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

[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.

[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]

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.

[Jonas_R]

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

[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.

[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.

[Jonas_R]

No need to reweld the downpipe. Just cut the flanges of the flexipipe and use a "normal" flexi pipe instead. I did it like this:

[newsh]

Pull the plug off the back of the light stalk switch and have a look for a burnt pin.

[newsh]

Put the WG in a vice, slip a bit of tube into the end of the flexy and lean on it (in the right direction) Sorted

[Jamo]

Ditch the OEM flexi and use an aftermarket with the flanges from the OEM, the OEM flexi has a 1" tube in it for flow which is a bit of joke to be honest.

[caterpillar]

i will check the ign switch again.... the org mod to the small chassi have men some ****.. and some people have changed to seat ( spanish verson) they does have some other manufacture....
if not; chech out the earth konect in the car, under the dash...

[Rusty]

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.

[A80Avant]

a lot of hids wont work if the engine is not on. Mine tend to flicker if the engine is not running

[sam80quattro]

is the battery fully charged? hid's are crap when they dont get enough power..

[Nuvo]

Any more ideas on the lights front?

It's possibly just the internals of the stalk that are needing cleaned out and re-greased.