2.0L stroker (06A block) Avant with lots of cool projects

[dougyfresh]

2002 A4 Avant build
I know its a B6 but there's a lot of good info in these links to help out a few of you B5 guys

History:
So, my car started as a pseudo bone stock 125,000mile 2002 A4 1.8T Avant. December 2007 I took AutoSpeed Performance up on their offer for their GT28RS turbo kit. Also installed a Southbend OFE SS clutch with my OEM DMFW while we were at it. My APR Stealth cat-back exhaust was also put back on with the GT28RS kit.

January, continuation of tuning and the car was not behaving. We left the tuning as-is. Dyno numbers were in the 275awhp range on 93octane. I also stumbled upon an AMU longblock for a good price so I picked that up (just to have).

February. I go out to Colorado to take advantage of their amazing winter. Nothing but powder runs for a week straight . Avant is back at ASP for more tuning. Compression check looked alright. Leak-down test showed excessive leakage through both the valves and the rings so tuning stopped. Hmm.?.

Next on my list was eventually to be a fully built motor and some stuff. Timeframe was about a year or two later. Given my tune was not optimal I moved this phase of my car up in schedule. Enter my AMU motor. I stripped it and kept just the block and cylinder head. Comissioned Bob Quindazzi of QED Power to build me up a proper 2.0L stroker with my AMU block and head. This build was going to be done correct and with a plan from the get-go.

AMU motor was stripped in March. Block was dropped off at QED's in April. Engine was built and swapped into my Avant in June. Turn Key on the new motor was early July. 5,000+ miles later (early September) the AVant is back at ASP for tuning.

Engine:
2.0L stroker motor
- AMU (06A casting) block and cylinder head
- AEG 92.8mm stroke crank
- Supertech 82.5mm bore forged pistons
- Scat forged connecting rods
- OEM main bearings
- OEM oil pump
- OEM timing belt kit w/ metal impeller water pump
- Supertech Inconel Exhaust valves
- Supertech valve guides
- OEM intake valves
- OEM hydraulic lifters
- Cat Cams 3651 camshafts
- Cat Cams adjustable cam gear
- basic valve seat grind/lap

Forced induction:
- Garrett GT2871R turbocharger
- ASP GT28RS hardware kit with manifold and downpipe ceramic coated
- ASP FMIC

Tuning:
- Custom Me7 tune by ASP (currently in process)

Other stuff while the Avant was down:
-2.8L 5spd manual trans
-4:1 center diff
-034 MotorSport Street Density motor & transmission mounts
-JHM 'solid' shifter & shifter linkage & bushings
-custom boost gauge in rear view mirror
-custom ash tray mount for EBC
-RS4 rear anti-roll bar
-034 MotorSport B6 High-Output Fuel Pump
-drive-way motor swap


Links:
Original build thread: http://audizine.com/forum/showthread.php?t=198330

4:1 center diff mod: http://audizine.com/forum/showthread...78#post2646778

First turn-key start on 2.0L motor: http://audizine.com/forum/showthread.php?t=223107

Cat Cams 3651 install thread (couple thousand miles into new motor): http://audizine.com/forum/showthread.php?t=229219

boost gauge in rear-view mirror: http://audizine.com/forum/showthread.php?t=234102

034 high-output fuel pump install (5,000miles into new motor): http://audizine.com/forum/showthread.php?t=233462

EBC install in ash tray: http://audizine.com/forum/showthread.php?t=217996

The Avant:




all my photos:
http://flickr.com/photos/omega29/set...7604479782061/


Once I get my car back (fully tuned) from ASP I am going to fab up a heatshield for my intake. I will also take apart my 1.8L 5spd transmission this winter. Most likely rebuild it with new syncros and swap in a European TDI 5th gear for highway cruising. Then put the trans back in the car and sell the 2.8L trans.

[317ssayzarc]

Sweet Doug! I figured Id read all your threads, but I missed quite a few! Got some catch up reading to do....

[Das General]

Doug, if that even is your real name, you are always whipping up crazy new stuff!


Keep it coming boss...

[317ssayzarc]

No his real name is Victor

[Das General]

I am familiar with this alter alias Victor!

[317ssayzarc]

Damn Derek, we are already breaking the project forum rules! Cut the crap asshole, your ruining Dougs thread

No seriously, its Dougs thread

Go screw with my threads if you wanna chat/goof

[dougyfresh]

I added some more info and stuff.

[urban96]

where did you get that boost gauge that u put in the rear view?

[CO AVANT]

Too bad your car is still slow. I hope ASP gets it done in October like you said they would.

[dougyfresh]

where did you get that boost gauge that u put in the rear view?

I made it. See the link in the first post of this thread for a thread I wrote about it.

Too bad your car is still slow. I hope ASP gets it done in October like you said they would.

We will see...

[CO AVANT]

I hope he cuts off a bit of the cost since he is taking his sweet ass time. Why are you making me give you shit Doug? I want to see it done sir!!!!!!

[dougyfresh]

Tuning is done and I have the first (of many) dyno charts...

Keep in mind these particular graphs do not go up to redline (around 7400rpm for me). Reason being was there are over 500miles on the dyno to get 1) Me7.5 figured out and 2) my files written from scratch. Mark did not take my car up to redline every single time but the files are written and work well up there. I will be getting more data as time marches on as well. Next time I'm back at ASP (later this month) we'll get some full pulls. I am also going to EPL this coming Saturday with a tank of C12 fuel so I'll be sure we get some full pulls there .

93octane fuel
93octane 'high boost' file
N75 controlled boost
partial dyno pull
uncorrected numbers


109octane fuel
109octane 'race gas' file
N75 controlled boost
partial dyno pull
uncorrected numbers


I will have logs to go with these dyno pulls soon. A/F, timing advance and everything is spot on.


We explored a lot of avenues within the ECU to hone in on the files I currently have. Higher boost on my car did not necessarily mean more power (naturally, given the turbo's efficiency window). What does this all mean? There is another source for tuning and for tuning these BAT and fully built motor projects you guys have. Both B5 and B6...

My impressions after driving it for a few days:
Idle is spot on and very smooth on both 109 and 93. Cold starts and hot restarts are as if the car was 100% bone stock. Fires up within one crank of the engine. Part throttle response is impressive. This car is extremely street-able and drives so smoothly. Step on it in any gear and the Avant takes off. Launch in 1st gear and redline arrives rather quickly. This is exactly what I was looking for when I set out to build my car to its current state. The numbers are what they are. I really care about how the car drives on the street and its pretty impressive. Mark showed me dyno graphs from a 30minute window. We overlayed all of them and they are ontop of each other. IATs only creep into the 30C range. Can you say repeatable power?

[bassed]

Looks good Doug.

[Nebone]

Nice numbers. Glad you like it.

[t1demont1]

Good numbers, so is ASP gonna be another me7 tunning solution? From the sounds of it, your car is still perfect in terms of drivability

[dougyfresh]

Thanks Guys.

Bassed... I'm trying to make it do their dyno day on the 20th. We'll see what happens.

Good numbers, so is ASP gonna be another me7 tunning solution? From the sounds of it, your car is still perfect in terms of drivability

Yes. Not 'gonna' but 'is'

I have already been chatting with a fellow AZ B5 guy about getting a custom tune from ASP for his car (1.8, HTA 3076, AEB head, crazy cams, etc., etc..). He also lives around the corner from the shop so its convenient .

[t1demont1]

aghhh i want a me7 car badly =( it will happen soon!

[bassed]

Bassed... I'm trying to make it do their dyno day on the 20th. We'll see what happens.

Sounds like a plan. I'll be there if it comes to fruition running but no where near 100% I have not touched a thing since doing the runs with Jackson and actually only put about 200 miles on since then.

ME7 for the win!!!!

[Nebone]

The GT28RS kit from ASP promised 300 wheel and now with a 2.0, GT2871R and cams you are below that. I hope next dyno will be better all the way up to 7400 RPM. Still, nice output tho.

[f15046]

yeh that has me wondering, All that motor work and still under 300whp on pump. That's a shitload of money for the amount of horsepower.

Is 7400rpm the highest this motor should be revved? Seems like it could rev higher?

[t1demont1]

Thosre arent the dyno sheets from the final tune iirc, and you dont need to go past 7400 on a 2.0 with a 2871r.

[dougyfresh]

Thosre arent the dyno sheets from the final tune iirc, and you dont need to go past 7400 on a 2.0 with a 2871r.

I will be back at ASP next weekend and we plan on tweaking the 93 file. Think we know how to get rid of that dip in the upper RPM band...