[s-cars] RS2 EM wrenches

[Rob Pecsar]

Hi, Ron.

I just finished a RS2 Exhaust manifold this weekend, so my experience 
quite vivid. I could have not done it without the posts from the s-car 
list. Thanks, guys!

Happy to loan my wrenches. I could use the tensioner in the future.

I have attached the posts that I used to come up to speed below:

http://forums.audiworld.com/s4s6/msgs/12090.phtml
http://forums.audiworld.com/s4s6/msgs/11031.phtml
http://www.urs4.com/technical/engine/UrS4_exhaust.html
http://pictureposter.audiworld.com/9882/image1.1.jpg

How long does it take: a solid 1 1/2 days with one friend. The 
disasssembly took 4 hours, and same with most of the reassembly. The 
rest of the time was lost on 2 things: bolting in the new exhaust 
manifold... it take patience and the special wrenches. I shortened mine 
further than the links shown above and then I could complete the 
install. I was running into an oil line that bolts into the block. The 
other big time waste was installing the water cooling line to the bottom 
of the turbo. One of the above posts called it a PITA and it is. It 
sounds kinky, but I eventually laid across the motor with my head where 
the air filter box would normally be located so that I could see the 
fitting on the underside of the turbo. The other trick with this fitting 
was to pull the nut completely up and then thread it into the fitting; 
don't try to push the metal tube in place and then start the nut.

Buy extra nuts for the exhaust fitting just forward of the cats; there 
are a total of 6. Mine were rusted. This was tough to reassemble by 
myself but it helped to used my hydraulic jack to align the fitting 
vertically and then use a large punch to align the mounting holes. I 
also used a large vise-grips to squeeze the mating brackets together. 
That gave me enough assistance to slide the bolt in a thread on the nut.

Drain the coolant was messy as you would expect. When disconnecting the 
coolant line from the top of the turbo, I used a long piece of tubing 
pushed into the turbo coolant hole and created a syphon to draw out the 
rest of the coolant from the block.

Buy all the replacement parts recommended in the above links. You will 
use them all if not most.

If you want to talk live, let me know.

HTH,

Rob Pecsar
'95 MTM 1+, Bilstien/Eibach, '92 sway bars, 993 Big Reds, RS2 exhaust


dooksniffer at comcast.net wrote:

>S-Gents,
>
>I have just completed a t-belt, serp belt, tensioners, water pump, yada yada.  If anyone wants a used serp-belt tensioner is yours for the price of shipping.  The roller bearing makes a good bit of noise, but I thought a spare might help eliminate down time during a rebuild.  Just a small token of appreciation to the list.
>
>Next on this summers laundry list is an RS2 EM install.  Couple things:
>I have read numerous write-ups and posts in the archives and it seems some people cut down the necesarry studs and some opt to replace with smaller ones.  What's the general consensus as to which way works best?  Any horror stories while using either approach?
>
>Lastly, any modified wrenches out there for rent?  I'll trade you for the tensioner and I will pay all shipping.
>
>TIA
>Ron Whiton
>95 S6
>05 cbr600rr (new commuter when S is down)
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