, it will make for a cracking motor

With respect to throttle body development , when I did the 1.8T test , we did not know what to expect and that was on a 1781cc - 2008cc engine. Having almost 30chp gain on a 420chp+ motor is welcoming . With a 2226cc engine I see the 66mm OEM unit as a restriction and considering no one has tried a 70mm+ , with collaboration with Doug@MRC & Marc@EFI , I think we will soon find out what a 75mm will do as a bolt on modification.

Sounds like a nice spec list.

You are making some cool stuff!

Interested to see how you get on with the EFR turbos, is Hank doing them with KKK hotsides?

Thank You! Hank is doing a KKK/T3 inlet to V-band adapter and then using the v-band externally gated EFR7163's. Same goes with the TiAL hotsides since TiAL manufactures the turbine housings for the EFR project line.

[andy10v]

Sounds like a nice spec list.

You are making some cool stuff!

Interested to see how you get on with the EFR turbos, is Hank doing them with KKK hotsides?

[Error404]

Nice development with the TB Issam - is it a restriction at 500hp though? Don't get me wrong if I had the resources to do stuff like that I would regardless of whether its necessary or not... but I would be surprised if many will pay the price it would cost for such a pimp item
That is some list of upgrades there, it will make for a cracking motor

[terrybullwon]

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?

Water manifold thermostat down by the water pump?

[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?

[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/showthread.php?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-original-s-cars-25/throttle-potentiometer-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

[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]

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?

[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/showthread.php?t=50050&page=39

[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?

[Wizard-of-OD]

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

I've sent it via PM

[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]

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?

[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]

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.