Well as some already know the MTM turbo upgrade kit and the Integrated Engineering Rods are installed.
Here are a few random shots from the work we did
Porsche Tuned Audi RS2 Turbo – K24 7200
took engine to bits, to install Integrated Engineering Forged conrods, built entire engine back up with all new gaskets and bolts etc.
Removed Standard Rods
Forged rods installed with new (Genuine Audi) Races and ARP bolts (much needed as this is the most stressed bolt in the whole engine
Head was now on the bench,
Head with MTM high flow manifold, Audi RS2 External Waste gate and the Turbo mounted up
Spent what felt like forever draining all old oil from the head, and also the old head gasket residue from both surfaces
Engine as expected was in very good order inside with it been 40 odd thousand miles
Testing the fit of the downpipe we had to make up to get this kit to fit.. The Miltek made item that came with the MTM kit was made for the Audi S3 and was fouling on my engine mount..
Kim collngs of QST (UK MTM Agent) had to have these made up because the MTM kit was based on Left hand drive cars and their downpipe will not fit a Right had drive set up
it was terribly made as most Miltek stuff is IMO. Really am amazed they sell so many systems.. some very bad welds and terribly rough finish, with odd sized bits of pipe randomly used…
glad it didn’t fit TBH haha!
Here is the offending item. I used the flanges though, so cheers Miltek
Had a Flange lazer cut in stainless to match the current join on my existing downpipe where it meets the rest of my system
Decided to vent the External waste gate externally under the car, not for the noise but to help keep the flow in the downpipe smooth and also heat temps to a bare minimum
These are the pipes that we came up with
I had to rebuild the Waste gate. The diaphragm was shot. Sourced a genuine Audi RS2 item which was not a easy job! £70 later I had one in my hands
Old
New
and then rebuilt the whole housing using new fasteners etc. also gave it a coat of black paint on the actual cast body..
Left the Cap in its Natural Metal finish for that OEM look
Head was mounted back on the car. The turbo only just fit in the bay!
I modified my TIP so the pipe was the same diameter right down to the inlet of the turbo.. all the ones available to buy for K04 etc. bottle neck down in size, even those 3” ones that cost a fortune have an adapter with a tiny bore hole (what’s the point in the extra large pipe if it cant flow into the turbo
)
Any how, cut my tip in half, had a mandrel bend made up, full correct bore right into the turbo
Next up, I had my Charge pipe (the one that sweeps round the drivers side of the engine with the little hand logo on it) modified by having the restrictive baffle removed and a straight piece welded on. Also had to weld up one of the holes where a pipe originally joined to the N75 valve (this now joins to the external waste gate instead
Modified rear engine mount bracket to clear my new downpipe, also had this strengthened whilst I was at it
Sent the ECU away to Kim Collins at QST for the MTM map to be loaded up… he didn’t have the correct file for my late engine so MTM in Germany had to sort this and send him the file
I opened up the ECU on its return, u can see the chip in the middle with the barcode sticker on it
(this will be getting replaced by a custom map)
The power is quoted to be between 325 and 345 bhp with this map.. the turbo can flow to 360bhp
Found a load of boost leaks on some pipes which are a nightmare to get to, these were only recently replaced with genuine items so iv now fitted Forge silicone items.. these are not visible when looking into the bay as they are located under the inlet
£35 for some tiny pipes felt like a rip off but needs must
Standard 380cc S3 injectors next to the MTM modified 540CC
I had these ultrasonically cleaned and flow tested before I fitted as I didn’t know the history of them
Oil return line that came with the kit looked to be slightly too small bore.. when compared to the outlet hole on the turbo so I had one made up locally with the same size bore as the hole on the turbo
You can just make out the difference in size
I had a lot of issues getting this kit to fit, it was by no means a easy install due to the nature of the kit which is basically a set up made by Porsche to use on the Audi RS2, then modified by MTM to fit on a Audi S3 8L… then modified here in the UK by us to fit a Golf mk3 with a S3 engine!!
But its been massively worthwhile,, this car is an absolute animal. Never have I been in a car so wild in my life.
The engine note has changed from sounding tame to a burble on normal driving , the turbo just sounds fantastic, once you hit 4k revs the thing goes ballistic and the Waste gate just makes what I can only describe as a crazy arsed bark..
Here is the engine back together and in the car
You can see the external waste gate poking up at the back of the engine
