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Thread: XS Power Downpipes & Manifolds

  1. #161
    Prawn's Avatar
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    I'll be fitting mine in the 1st week of Jan Jim, so I'll let you know how simple it is! From memory, due to the shape of the manifold, spanner access is almost non existant to some of the bolts, so I'll have to wait and see how best to tackle it!
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  3. #162
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    Quote Originally Posted by Dani_B19 View Post
    Westy what gaskets did you use when doing the DP and decat?
    4 Rings did the job for me as they removed the turbo and fitted the new one.

    As far as I know they just used OE gaskets from Audi and I'm sure it's only the 1 gasket that you need. But I'm not 100% mate.
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  4. #163
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    Quote Originally Posted by Prawn View Post
    I'll be fitting mine in the 1st week of Jan Jim, so I'll let you know how simple it is! From memory, due to the shape of the manifold, spanner access is almost non existant to some of the bolts, so I'll have to wait and see how best to tackle it!
    Thanks. Appreciate your help. I'm just weighing up whether to get stuck into the whole manifold, rods, head and hybrid experience.

    Ming Blue S3, Stage 3 Hybrid Turbo, Custom Map, Bosch 480 injectors, Custom TIP, Forge FMIC, 3" Downpipe, 200 Cell Sport CAT, Full Stainless, XS Power Mani, 6 Paddle Clutch, Red silicone hoses, LCR Brembo's, Forge 007p, KW Suspension Kit, Green filter, THS Mounts, 11mm & 16mm spacers, H&R Anti-roll bars, RS6 18" alloys, Michelin PS3's, Red Dog Bone Mount, Neuspeed quickshift, Boost Gauge, Aero wipers, LCR splitter, Forge Tie-bars, LED bulbs, Armrest, Custom TT pedals.

  5. #164
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    Quote Originally Posted by Westy View Post
    The manifold is not an easy thing to change. Most will remove the cylinder head to get at it.

    With the head off you will need a new head gasket and timing belt. Also whenever doing the timing belt it's a good idea to do the water pump too.

    You can make this job as involved as you want In terms of work and replacing parts.

    You may want to get the turbo checked or refurbed while you're near it. It would also be a good idea to do the DP at the same time. With the head off you might want to get that checked over or change the rods for forged ones. The list is endless.

    Even if you only wanted the mani fitted it'll still end up bein an expensive labour bill as it's quite a big job.
    Thanks westy.

    Very informative and lots to consider. I'd assumed, like any mod, that one thing very much leads to another and this is no different.

    I'd love to see the performance difference in the vehicle with all of the above in situ compared to mine.

    Ming Blue S3, Stage 3 Hybrid Turbo, Custom Map, Bosch 480 injectors, Custom TIP, Forge FMIC, 3" Downpipe, 200 Cell Sport CAT, Full Stainless, XS Power Mani, 6 Paddle Clutch, Red silicone hoses, LCR Brembo's, Forge 007p, KW Suspension Kit, Green filter, THS Mounts, 11mm & 16mm spacers, H&R Anti-roll bars, RS6 18" alloys, Michelin PS3's, Red Dog Bone Mount, Neuspeed quickshift, Boost Gauge, Aero wipers, LCR splitter, Forge Tie-bars, LED bulbs, Armrest, Custom TT pedals.

  6. #165
    Chugger

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    I was always under the impression that it was a head off job. I'm tempted to do mine as mine manifold has a crack in it. I'm happy to have the head off and fitting a new headgasket etc, although I have done the timing belt a few times on other cars im not sure I'd be confident enough to do it on mine... Although massively tempted to give it a go.
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  7. #166
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    I have removed the manifold in situ and removed the head to access it needless to say if i ever have to remove it again i will certinally be removing the head to do it, a tubular manifold im sure will give you more room to work with between the runners than a cast one but i would advise still removing the head

    You could also find a tight one that draws the stud out with it which again will be a complete pita
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  8. #167
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    Downpipe will need a Turbo - DP gasket from Audi, and also a generic 3" flange gasket for the join between the downpipe and the decat. Annoyingly, this was one of the things I told XS they should provide - and they haven't. C'est la vie.

    One of these should do nicely: 3" Inch 76mm Universal Quality Replacement Performance Exhaust Gasket 2 Hole | eBay
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  9. #168
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    Anyone who says fitting one of these is a breeze, think again.

    Not an easy job by any means. However, it depends ultimately on how much you want that extra flow.

    So, what makes it such a pain? The arrangement of the holes on the Turbo flange in conjunction with the runners of the manifold simply.

    It is outright impossible to use OEM bolts to mate this, they won't work.

    Use 3 x K04 turbo/downpipe studs. Wind those into the turbo short end first from memory. Makes sure they're tight. Then, when manifold fitted, use 3 stainless nuts (preferably with Nordlock washers to stop them loosening) to bolt the tubo and manifold together.

    One of the nuts (top left of the three) will require a 'special' spanner to actually get to the nut at all. Trust me, it can be done.

    Mani fitted to head:



    'Special spanner'




    Et voila:

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  10. #169
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    Manifold in use:

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  11. #170
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    Cheers Welly.

    Sorry but I'm still a bit lost with what nuts and bolts are needed?

    As you know I've already got the XS DP and will soon be fitting the mani to a standard k04 turbo.

    I need to ensure I have everything I need before I do this job along with IE rods and large port head.
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  12. #171
    Westy's Avatar
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    Also is it worth heat wraping the mani?
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  13. #172
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    Quote Originally Posted by Westy View Post
    Also is it worth heat wraping the mani?
    That's a good question! I'd also like to know

    Pat






  14. #173
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    Quote Originally Posted by Westy View Post
    Cheers Welly.

    Sorry but I'm still a bit lost with what nuts and bolts are needed?

    As you know I've already got the XS DP and will soon be fitting the mani to a standard k04 turbo.

    I need to ensure I have everything I need before I do this job along with IE rods and large port head.
    OK, this what you should be aiming to do:





    Would into the turbo in the above pictures are 3 K03 (not K04 sorry - will edit original post) downpipe studs - part number N 907 678 01. Cost around £0.55 each inc VAT.

    I think those studs are M10 thread, so get some stainless steel nuts which mate them from the local hardware shop for pence.

    This way the manifold will slot onto the turbo. Does that makes sense?
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  15. #174
    Welly's Avatar
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    Quote Originally Posted by pats3poa View Post
    That's a good question! I'd also like to know

    Pat
    Not really. I think it's arguable how long heat wrap would last on it, that video shows how hot they get. Also, it is very tightly put together, with very little gappage in between the runners.
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  16. #175
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    Cheers, should the DP be done?

    Pat






  17. #176
    Welly's Avatar
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    Quote Originally Posted by pats3poa View Post
    Cheers, should the DP be done?

    Pat
    Again, up to you. No harm in the downpipe being done. Don't use cheap heat wrap though, it turns to glass and falls off....
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  18. #177
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    My brother (ex mechanic) and a friend (Audi Mechanic) wanna try it with the head on. Who am I to argue its them who will be doing the work for beer tokens.

    2003 Audi S3 + Go faster bits

  19. #178
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    Quote Originally Posted by MintyS3 View Post
    My brother (ex mechanic) and a friend (Audi Mechanic) wanna try it with the head on. Who am I to argue its them who will be doing the work for beer tokens.
    Fair enough, I say go for it. It's just always been easier IMO to take the head off. Less hassle, everything accessible. Less scrabbling around in the dark, at the back of an engine.

    Whatever works
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  20. #179
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    Quote Originally Posted by Welly View Post
    OK, this what you should be aiming to do:





    Would into the turbo in the above pictures are 3 K03 (not K04 sorry - will edit original post) downpipe studs - part number N 907 678 01. Cost around £0.55 each inc VAT.

    I think those studs are M10 thread, so get some stainless steel nuts which mate them from the local hardware shop for pence.

    This way the manifold will slot onto the turbo. Does that makes sense?
    That crystal mate thanks. What's different with the standard turbo bolts then?
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  21. #180
    Welly's Avatar
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    Quote Originally Posted by Westy View Post
    That crystal mate thanks. What's different with the standard turbo bolts then?
    When you get the mani mate, you'll understand immediately.... Trust me!
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  22. #181
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    Quote Originally Posted by Welly View Post
    When you get the mani mate, you'll understand immediately.... Trust me!
    Ok mate. I'll order the bolts

    My biggest nightmare is getting everything apart and not having the right parts to get it back together again straight away.
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  23. #182
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    Quote Originally Posted by Westy View Post
    Ok mate. I'll order the bolts

    My biggest nightmare is getting everything apart and not having the right parts to get it back together again straight away.
    Yep, I can understand that. OEM bolts will not work. Simple.
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  24. #183
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    Quote Originally Posted by Westy View Post
    Ok mate. I'll order the bolts

    My biggest nightmare is getting everything apart and not having the right parts to get it back together again straight away.
    Dont forget that i got you some bolts and washers from bill
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  25. #184
    Westy's Avatar
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    Quote Originally Posted by Welly View Post
    Yep, I can understand that. OEM bolts will not work. Simple.
    So the part number you quoted earlier, is that for the OEM bolts?

    Edit:

    I've just remembered that the standard bolts go down through the top of the mani and scre into the turbo thread.

    I've also just bought 3 new ones from Bill
    Last edited by Westy; 19th December 2011 at 13:16.
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  26. #185
    Westy's Avatar
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    Quote Originally Posted by StaceyS3 View Post
    Dont forget that i got you some bolts and washers from bill
    Yep. The nordlock washers will come in handy but the bolts are useless
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  27. #186
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    Quote Originally Posted by Westy View Post
    So the part number you quoted earlier, is that for the OEM bolts?

    Edit:

    I've just remembered that the standard bolts go down through the top of the mani and scre into the turbo thread.

    I've also just bought 3 new ones from Bill
    Part number above was for the studs in the picture, wound into the turbo.
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  28. #187
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    should be getting my 3"dp and sports cat fitted tomorrow. I'm just hoping the gaskets arrive in time. If not the place doing it said they can fabricate some as the custom build exhausts..
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  29. #188
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    I see the buy it now on eBay has magically gone up from £380 ish to £450 now :-/

  30. #189
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    welly, i saw a yellow s3 on ebay and thought of your bumble bee. good to see youre still pioneering this stuff.
    woodyS3 likes this.

  31. #190
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    I am installing the decat downpipe and the manifold at the moment. will post pictures on a new thread once im done.
    Audi S3 AMK
    Relentless-Manifold, Relentless-3" downpipe decat, Forge 007 DV, autobahn88 TIP, K&N Panel filter, EBC yellowstuff brake pads, R32 ARB, Custom column dual gauge pod...waiting for a remap!

    For help/info/pricing on xs manifold and downpipe pm me (not affiliated, nor a reseller trader, just an enthusiast!)

  32. #191
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    Ordered my decat DP a few days ago should turn up today.
    Can't wait to get it all fitted!
    -------------------------------------------------------------------------------------------------

    Prawns TFSI Turbo'd 1.8T Track Car

    But I know nothing so ignore me.

  33. #192
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    Quote Originally Posted by badger5 View Post
    I am waiting on seeing a std k04 car with decent flowing manifold to see how it goes.
    wellys hybrid luved the additional flow
    not mine by any chance

    BADGER 5 TUNED gt2871, 360bhp 360ftlb



  34. #193
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    westies is another in mind.. whichever comes first we will see
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  35. #194
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    Quote Originally Posted by badger5 View Post
    westies is another in mind.. whichever comes first we will see
    Easter holiday will be the date the XS mani will be fitted but I'll then need to come across to see you again for some dyno action.
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  36. #195
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    guys i have been in contact with usa XSpower (relentless) and i can get these downpipes and manifolds alot cheaper. the new manifold will cost $300 shipped and dp with decat $325 or with sports cat $375.
    these need to be bought through me to get these prices.
    i have also created a facebook advertising this. Log in | Facebook
    Last edited by sambryant; 8th January 2012 at 14:11.

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  37. #196
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    Quote Originally Posted by Westy View Post
    Easter holiday will be the date the XS mani will be fitted but I'll then need to come across to see you again for some dyno action.
    i may sneak in there before. im hoping this feb

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  38. #197
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    Sam you will have to pay customs and import charges. So prob wonnt be cheaper at all. And tbh, theyre cheap enough.

  39. #198
    sambryant's Avatar
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    Quote Originally Posted by superkarl View Post
    Sam you will have to pay customs and import charges. So prob wonnt be cheaper at all. And tbh, theyre cheap enough.
    decatted down pipe is around £150 cheaper and sports cat is £210 cheaper

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  40. #199
    Prawn's Avatar
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    Quote Originally Posted by sambryant View Post
    decatted down pipe is around £150 cheaper and sports cat is £210 cheaper
    ARGH! SCN are invading, another one! Hey Sam. Welcome.

    For those who are genuinely bothered about flow, I noticed something on my XS downpipe this evening:

    The flange on the end of the downpipe, is 3'' where it joins onto the decat section:



    But then the flange that it bolts to, leading into the rest of the system, is only 2.7'' across:



    So it gives an instant 0.3'' step reduction in the system.

    THe pipe going into the flanges on each side is genuine 3'', but for some reason the second flange has a smaller hole causing a restriction to flow.

    To get around this I'm going to get my dremel out and port out the smaller flange until it matches the bigger flange. Probably a horrible job, but I think it'll be worth it.

    Also worth mentioning that the holes in the flanges are slotted too, so any misalignment when joining them together could also cause a nice stepped restriction.

    Seems a waste to sppend all that money and not fix a few little issues like that, shame XS didn't address these issues though.
    -------------------------------------------------------------------------------------------------

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    But I know nothing so ignore me.

  41. #200
    sambryant's Avatar
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    unless you have a 3" catback then its not worth doing.

    BADGER 5 TUNED gt2871, 360bhp 360ftlb



 

 

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