200,000 mile overhaul time - turbo and EM required at least..

[shark_90]

Well the Avant is coming up to 200,000 miles very quickly. I've done a couple of trackdays and generally thrashed the funk out of it over the past year and I've loved every mile. After Mallory it started to blow a bit of blue smoke on gearchange and it's still doing it, perhaps a little more now I've been to Le Mans and back.

I have long term plans for the car roughly as follows:

Upgrade power, so turbo, EM, air box, injectors
Sort suspension, bushes and roll bars out

Not necessarily in that order.

The suspension stuff I will ask about in the relevant forum.. in here I'd like to know people's experiences and costs for doing things. I'm happy with how well the S2 goes in standard + Homefries trim. I know many people aren't, but I think it's pretty quick and when a CSL and Z4M driver comment, well that's enough for me. Having said that, if the smoke I am getting is turbo related, and I have to replace it, then surely I might as well go for a larger unit?

So, how far can I go on standard internals? RS2 power? RS2 + remap power?

Should I do an RS2 conversion and try to do it with all the standard RS2 bits? Or shall I buy a turbo from 034 and go aftermarket? Again if I do that, how far can I go before I start mashing bits of engine together at full boost?

Apart from the turbo and injectors, what else do I need to change? Air box? Exhaust manifold? What options do I have here? Are the £90 manifolds from Ebay any good?

I absolutely am not interested in going above 400bhp (I might live to regret saying that in years to come) and I'm thinking that RS2 spec + remap would be plenty for me.

Please could those more experienced than me share their views and wealth on this topic

[Sonic]

From my research the power upgrades pretty much go in stages. I am by no means any kind of expert on the matter so anyone in the know please feel free to correct:

For the most powerful rs2 setup you will want rs2 turbo, exhaust manifold, rods, injectors and ideally intercooler and airbox. With a custom map you will be looking at about 380bhp and **** loads of torque.

You can drop this down a touch, and keep the original EM and rods, but the remap will have to limit the torque. Or you can go further up the scale and look at the Garratt turbo's and a more custom setup to reach 420bhp+ and the sky's the limit.

One of the key OEM parts seems to be the rods, which turn into banana's after having full rs2 amounts of torque applied to them.

RS2 spec is the way i plan to go as its well proven and is pretty "bolt-on".

[shark_90]

I think my EM is cracked as I can smell exhaust fumes when I boot it, so that's on the list for replacement anyway. So the ABY and ADU aren't the same internals?

[shark_90]

Any ideas on a turbo to use on standard internals and what power I can have without bending anything? Do I need to upgrade the EM? I presume I will need to change to RS2 injectors too?

[spink]

So the ABY and ADU aren't the same internals?

i am not aware of any difference,rods and pistons are the same for certain (pretty sure the bearings are too,its only the 3b's that have different ones afaik).

[Jamo]

I'd use a 2871r/3071r over an RS2 turbo on stock internals although both can work fine if mapped correctly.

Depends on your money, the RS2 setup is more bolt on than the Garrett route.

[shark_90]

Money is always a difficulty, as we all know I have no budget for this one, I'm just looking to see how much it's going to cost and try to get bits as and when, and then spend the dark winter nights getting it all together. I have seen the 3071R on 034, so this is safe on stock internals? What sort of power is safe?

I need to come to a decision on which turbo I'll use so I can get an EM to suit it, I presume. I was also thinking that RS2 bits might be hard to come by and I will pay a premium for them, when I can buy newer, arguably better technology for the same or not much more money.

[Jamo]

You can buy the Garrett to fit the stock RS2 manifold.

The better option is to buy the Wagner RS2 T3 manifold and buy the Garret with the T3 flange.

RS2 will be half the price of the Garrett route as you need need oil and water lines plus they are available 2nd hand

[S2central.net]

The GT2871/3071 turbos are higher tech and ultimately higher performance than the RS2 turbo. Do get the best from GT3071R though it is advisable to upgrade some engine internals - motorsport spec forged conrods as minimum safety margin. Jamo is right to say to point out the options you have and that RS2 route is always going to be cheaper and less hassle.

ABY and ADU internals are the same in every way. Only difference worth mentioning is the EX camshaft - you'll need a 7A or RS2 EX cam with the higher lift to get full benefit of bigger turbo.

Truly bolt on upgrade with the RS2 path - its a great setup when running on good chips with that - only beaten at the top end by much more expensive turbos that require additional money and pain to get the best out of them.

You need the following for RS2 path -

RS2 or 7A ex cam
RS2 exhaust manifold
RS2 turbo (refurb'd along with new gaskets and h/t fixings)
RS2 airbox (unless you want to be strangled by an ABY one)
RS2 injectors (Bosch Greens rated at 37lbs @ 3bar)
RS2 intercooler
ECU upgraded with 3bar VMAP, a tweak and suitable software
Bosch 044 fuel pump NOT required by definitely recommended for additional headroom on full chat

[S2central.net]

The other route is small hybrid K24/K26 as per Nothelle.. running with RS2 EM, AB & IC for improved flow. Runs to ~320bhp on ABY fuelling and camshafts from memory. I'd need to get a sneaky peek inside a Nothelle ECU to learn more but this is a setup not to be sneezed at.

All about compromises here - money, lag & headroom !

[shark_90]

Paul, I presume you can do the ECU work?

I have an 040 pump already which I think will be sufficient. I think I have some injectors from a friend if he still has them.. better start looking for the other parts.

RS2 spec + correct code I'm guessing is about 360bhp?

[S2central.net]

Yep - can do it OK. Drop me a line when you have all the parts together.