Author Topic: 1996 Audi RS2 Brilliant Black  (Read 46779 times)

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Offline le mans

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Re: 1996 Audi RS2 Brilliant Black
« Reply #220 on: November 01, 2020, 11:57:32 pm »
Seven Years

Today marks the seventh anniversary of my purschase of this special car and I'm feeling a little reflective!
 
When I bought the car it wasn't running very well. Starting was inconsistent and it had a bad misfire under boost. There was also an intermittent short circuit causing the ignition fuse to blow. The short was in the ignition coil wiring and diagnosed and repaired by Brodie European during it's first service there (the car actually broke down during a road test by them due to the ignition fuse blowing and had to be towed back to the garage!). I discovered after some months that the vacuum lines to the boost control solenoid had been incorrectly plumbed. I'm sure this wasn't the case when it was tuned in Wellington at the end of 2010 by STM (as can be attested to by the smooth dyno plot and healthy power figure) but at some point subsequent to this they were messed up. This was the main cause of the misfire under boost, although I suspect the ignition system was also tired. With further research I was able to correct this and start my steep learning curve with the Link engine management system installed in the car. Installing an aftermarket ECU is probably not something I would have contemplated doing, but I must admit I was curious when the car came up for sale and I knew about the ECU. Since buyng the car I've completed half a dozen online HPA tuning courses and spent countless hours making tweaks to the ECU and reviewing log files. During this 'tweaking' I discovered the ECU was using an incorrect intake air temperature calibration and was able to correct this. Quite recently I discovered that the injector dead time table was incorrect and was able to correct this with data I found online. The injector dead times have little effect at high load as they are only a fraction of the overall injector duty cycle at that point, but at low load (starting and idle for example) the dead time is quite signicant relative to the total duty cycle. Correcting this has made AFRs more consistent on start up.
 
Not too long after getting the car I had the original alloys repaired and repainted in 'shadowchrome' by Arrow Wheels and shod with fresh rubber. I replaced the slightly 'boy racer' after market blow off valve with a working factory diverter valve Iíd removed from my RS4. I was fortunate to be able to get my hands on an original shifter purchased off a fellow vasker and previous RS2 owner. I also purchased factory fog lights. There was a bit of a saga with KW suspension that couldn't be certified without jumping through interminable hoops. After running H&R lowering springs for some time I've now settled (no pun intended) on the original springs with adjustable Koni dampers, which I feel is a more compliant and road friendly set up than the same dampers with H&Rs.
 
There have been numerous mechanical and electrical repairs made during my ownership, some of which I'm sure to have forgotten about! A radiator was replaced, the alternator was replaced, the oil pressure sender and multi function temperature sender (MFTS) were replaced. The fuel pump failed at some point and was replaced with a new one (that was fun breaking down on Ti Rakau Road in peak traffic!). A TFSI coil harness and Audi R8 ignition coils were also added to the car to replace the old factory system.

A rather gash aftermarket radio was replaced with a more elegant Becker and Iíve more recently put in a Blaupunkt. Both the Becker and Blaupunkt are very good but the latter has built in blue tooth streaming whilst the Becker had an adapter for this.
 
After an unfortunate altercation with gale force winds and a glorified tent, I decided to have a full glass-out respray of the car which was covered in part by insurance.
 
More recently (but still a few years ago now) the car was sent to Dave at Tunetechnic (previously Dave was the Link tuning guru at Torque Performance) who installed an ALM wideband oxygen sensor, Link 4 bar map sensor and retuned the ignition and fuel maps along with dual boost maps, switchable via a discrete digital input to the ECU. The factory knock sensors were also wired and tuned to the ECU but using a single retard table for all cyclinders due to a shortage of available free tables in the ECU. About a year after this Dave was also able to get the factory fuel computer working with the ECU based on some information I had managed to unearth from the interweb (where would we be without it?!).
 
Over all this time the car has been ably serviced and repaired by the team at Brodie European. As detailed in my ownership thread above, WestWorx did a great job of repairing the interior trim for me.
 
As previously mentioned, I've been able to apply my learning from the HPA courses I did to manipulating the ECU software and have managed to enhance it in several ways, improving safety and driveability. For example, I've been able to make more efficient use of the available tuning tables to allow the built-in knock detection system (as tuned by TuneTechnic) to retard individual cylinders rather than all cylinders at the same time. The ignition map has been smoothed and adjusted to enhance drivability. The fuel map has been tweaked to get the AFRs just so, improving cooling at high load while keeping knock in check. Quite recently I've successfully been able to configure three live switcheable boost maps (using some trickery with 'virtual auxilary outputs' and an ECU timer). These are currently set for: A) The factory boost of 1.3 - 1.4 bar, B) 1.6-1.7 bar, and 3) Valet/limp 'no boost' mode (0.4 bar in reality as that is the factory wastegate spring pressure). All the maps are very progressive with full boost only commanded from 95% throttle and above. Any of these maps can be instantly selected via a discretely positioned switch when ignition is on, including while driving the car. It took me a while to figure out how to select 3 maps using only one on/off switch! For safety, I've configured the ECU tables so that full boost cannot be commanded until the engine is warmed up (it comes in progressively as the temperature rises, but in reality you only notice if you have no sympathy and bury your foot when itís cold), and similarly the high boost map will not engage or stay engaged unless the coolant temperature is between 80C and 100C. Just like the factory ECU, boost is also reduced if the engine or intake temperature is exsessive. I've also implemented a fuel enrichment strategy for the same scenarios. Just for fun I've set up launch control, although I must admit I've never used it! I've configured it with a safe 'fuel cut' strategy which won't damage the turbo or catalytic converter (it still has the factory exhaust system). 
 
So there we have it! It certainly hasn't been all beer and skittles by a long shot, but I'm fortunately a 'slow burner' which has allowed me to maintain a degree of enthusiasm throughout my ownership. Whilst sheís not 100% original, she is quite the machine and the modifications are now well executed and mostly under the skin. Sheís a keeper!
 

Offline Filx

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Re: 1996 Audi RS2 Brilliant Black
« Reply #221 on: November 02, 2020, 07:34:23 am »
Great summary Jon, some interesting reading and reflection on the learning curve with Link and the car.
FAIL - First Attempt In Learning

Offline 80 Vert

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Re: 1996 Audi RS2 Brilliant Black
« Reply #222 on: November 02, 2020, 11:04:17 am »
Nice work Jon, one of those irreplaceable cars that's for sure.
2010 T5 Transporter TDI  Tuned by Superior Tuning NZ
2003 Jetta Coupe soon to be R36TT
1991 Golf GTI 2.0 TSI swapped
1963 Type 34 Karmann Ghia, turbo 2.0
1990 Porsche 964 911 Carrera 4
1980 1303 Beetle vert, under restoration

Offline RS ZWEI

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Re: 1996 Audi RS2 Brilliant Black
« Reply #223 on: November 02, 2020, 04:05:34 pm »
Awesome Jon.
1980 VW Golf GTI Track Car
1995 Audi RS2
2003 Mini Cooper S
2006 Skoda Octavia vRS Combi
2009 Renault Megane 230 R26 (Written off by a motorbike)
2013 Renault Megane RS265 Redbull RB8

Offline NasTnaS

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Re: 1996 Audi RS2 Brilliant Black
« Reply #224 on: November 02, 2020, 08:36:49 pm »
Nice mate. Itís an epic car and they donít make them like they use to.
...Nigel Aston
1971 Porsche 911T
1989 Volkswagen Golf GTI 16V
1989 Peugeot 205 GTI 1.9
2009 Renault Megane R26

Offline robh

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Re: 1996 Audi RS2 Brilliant Black
« Reply #225 on: November 03, 2020, 02:19:07 pm »
Really interesting reading.

Sounds like I'll be calling on you for help shortly with my ecumaster ecu on the Lotus ;) with us being local and all.

Daily Driver - VW Touareg V8 TDI 2012 "towing beast"
Too Many Cars - Lotus Elise S 2013 "tangerine dream"
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Offline le mans

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Re: 1996 Audi RS2 Brilliant Black
« Reply #226 on: November 03, 2020, 05:00:54 pm »
No worries, Iíve only played around with the Link but in principal they are all trying to achieve similar things. Give me a shout when you are ready and Iíll have a look if you want.

Offline le mans

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Re: 1996 Audi RS2 Brilliant Black
« Reply #227 on: January 30, 2021, 10:30:08 pm »
Sometimes itís the little things...

Like this new ash tray (not that I smoke):


Old vs new:



And new hood pins:



Old vs new:



They are adjustable so need to take care to position them correctly before closing the hood or it can jam. Some plasticine spread over the latch allows you to check the position without closing it all the way. End result:



Offline RobClubley

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Re: 1996 Audi RS2 Brilliant Black
« Reply #228 on: January 31, 2021, 11:22:18 am »
So satisfyingly, fixing little details like that.
1985 ur quattro
2011 Mercedes C200 Wagon

Offline le mans

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Re: 1996 Audi RS2 Brilliant Black
« Reply #229 on: January 31, 2021, 12:50:31 pm »
Absolutely Rob.

Offline Poonmobile

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Re: 1996 Audi RS2 Brilliant Black
« Reply #230 on: February 01, 2021, 03:02:09 pm »
Awesome Jon!
Current:
06 NZ B7 RS4 Avus Silver, 01 NZ B5 RS4 Avus Silver, 93 NZ VR6 Tornado Red 3dr, Renault Clio 172 & Renault Clio 197
Past:
MK2 VR6, MK5 GTI, 2 x MK5 R32, 8L S3 Imola, MK4 Golf V6 4MO, Polo GTI, 2x MK3 VR6, D2 S8, B5 S4 Avant, 03 NZ R32 Deep Blue Pearl, Renault Megane R26 liquid yello

Offline le mans

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Re: 1996 Audi RS2 Brilliant Black
« Reply #231 on: February 21, 2021, 08:44:31 pm »
I am tremendously grateful to John (80 Vert/West Worx) for completing what turned out to be a very tricky sunroof repair for me. I think itís fair to say he has had enough of old sunroofs for a while!

The sunroof had starting making some unusual noises and not opening and closing properly (the trim panel had become dislodged). Iíd had the car at Brodies in December and told them about it. They discovered the rain channel at the back was broken but that turned out to be not even the half of it. I noticed the two pins that the sunroof trim clip onto had also broken off. I took they car to John and he removed the sunroof. We noticed the forks that drive the sunroof forward and back were bent indicating it had been under some strain.

Sunroof removed with bent forks visible:
« Last Edit: February 21, 2021, 08:49:17 pm by le mans »

Offline le mans

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Re: 1996 Audi RS2 Brilliant Black
« Reply #232 on: February 21, 2021, 08:45:53 pm »
John carried out a very effective repair on the rain channel and came up with a cunning plan to install two new pins for the trim to clip onto.

Repaired rain channel (which is now a spare):



Offline le mans

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Re: 1996 Audi RS2 Brilliant Black
« Reply #233 on: February 21, 2021, 08:46:22 pm »
New pin installed for trim to clip onto:


When we were putting the sunroof back in we noticed that a small piece of plastic that acts like a cam to drop the sunroof when retracting had broken off.

Photo showing the missing cam (middle of picture in the slot):

« Last Edit: February 21, 2021, 08:55:53 pm by le mans »

Offline le mans

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Re: 1996 Audi RS2 Brilliant Black
« Reply #234 on: February 21, 2021, 08:47:13 pm »
It was decided to put the sunroof back in without the motor and I would go off and see if I could find any spare parts for it. I was in the process of building up an order for the S8 from Audi Tradition so the sunroof parts were added to the list. Tradition had the rain channel and RH sunroof guide but not the left, which is the one that was damaged. I added those to the order and John planned to make up a new Ďcamí for the left guide when I could leave the car with him again. The Tradition order duly turned up in late Jan.

New rain channel and RH guide showing the cam down toward the bottom of the image:



When John was finished with the S8 (sans A pillar trims) we swapped the cars over and he got to work. He came up with the idea of using resin to make the new cam, filing it into the correct shape once it had set. He also did the same for a plastic tab that had broken off at the other end of the guide.

Here's a photo of the resin before being shaped/filed:

And after...


The sunroof was duly installed with the new parts and the repaired LH guide and trim pins and it works like new! What a result! Super happy with it, thank you John.
« Last Edit: February 21, 2021, 09:01:49 pm by le mans »

Offline RobClubley

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Re: 1996 Audi RS2 Brilliant Black
« Reply #235 on: February 22, 2021, 08:38:38 am »
Awesome work.
1985 ur quattro
2011 Mercedes C200 Wagon

Offline le mans

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Re: 1996 Audi RS2 Brilliant Black
« Reply #236 on: March 02, 2021, 02:00:34 pm »
Now with 4 closed loop boost maps (because I found a way, not because they are needed). I challenge you not to fall asleep while I explain how I set that up!

https://youtu.be/dCoJZjDwHBI