Wagner Exhaust Maniflold Fitting & Issues

[mcandmar]

As David said above we will be fitting a K24/RS2 Downpipe onto a wagner manifold so will be interesting to see how it fits. One advantage we may have is the single mass flywheel will allow us to push the engine back and create a bit more room around the subframe. Bit disappointing though i would have expected the mounting flanges to be in the same position as the OE manifolds.

[JariP]

I don't think you will have any problems with the RS2 downpipe as there is plenty of clearance for the OE dp and exhaust. There's no denying the Wagner manifold is a great product and all the respect for going through the troubles producing it. But why make the dimensions close but not close enough to fit right, I just can't understand.

[Ross]

Obviously with the RS2 studs I had no fitment problems... the EM has much bigger runners, so access is a pain, and I'm sure it does move the turbo a little closer to the chassis. I have some vibration issues now, still hoping to solve it with an engine mount change (to which access from above is now impossible )

It's a great quality piece of kit. I too would have liked a bit more idea of the movements, but I must say with the stock RS2 downpipe I had no problem fitting it. Perhaps it was out a few mm but nothing that caused a problem.

[veneto rs2]

To be honest I fitted the Wagner EM on my RS2 with standard turbo without any problems nor for the turbo nor for the DP (original)
Only thing to adapt where the manifold heat shield (just one) but it was'nt a big deal.

Same thing on another RS2 from our Club (also with stock turbo and DP)

So for me i can say it's defenetely a straight replacement as stated by Wagner.

For sure you need healty or new engine mounts.

Stefano

[Rusty]

I doubt it's got nothing to do with the engine mounts as it was all off 2 months ago for a turbo change and was fine then.

The water cooling pipes on the turbo also had to be massaged to make up for the small movement of the turbo and get them to fit; something that again indicates that the EM has moved it all a little.

A stock EM & turbo came off and when this was fitted to an ABY, there were a few differences/movements, as detailed above. It seems that others have had similar issues and some have got away with it but others haven't noticed any differences or things have been close enough that there's enough movement in the system to make things work. Makes me wonder if there are a few more differences between ABY and ADU that are small but which add up to a possible headache - Ross and Stefano are both talking RS2s...

I'm going to book the car in to have the DP sorted but it's something that I'd not expected to have to sort and it's certainly not something that I was aware might be an issue - it was almost at the point where I couldn't have had the car running due to it all being too misaligned.

It's in no way a deal breaker, as the Evo manifold is easily the best cast item out there, it's just better to know that this sort of thing might happen, rather than believe that it's going to be a 100% straight swap and then end up getting a little stuck.

[Rusty]

For sure, it's worth finding out the maximum compressor housing diameter that can be fitted with this manifold...

[Rusty]

Car is booked in to have the DP adjusted and a few other things... I'm also going to look into a side-exit idea that I've had for a while but that might have to wait for a bit.

[Rusty]

Original post updated with information from Carsten on the turbo position.

Just the WG difference to resolve now.

[Rusty]

Hats off to Carsten: just received a call from him to discuss the issues I was having and possible causes for them As ever with these things, there are always other possible causes and obviously his experience with this product was most useful...

Anyway, to clear things up (straight from Carsten) -

1. The RS2 manifold holds the turbo in a slightly forward position when compared to the ABY - approx. 8mm.
2. The WG should be a straight fit to both standard ABY and RS2 DPs.

He also said that the manifold was modified for use with T3 flange turbos and this is why it can have the clearance issues with larger cold sides...

I must therefore conclude that, despite appearances, the DP was a little different to stock and that the water lines being a little tight could be explained by a combination of the turbo movement, perhaps a little rotation of the centre section and by the tolerance build-up on my car.

Thread cleaned up.

[Jamo]

Thread locked issues resolved