Calling all electrical gurus (+ Wagner EM Nero DP issues)

[Lupo911]

Exactly the same issue I had with the same EM and was told it should not happen on an RS2... which it seems to have done, albeit on an aftermarket DP.

I need to adjust the water line on the underside, as it's not sat quite right and the top water line was also tight, indicating that the turbo had moved outwards compared to the OE EM. The DP modification cost £100 that I hadn't expected to spend on top of a bolt-on EM At least it's a complete animal of an EM :mischeif:

Are there aftermarket water lines for the S2/RS2 that allow a little more movement in the system than the stock solid items?

@ sonic and lloyd - email Wagner and tell him of this problem. He phoned me when I posted up about it and I was told that it sohould not happen but it would seem that you've both had an identical issue to me.

I am very sorry, for you Guys.

But have have to say, that when i designed this Manifold over 5 years ago, i did the testfitment only with OEM Parts, as Turbos and Downpipes.
And everything did fit well, as many People can vouche for.

I can not check every Aftermarket Downpipe for perfect fitment, with our Manifold, sorry.
Designing Performance Parts means also maxing out the Tolerances, and when a other Part is maxed out to the oposite Way, you will may run into some fitment Trouble.

@Rusty, regarding your Waterlines, as i told you already on the Phone, i believe that your Turbo Middle section is not adjusted in the right angle, so in that case you run into fitment problems. You can adjust that by yourself or have somebody with experience do that.

[Rusty]

Hi Carsten, I've checked on the car and both upper and lower lines need to be slightly extended - if one was short and the other loose, then I'd agree it was a rotation but as that's not the case, I can only conclude that the whole turbo has moved a little further away from the block. The movement you described between S2 and RS2 will also be adding to this misalignment compared to OE S2 setup that the water lines were fitted to originally.

Lloyd's picture above is exactly the same offset that I had - mine was a custom fit DP to my OE S2 turbo and EM as opposed to Lloyd's OE RS2 setup.

[Jonas_R]

I never had any issues with the water and oil lines, just the wastegate flexi pipe

[Rusty]

S2 or RS2?

Tolerance buildup will mean that there are differences between all setups - I'm sure that there wil have been some adjustment from the factory to make up for the odd mm here or there. The pipes were only about 5mm off but as they're metal, there's very little flex in thembut just enough to get it all fitted.

I think that loosening off the lower line at the block pipe and massaging the top line mounting point will help. I guess we're talking about an 18 year old car so things move and expand / contract / warp over time.

[Lupo911]

Hi Carsten, I've checked on the car and both upper and lower lines need to be slightly extended - if one was short and the other loose, then I'd agree it was a rotation but as that's not the case, I can only conclude that the whole turbo has moved a little further away from the block. The movement you described between S2 and RS2 will also be adding to this misalignment compared to OE S2 setup that the water lines were fitted to originally.

Lloyd's picture above is exactly the same offset that I had - mine was a custom fit DP to my OE S2 turbo and EM as opposed to Lloyd's OE RS2 setup.

OEM Waterlines will fit 100%.

Lloyd and you using the same Downpipe, = same Problems. Wastegate Flange is not 100% on OEM Position.
Here Pictures of a Stock S2 ABY with our Manifold. As you can see, DP and Waterlines fit without Problems.

[Rusty]

Lloyd's picture above is exactly the same offset that I had - mine was a custom fit DP to my OE S2 turbo and EM as opposed to Lloyd's OE RS2 setup.

I am not using the same DP as Lloyd, sorry if that information was not clear.

As posted before, the water lines are on there, they just needed a bit of massaging to get them to line up properly and the lower one needs to have the block end moved a little to make it sit properly, as it's not sealed properly and is weeping a little.

[Lloyd]

Thanks everyone for your input. Much appreciated.

OK, so maybe I was too tired last night. My main beam lights DO work as expected.
It is just my HID's - both sides that have stopped working. Engine running or not makes no difference. Battery is fully charged.

I've stuck a voltmeter on the plug and played with the stalk. Does anyone know the wiring layout for the plug?

[Rusty]

Have you got a connection inside the lamp? I usually wrap tape around these to prevent grounding and also to keep them all together!

[Lloyd]

@ Carsten, no problems with waterlines, apart from them needing a tweak due to large coldside housing. Definitely no issues there due to EM.

I understand and appreciate that Carsten is right about tolerances. However, as I am doing this for the firs time (and have no time) I think you should highlight the potential for issues with non stock downpipes. Perhaps add a note to your website?

That way your customers will be well informed and can ensure they allow enough time and money for the entire job, or choose to go to Audi!

For the record I would have still bought a Wagner EM but do wish I had known about the potential for issues.

[A80Avant]

Lloyd, if you put a halogen bulb as normal, does your main beam work? that way you will know if it is just the HIDs while the wiring is ok.

[Nuvo]

I've stuck a voltmeter on the plug and played with the stalk. Does anyone know the wiring layout for the plug?

You can find the wiring info here.

[Rusty]

Lloyd, if you put a halogen bulb as normal, does your main beam work? that way you will know if it is just the HIDs while the wiring is ok.

[Lloyd]

Lloyd, if you put a halogen bulb as normal, does your main beam work? that way you will know if it is just the HIDs while the wiring is ok.

Main beam is fine . Think I just forgot to flick the stalk last night, too tired....

So, it's just the HID's that are faulty..... It's odd that both sides are not working?

Can anyone label the cables in the headlight connector?

Brown = earth
Yellow with black stripe = ????
Grey with black stripe = ????
White with black stripe = ????

I've also had a look at my HID's and I can not find an external earth for them.
The only one I can see is inside the lamp housing on the back of the HID lamp plate.
It is very clean and soldered, no apparent issues there.

[Lloyd]

You can find the wiring info here.

Thanks Nuvo

[Acidburn]

Did you remove the ballasts at any point? check the plugs are the right way as they can be put on the wrong way around.
Might be worth while connecting them up direct to a battery (one time a 3b is better than a aby/avant)
probably something simple.