Finally Preparation For Stage 2 Remap - With Results :)

[j1sgo]

RS4 open heart , do yourself a favour unlike me and do this before you start blasting carb cleaner into the ports


Soalk for half/hour:


Sponge out with blue roll then blast/vacuum (the old Dyson DC02 didn't miss a beat and kept up with the blaster no problem )





First go result:



Finished articles - I found some stubborn areas particularly behind the valves needed a bit of scraping:


Spot the clean 4nr ports:


Last 4 to do tonight - I would say it takes a good total 6 hours to do all 8nr ports based on my 4nr last night, not even sure how you would achieve this without blasting/vacuuming TBH, thanks to Tony for that

[Surrey Sam]

Great work and update

[neilparf]

Nice thread and update - much respect for doing this DIY...

[j1sgo]

Cheers guys,

Got the last 4 finished tonight, it's no wonder it robs power, you should see the sludge in the bottom of Some of the worst ports once the carb cleaner has softened it

Also the stage 2 manifold arrived, cheers MRC.

Off to a wedding tomorrow so back Sunday to fit the manifold and hopefully get her back up and running.

Will chuck some more pics up on Monday

[Rick_RS4]

Can you post a pic of the manifold. Curious to see what they call a stage 2?

Cheers

[Matt_lad]

Nice thread and update - much respect for doing this DIY...

+1. Good on you for doing this yourself

[j1sgo]

Pics as promised, got her finished and running last night.

Thursdays carbon removal completion of the last 4nr ports:




Crucial parts for the job:


Standard and Stage 2 MRC manifolds together, between the de-carbon and this port work/flap removal I would think it will breath much better now from inlet side, bit darker than mine too which I like.








Cleaned the throttle flap/pipe and airbox as they were pretty dirty.






Yesterdays completion




Was a bit nervous on start up as she didn't sound great but a few minutes and she was sounding smooth, I have an EPC and engine light up but assume this is because of the stage 2 manifold.

Now for and oil change and cat gutting on Tuesday night - I anyone has some tips on the best was of going about this please share

[TonyHayers]

Nice job mate. Cat gutting is a piece of cake compared

[TonyHayers]

Did you get any better pics of the MRC manifold? curious to see how they handle the "step" bit.

[j1sgo]

Nice job mate. Cat gutting is a piece of cake compared

Thanks mate, care to elaborate what did you use to smash them out and ensure nothing left in?

Sorry didn't take any more manifold pic's when it was off, what do you mean by the "step bit"?

[TonyHayers]

Nice job mate. Cat gutting is a piece of cake compared

Thanks mate, care to elaborate what did you use to smash them out and ensure nothing left in?

Sorry didn't take any more manifold pic's when it was off, what do you mean by the "step bit"?

I thought I posted a howto on here. I'll have a dig...

There is a step in the casting, where the flaps bolt onto the shaft, to smooth airflow over the flaps when fully open. When the flaps and shaft are removed the step doesn't really serve a purpose and by grinding it out you can apparently gain improved airflow (I say apparently because I'm assuming MRC did some flowbench testing to warrant the effort). I bottled out of doing it on mine because it looked too easy for me to get it wrong.

[j1sgo]

Nice job mate. Cat gutting is a piece of cake compared

Thanks mate, care to elaborate what did you use to smash them out and ensure nothing left in?

Sorry didn't take any more manifold pic's when it was off, what do you mean by the "step bit"?

I thought I posted a howto on here. I'll have a dig...

There is a step in the casting, where the flaps bolt onto the shaft, to smooth airflow over the flaps when fully open. When the flaps and shaft are removed the step doesn't really serve a purpose and by grinding it out you can apparently gain improved airflow (I say apparently because I'm assuming MRC did some flowbench testing to warrant the effort). I bottled out of doing it on mine because it looked too easy for me to get it wrong.

Ahh I see, well from looking down the manifold ports there was definitely no step so I would say they were ground out, I will search for your how to also

[j1sgo]

Nice job mate. Cat gutting is a piece of cake compared

Famous last words tony!!!!

What a nightmare job, spent the last 2 nights in my mates garage getting the darn downpipes off, 1st was bad enough with corroded nuts but the second was properly seized, fair play to my mate though with extreme patients and heat he teased the last top nut on the passenger side d/p off.

Gutting downpipes was easy enough though.

Now for the remap tomorrow can't wait as driving round like a granny with Christmas tree lights on the dash is not fun.

[GlenRS]

RS4 open heart , do yourself a favour unlike me and do this before you start blasting carb cleaner into the ports

Good idea on wrapping up. Wish I did this when I did mine, would have saved on a lot of extra cleaning. I for one didnt appreciate just how much mess it would make.

[Rick_RS4]

Good job. I'm looking forward to the results. The downpipes are a complete mare to remove. 8 used new studs and copper washers this time so hopefully won't corrode.

What lights do you have on the dash? I removed SAI and do t have a code up yet only a lambda code pending but I have a couple of spacers to go on at the weekend.