RS2 Turbo's and Exhaust Manifolds

[Greg_S]

When converting to RS2 turbo and exhaust manifold what other parts need to be changed, other than gaskets etc.

What is the cost of these items?

Finally anyone got any for sale..... long shot i know

Greg

[S2central.net]

The RS2 turbo and manifold are really the only two parts you *need* to break the 300bhp barrier on the S2, BUT....

These other items come highly recommended -

1. RS2 intercooler with associated X-member (or a mod to the S2 one) to reduce heat soak as much as possible.

2. An exhaust camshaft from an ADU (RS2) or 7A (20V non turbo) engine which allows the engine to flow a little more air than the 3B or AAN/ABY. Gives less lag, quicker spool up and a stronger top end.

3. A 3bar MAP sensor will be required if you wish to run beyond the 1.5bar threshold permitted by the ABY's MAP sensor. A stock RS2 boosts to about 1.4bar so its OK to run on the 2.5bar sensor if that's your limit. I can program chips either way for that. Obviously the 3bar device gives additional headroom in the overboost department - say for 1.6-1.7bar with care.

If you want to show off and spend money on RS2 'green' injectors then you can but there is actually enough capacity in the ABY ones to properly fuel the beast with the ABY fuel pump and FPR. The FPR is the same on ABY as RS2. The ECU can be tweaked to work with ABY or RS2 injectors. Obviously the green injectors have additional capacity for larger systems and you could argue they don't get worked as hard as the ABY ones would in the same environment but its no big deal either way.

If you can locate an RS2 MAF it might be worth fitting as it flows more air than the S2 item due to less restrictive screens, but I still haven't got a definitive answer from anyone with eveidence on whether they are electrically any different or not.

I know you can run happily in 'RS2 mode' with the S2 MAF so don't worry about it - unless you happen across a good RS2 MAF going cheap.

That's about it unless my deep fried brain has omitted something else - oh yeah - chips of course

Paul

[APNess]

RS2 intercooler another 'must' if you want decent power gains, and of course, remap. As advised by Paul N the RS2 injectors not needed so much, but a camshaft from RS2 or 20v normally aspirated engine is a good way to go as well. I think I did a list of costs somewhere in another thread, all from Vagparts (where else? )

[APNess]

Oops posts crossed. Yup. What he said ^^^^^ (Paul N)

[Greg_S]

Looks like this is gonna get expensive.

Any idea for the cost to start with of RS2 Turbo, Exhaust Manifold and Re chip?

[APNess]

http://www.vagparts.com/pages/RS2-s2.htm - start there I guess.

These guys, being specialist turbo manufacturers, might be cheaper with the cost of the turbo, but if I recall right, Leigh said they charge about £700+vat for an RS2 blower:

http://www.aet-turbos.co.uk/

Just bear in mind the crossmember that holds the intercooler on is different for the RS2 item and your ABY (assuming it's ABY) X Member will either need modifying (anyone done this? photos? Work involved/costs?) or you'll need the RS2 item, unless you can source one from a scrappie (doh, good luck on that )

So, from Vagparts £961+vat, plus remap (Paul N best man to see) and X member either modding or a new one (Martyn/Vagparts - any ideas on that one?)

This is a modification I *need* but cannot do till next year, due to no cash, so I'll be interested to see how people get on with this.

If it came down to a group buy and decent discount, especially for intercooler and x-member, I'd have to break a few personal rules and *nnngh* borrow the money from somewhere I think.

Or ram raid another off license.

[Pisobiker]

Here are my X-member mods:
1) front wiew

[Pisobiker]

...
2) and custom bracket detail.

Don't pay attention about IC left side mounting cut. I did that previously when I fitted it to my 2.0L 20V coupé 3B converted.

[APNess]

Is that all that's required? A piece of metal on the left hand side? Many thanks for casting light on that - I was expecting some kind of 'miracle of modern technology' with what Audi were charging for a new crossmember.

[Pisobiker]

Well, there might well be other better and "nicer looking" ways to do the job, but this was for me simple and fast
About 2 years running this way with no problems!
Right side mountings are exactly the same between ABY and RS2 IC. Dunno if 3B IC is different, though...

Ciao

Marco

[Martynf]

Ignore the parts prices on the website guys, that is NOT what you guys pay!!!

If you want 'your' prices, mail me on my work address Martyn and I'll reply.

I've often considered having KKK do some 'special work' on a RS2 turbo for us, to clarify.... we work VERY closely with KKK themselves on 'special projects' I cannot say too much in the open!! but... we have had some custom work done on certain turbos and supplied them to 'a customer' who was extremely satisified! This customer is not your avg. Joe Bloggs and I can say no more.

BUT..... with the knowledge and ability of some of the guys in this club, I've never followed it up. I know Mihnea is working on a special hybrid, so I'm not going to reinvent the wheel when someone else with greater knowledge than me is already doing it.

Forget buying the RS2 x member, sure we can supply them for a good few hundred £'s less, but I don't think it's worth it! Check out what Marco has done to rig his RS2 IC, simple and effective, perfect!

Martyn

[akojacko]

can anybody recommend someone to do engine work in yorkshire area?? must admit i think i need the camshaft to improve reponse, but thinking of going to 430ish bhp with all the relative mods req'd so may wait till do the full job. if not can i just get someone to fit the camshaft as mentiond earlier and how much would this cost. also would the car need re-setting up to suit new cam???

[S2central.net]

The 7A or ADU exhaust camshaft won't stop you getting to ~400bhp. If you have a big enough turbo, mated to an RS2 or better exhaust manifold along with green injectors then all is needed is custom ECU chips for your needs.

Is your car a 3B or ABY - further mods will be needed if you have a 3B (ie different FPR and beefier ignition coil) and the ABY is easier to map accordingly.

The camshaft will help though - particularly low - mid range.

Hopefully someone can recommend you a good local S2 mechanic to change the camshaft for you - no remapping is needed to drive home and beyond with the camshaft mod on its own.

When you are ready for the chips let me know and I can get you sorted with a suitable 'baseline' ECU upgrade with a 3bar MAP sensor etc etc. Send me an Email or PM and we can go from there...

Paul

[APNess]

Garage/Specialist Review

Well I've had good (but slow) service from David Underwood/Swift Autocare in Sheffield - several things to note:


Garage/Specialist 'Review'

David Underwood/Swift Autocare - Sheffield - 0114 270 0124
===========================================
1)Labour is around £30 +vat/hour (cheap imo)
2)The head guy - David Underwood, knows his stuff (had all sorts of S and RS cars)
3)They are very busy, all the time, and getting to talk to Underwood himself is sometime frustrating.
4)They will work with you if there are any problems - they drove a courtesy car up the A1 to Ferrybridge for me.
5)They are slow, being so busy - also recently had the car off the road for 4 weeks because of a **** up in ordering parts.
6)They will fit parts you buy - so whatever you do, see Martyn/Vagparts and get your parts from him, then take them to Underwood - I did this with Milltek Exhaust - I should have done with all other parts (seat pads etc) from Vagparts.
7)David himself blows hot and cold - sometimes friendly, sometimes not, always professional imo
==============================================

With all those good/bad points in mind, it's worth a try with a single job and see how you go from there. Despite the problems I have had with the garage (because they cocked up with parts ordering - if it's something out of the ordinary - and it usually is for an S2, you *must* speak to Underwood - someone else will get it wrong) I will go back there for other work to do on my car.

Some of the other guys (e.g. Leigh is from Sheffield) may have something to add to this.

Anyone else got similar things to say about specialists/garages in their areas? Worth starting a seperate Good/Bad/ugly suppliers section/thread?

Hope I've not bored you with rambling on.

Paul J

[Dr H]

I agree with Paul's comments on Mr Underwood. Does seem to know his stuff. First time I went to him he was great, second time they seemed to be too busy to do what I asked.

Had the car for 2 days and only did a service, didn't do the tracking/alignment I had asked for and something else was missed.

Asked them to fit a new air filter during the service. It wasn't on the bill and when I asked they said that it didn't need changing. Got home and opened the air box and hey presto there was a brand new air filter

Also they said the car didn't need tracking, which is funny beacuse it was them that pointed out that it did (about a month earlier) and they were right it did need it (and still does).

Maybe they were having one of their super busy periods.

Having said all this Dave does seem to know a lot about the S2 so he could be a good choice.

Leigh

Oh yeah biggest down side to Dave Underwood is that he is a massive fan of Superchips and we all now that there are much better chips out there.............