Project: Audi ur-S4 2.2TQ Evo 3

[RWHP]

Thought i could share what me and my friend are building. Hope you enjoy!

The first evolution was pretty basic with a Garrett T3/T04E, custom exhaust manifold, 3" exhaust, front mounted intercooler, bigger injectors and a reprogrammed ECU. The car never went any good, there was always something that made some issues and in the end the engine had to be filled with a quarter oil every week so it was pretty much done!

The second evolution, the car that never got built haha
Somehow on the way the project got out of track and almost everything got sold.


Evolution 3
Well this is where we are now, pretty much has changed anyway but we are still on the same plan so far haha

ENGINE BLOCK
JE pistons with 8.8 comp, ceramictreated pistonhead, skirt coating and accumulator groove
Total Seal gapless pistonrings
AutoVerdi rods with ARP studs
ARP headstuds and maincap studs
Rodbearings from a diesel engine
OEM mainbearings
New oilpump
Rebuilt oilpan

HEAD
Max ported with raised and widen channels
CatCams camshafts with 12mm (0.47") lift and 280 degree duration
CatCams adjustable inner camgears
Dahlback Racing outer camgear
Solid lifters
Titanium retainers
RaceTech valvesprings
Inconel exhaust and stainless steel intake valves
OEM valveguides

FUEL
Aeromotive Eliminator fuel pump
Aeromotive AFPR
Aeromotive 10 micron filter
034 Motorsport fuelrail
1600cc injectors
AN10 fuel lines

EXHAUST SIDE
Tial 44mm wastegate
Borg Warner S480 turbo
Custom Part Service exhaust manifold
4.5" downpipe and then 3,5" to the back

INTAKE SIDE
Tial 50mm blow of valve
Custom Part Service intake manifold

CHASSI
Yellow Koni Sport shocks (adjusable stiffness)
H&R 40mm lowering springs
Audi S6 front struts
Steal bushings for the front and rear subframe
New OEM bushings for everything else
034 Motorsport engine and transmission mounts

ELECTRONICS
Nira i3+ engine management system
Innovate LC-1 DB digital wideband lambda
034 Motorsport High Output Coil Kit
High Output sparkplug wires
Bosch F6DTC sparkplugs

TRANSMISSION
Modified center differential for constant 50/50 wheeldrive
034 Motorsport adjustable shortshifter
Spec stage 5+ clutch with pressure plate
Spec aluminium flywheel
Redline Heavy ShockProof transmission oil

INTERIOR
Greddy EGT gauge P/H&W
Greddy Boost gauge P/H&W
Audi S steeringwheel
Momo carpets

[C4.Style]

will be waiting for those pics.

[RWHP]

Pictures in the first post

[s6sputnik]

Priceless

[deephouse]

Please tell me where you got these bits!! I recognize the AMD subframe bits, but where did you get that solid rear diff "bushing"?

Thanks!

Brian

[RWHP]

Please tell me where you got these bits!! I recognize the AMD subframe bits, but where did you get that solid rear diff "bushing"?

Thanks!

Brian

We left some measurements to a friend that made them. Only took a few hours to made all of them, excellent fit also

Think its bad that nobody makes bushings like these.

Sorry that i cant help you more!

[deephouse]

We left some measurements to a friend that made them. Only took a few hours to made all of them, excellent fit also

Think its bad that nobody makes bushings like these.

Sorry that i cant help you more!

PM'd. =)

[Silvant]

ohh, i like... what kind of power you lookin at with this build. . ..

[Silvant]

i dont get why you would want to go to 50/50 power ratio.... you just planning on
draggin this car in the 1/4 or 1/8th?
60-80% limited slip rear is what i'd want.. if that's even available?

[RWHP]

If you read it says that the centerdiff is modified, so it drives 50/50 on the front and rear wheels :) The front and rear differential is unmodified.

[Silvant]

i did read.. and that's why i asked...
why would you want 50/50.. doesnt sound fun to me at all when you could at least pop
60% or more to the rear and have a much more lively set up.

[fr3drik]

It's hard to weld the diff solid and get a percentual transfer in power.. ;)
We made it like this to decrease wheel hop in the rear and hopefully it won't snap driveshafts like toothpickers :)

[RWHP]

Here is a small update, still waiting for the turbo to come and to get the intake and exhaust manifold welded so we can draw fuel lines and ems harness


2.5L diesel block that we are going to build on as soon as the 2.2L engine is started.


Cut the original ems harness to make place for the new one.



Started with fuel system in the trunk, a 4.5L catchtank for the fuel that we hope wont be sucked dry.

[PRY4SNO]

That's a hell of a set up you have going!

Curious as to why you chose the Nira i3+ over the 034 IIc?

[RWHP]

That's a hell of a set up you have going!

Curious as to why you chose the Nira i3+ over the 034 IIc?

We hope this setup will do

The Nira EMS is made in Sweden (swedish manuals etc.) and there are people that have a big experience with it.

[Turbo Nerd]

damn thats a sick as setup man
is the car runing now? whats the power output if u dont mind ?

[Rejmow]

damn thats a sick as setup man
is the car runing now? whats the power output if u dont mind ?

Nice bump ;) but I can update you, yes it's alive and it's delivering 750hp







"Something happened with the dyno here.. don't really know what"


NOTE: I don't have anything to do with this build but I have been following this project on another site.

[RWHP]

Its been a while since i posted here but here is a update that i hope you enjoy :)

The setup as we speak..

ENGINE BLOCK
JE pistons with 8.8CR, ceramictreated pistonhead, skirt coating and accumulator groove
Total Seal gapless pistonrings
Verdi rods with ARP studs
ARP headstuds and maincap studs
Rodbearings from a diesel engine
OEM mainbearings
New oilpump
Rebuilt oilpan
Engine girdle from Custom Parts Service
Fidanza aluminium flywheel with ARP bolts
Canton Accusump pump for pre-oiling and surge

HEAD
Max ported with raised and widen channels etc.
CatCams camshafts with 12mm (0.47") lift and 280 degree duration
CatCams adjustable inner camgears
Dahlback Racing outer camgear
Rebuilt from hydraulic lifters to solid lifters
Titanium retainers
RaceTech chromesilicone valvesprings
Inconel exhaust and stainless steel intake valves
New OEM valveguides and seals

FUEL
Weldon 2345-A fuelpump
Weldon A2040 regulator
Weldon 14000 pump controller
Aeromotive 10 micron filter
034 Motorsport fuelrail
1600cc injectors
Henko Racing in-tank pump feeding the catchtank

IGNITION
034 Motorsport High Output coils
034 Motorsport High Output spark plug wires
NGK 4554 plugs

EXHAUST SIDE
Tial MVR 44mm wastegate
Precision HP7168 Billet
Custom Part Service exhaust manifold with 2 EGT sensors and 1 for backpressure
4" downpipe and then 3,5" to the back

INTAKE SIDE
Pro Charge b.o.v
Custom Part Service intake manifold with cnc machined matchported intake flange with O-ring seals, water cut plenum, cnc machined velocity stacks
70mm Billet throttle-body
CNC machined pop-off valve

CHASSI
Yellow Koni Sport shocks (adjusable in stiffness)
H&R 40mm lowering springs
Audi S6 front struts
Machined steel bushings for the front and rear subframe
New OEM bushings for everything else
034 Motorsport track-density engine and transmission mounts

ELECTRONICS
Nira i3+ engine management system
Innovate LC-1 DB digital wideband lambda
STRI DSD-CS 52 mm EGT gauge
STRI DSD-CS 52 mm 3 bar boost gauge

TRANSMISSION
Modified center differential for a 50/50 wheeldrive
034 Motorsport adjustable shortshifter
Spec stage 5+ clutch disc with a Sachs 707 pressure plate
Redline Heavy ShockProof transmission and differential oil

MORE FUN STUFF
BMPC intercooler (from Mario Deniz old SC300)
Ford radiator
Custom crankcase breather setup
3" aluminium intercooler piping
Removed ABS and PS
Custom engine harness
The outside of the car is not something we care about right now :)












With the old S375 turbo, was too lagy for this engine.. The enginebay will be refreshed with some paint so things will look more discrete ;)

[RWHP]

Some parts from Pure Performance Factory and BoostLab :)





Welded a 1/8 inch fitting so we can check the backpressure with the new turbo!





The outlet on the new turbo was kind of a odd size, doesnt match the 3.5" to 4" reducer but after some work with a hammer it matched!

[RWHP]

Really heavy quattro transmission! We change the pressure plate to a Sachs 707 which has 1100 lbs more clamp force then the Spec stage 5+ pressure plate but the new PP easy more easy to disengage!



The new Precision HP7168 billet is mounted, looks very small compared to the old Borg Warner! Intercooler pipes almost match up too, will use the v-band flange from the BW turbo and weld it on the new comp housing.







Here it sits and wait on a new radiator and some minor parts and she will be up and running next week :)



These should have a BIG thanks!

[RWHP]

Went to the tuner, only made 675 whp and 533 ft/lbs at 39psi boost. We are going for a new try next year, probably the cams that was setup a few degrees wrong which was the reason we had so much boost and little horsepower, will probably get another 150whp with everything setup right.


http://www.youtube.com/watch?v=VhfkTzJBTfQ

[RWHP]

Unfortunately the car has been parked since we broke the transmission 2 days after the dyno and the owner lost the spirit or what i should call it. Have been looking at new transmissions from the newer S4 bi-turbo V6, its basicly the same transmission but the first gear is more "heavy-duty" and synchros and hubs are stronger. We are also planing on moving over all the parts to an Audi 100 -78 that weighs almost 750kg less :) Could be fun when we have AWD, 750+whp and a 1000kg car!

[CKYmike]

Definitely look into the 01e from the s4. its a great trans. It still has its 1-2 synchro issues but their lessened if you use the rebuild kit. I'm using an rs2 trans and may need to do that rebuild as well.

[Dagi]

Have you looked for 6 speed gearbox from Audi 100 and A6 C4 2.5 TDI?(5cyl) Rumour has it that they are stronger then the "gasoline" gearboxes...

[RWHP]

Yea but the gearing in a diesel tranny wont work on a high revving car, you run out of gears except for on the 6th that is a overdrive. A friend tested this setup once but it may have been a 5spd.

We will look into rebuild this tranny or go with one from a bi-turbo S4 :)

[Turbo Nerd]

I would PM Scotty@Advanced on here and ask about making you a custom 01E 6 speed. The gearing on the 01E isn't really the best for drag, so I know he can make you custom gear sets. Great guy and very knowledgeable when it comes to this kind of stuff. Just a suggestion of course.

Goodluck.

[pilihp2]

The gearing on the diesel 01e is supposed to be tall, and is supposed to be the strongest 01e from the factory. What do you mean run out of gears? I'm trying to follow what you're saying, but I'm lost.