Wagner Exhaust Maniflold Fitting & Issues

[Rusty]

I've just fitted my Wagner EM and it's a great piece of kit for sure; certainly an upgrade over the RS2 item (as the Evo name would infer!).

To fit the EM, I needed 5 shorter studs (compared to the RS2 EM's 4) - 4 on top on cylinders 2, 3 & 4 and 1 underneath on cylinder 2.

Once the manifold was on, I noticed that although it's supposed to be a direct replacement for OE, the turbo and WG had moved a little. The turbo has moved forward 5-10mm and the WG flexi pipe was 10mm or so higher when offered up to the DP. To get the car running and tested, I made it fit but for my troubles, I've now cracked the WG pipe on the DP and will have to get it to an exhaust place to get it all sorted and make sure that it all fits properly.

Has anyone else had this issue? It's a K26 flange item and I was expecting it to be a straight replacement for the OE but it's not quite...

Overall, it's a great piece of kit and will certainly help things along nicely, it was just a shame that it didn't quite fit as expected...

EDIT:-

Carsten has confirmed that the S2 and RS2 turbo positioning is different by 8mm! So that's explained that one. Just the WG position to nail down now.

This explains why, later in the thread, the RS2 users don't have the same problems!

[s2_bo]

Sorry to hear that Andy.

Do you already have a custom downpipe? When i fitted my evo one i had a custom 3" downpipe with flexis and it went on fine.

I know that shouldnt make any difference but was just thinking that your DP may be stiffer hence making the tiny differences more noticeable then on mine...

Hope you get it sorted soon..

[Rusty]

Yeah, it'll be sorted soon enough.

DP was custom made and fitted my k24 7000 perfectly.

It's well worth the effort but I wasn't expecting any fitting issues, so wanted to check if I have a rogue unit...

[twenty valve]

I had to cut a few studs when I was fitting my wagner, I also had my downpipe made in situ after the engine and turbo where fitted, no really a problem....

The annoying thing was the air housing on my 3076 fouled the manifold. I had to file part of the manifold away, and make a 0.120" spacer with 2 gaskets either side, before I had clearance! note how close it is!

[Jamo]

The reason the AR fouled is that is not a 3076r compressor housing, the wagner EM is designed to take the stock 3076 compressor housing which has a housing of 0.60 AR.
The housing in the pic is a 0.70 AR which is the GT35r housing

[JariP]

I had the same fitment problem as Rusty, turbo moved some 8mm forward. It's kind of effin annoying when you've had a custom made dp and exhaust for years without any fitment issues and then you change in a so called "direct OE placement" part and dp starts to hit the subframe and exhaust is banging on the frame. Plus some other problems too.

Well maybe we can be thankfull that it is a high engineering european made part and not some chinese crap copy. Imagine how bad the fitment would be with chinese parts...

[Jamo]

True but if you have aftermarket dp it's not an OE car it's custom fitted to your car, the stock system probably has more movement tolerance as seen by the fact yourself and Rusty have custom downpipes.

So maybe the advice is if you have custom parts on the car beware the fitting maybe different which in my experience is always the case no matter the part

[4WheelDrifter]

I agree with Jamo. I've seen a few GT3076Rs from AET with 82mm .70 AR housing on.

[macspring]

We've fitted the orignal k24 back onto the new Wagner exhaust manifold yesterday and if we can get a hoist today or certainly next week, we'll be offering up an oem RS2 downpipe. Wll post how the fitting goes for reference.

In due course, when the final turbo is finally picked, , and fitted we'll see how it matches up to the FI Express three inch down pipe.

Doing it this way as it will allow the car to get back on the road and be a daily, and the turbo, injectors, downpipe can be swopped in later, hopefully without too much grief.

Can't find my hoist, and Mark's is on loan to someone we can't contact.

The joy's !

[Sonic]

Mine required some modification to get it all in and spaced nicely... learnt a long time ago that no modified part is ever "standard" fit though, all required modification to fit

[macspring]

@ Sonic,

btw, what downpipe ?

[JariP]

So maybe the advice is if you have custom parts on the car beware the fitting maybe different which in my experience is always the case no matter the part

In that case the Wagner manifold should be classified as a custom part too, don't you think? And not advertise it as OEM fit as Wagner does.

[robo]

wagner

As above Wagner mani is great kit, I fitted one with rs2 turbo and stock aby exhaust and it was few mm out.

[Rusty]

DP was jigged off a stock DP so was a direct replacement.

[terrybullwon]

DP was jigged off a stock DP so was a direct replacement.

More than likely unless it was a monster big Jig it would have moved when welding it any how.

I fell into this trap with my down pipe took a good day to get it right