S2 ABY Crank pulley bolt went for bananas

[Torsen20v]

Hello S2Forum,

At first time excuse me for not to doing a properly present on this Forum. I’m owner of a Coupe ABY since Sep 2010 and I have read a lot about your Know How.

Last week I tried myself to do the timing belt change including pulley pinion Gear, Water Pump, etc. The catastrophic moment it came when I tried to loosen the pulley center bolt. This one was stuck with the crankshaft and it turns even when the pulley dumper,gear and camshafts are fixed with the Blocking tool.

Unfortunately I was able to move the crankshaft (I could see how flymasswheel turned at the same time than the pulley center bolt). I´m totally sure I have broken the crank gear Woodruff key so I think some valves have been damaged.

My ABY is totally stock so I´m going to take advantage of this problem to make a slightly upgrade. I have the following parts in mind to install While my car shop makes the retrofit.

Wagner 5:1 KKK Exhaust manifold
Wagner Evo 1 IC
Original RS2 Intake Manifold
RS2 PKMotorsport crank Gear
RS2 PKMotorsport Water Pump
Rs2 OEM Timing belt.
Sachs race Clutch

Previously installed:

Audi TTs Ignition Coils without LAZ
Forge fmcl007p “Green Spring"

Assuming that the other components works properly (Air Flow Meter, N75, Throttle potentiometer, no air lacks, knock and Speed sensors) what kind of remap or chips you would install on this car? I´d like to preserve Diagnose option and limp mode.

How affect on turbo spool the bigger IC and Wagner Exhaust manifold in the K7000 if I run with 230HP stock mapping?

I know there are a lot of Chips - MTM , Ultimot , Fastech, PKM , Superchips, ABT...

Actually I have 2 Ecu´s ,one of them is stock with welded eproms (installed in the car and no INMO) but I have another already socketed without eproms but inmo (this one is the original factory installed in the car)


Thanks Very much

I would appreciate a little of help in this issue.

Best Regards

Torsen20V

[K Simmonds]

You didn't remove the four 6 mm Allen head bolts from the damper before attempting to undo main 27 mm bolt in the centre by any chance?

It's not best practice but the crank can be locked using a pry bar in the ring gear to stop the flywheel turning, I'm sure I'll get flamed for suggesting it but I know of plenty of folk who have done it this way. Personally I'd only do it as a last resort.

There's nothing to be gained from using an RS2 inlet manifold, the casting is the same as an ABY, in fact the 3B inlet flows the best out of the stock options though the difference is negligible.

A stock clutch in good condition is fine for a chipped stock K24.

Timing belt wise I'd stick with a stock genuine Audi water pump, one of Terrybullwon's (he's on here) bottom cam belt pulleys and a Gates belt.

Unless your gong to be upgrading to a larger or modernised K24 turbo there's not a lot of point fitting loads of up-rated parts, the stock set up will keep up with all the air a stock K24 7000 can move. That said an RS2 type exhaust manifold is a massive improvement over the stock design so it would probably help spool a little though I doubt you'd notice the difference. I'm pretty sure the Wagner 5-1 tubular manifold requires a different down-pipe in order to fit it, I'd go for the cast RS2 Evo item which is a straight fit.

Software.... The (homefries) chip sets S2central and Prj offer for the stock turbo are what most members on here are running if chipped so their well and truly tried and tested. On a healthy car you should see 280 BHP or thereabouts which feels like a massive improvement over stock and both retain all safety features which can't be said for some of the other chip sets available.

Superchips are about the worst option going, from the couple of installations I've seen on here they basically consist of a bleed valve and different boost chip. MTM, ABT and PKM should all retain safety features though I can't be sure about any others.

That said if your prepared to spend the sort of money the parts you mention entail you may as well go for a different turbo and injectors as well, the RS2 unit is great value if you can pick up a good second hand one. There's a couple of members on here who offer some cracking hybrids, Vidar Skotheim has all sorts of options available and Albert did some interesting K26 hybrids.