So while most of my threads have been about my 1.8t, most of you may not know that I also picked up a 2003 6 speed 3.0 A4 about a year and a half ago. I had gotten it with the intent of just keeping it stock as a reliable daily driver. Well, as we all know, the road to hell is paved with good intentions lol...
While I did keep it stock for over a year, the fact that my 1.8t is dead in the water at the moment (dropped exhaust valve) means that I've had to turn my performance lust to my 3.0 instead.
So I'll be keeping a running tab on what I've done and what I will do, with the hopes of at least being able to let those of you with the V6 to make some informed decisions as to what you might choose to do to your cars to get a little more out of them.
On thing to note is that I've done the math and I think the 3.0 is a lot better tuning value than most think. If we assume
Stock HP: 220 HP
CAI or Zingo mod: 5-10 HP (free for the Zingo mod and the CAI can be made for $50-$75)
Ran-up additive: 5 HP ($45)
Uni 93 flash: 10-15 HP ($400)
2.5 in Downpipes and 2.25 in catback w x-pipe: 15-20 HP ($280 in components)
This makes for a realistic total of 250-260 HP for about $725 if you DIY the downpipes and $1200 if you buy the JHM ones. Adding a x-pipe catback will also net some gains, but it'll set you back another $500-750.
Still, you're not going to see those numbers on a 1.8t without a $1650 Frankenturbo upgrade package. Just something for you all to think about.
MODS TO DATE
-Zingo/Zimbu airbox mod
-RSR Ran-Up ceramic oil additive
-Unitronic 93 Octane flash
-2.5 in catless downpipes
-2.25 in exhaust with X type crossover
-playing with different fuel varieties (i.e. 94 octane + methanol, toluene, xylene) and Lemmi/Unisettings
MODS PLANNED
-JHM lighweight flywheel *really good expanation of the benefits here:* http://www.uucmotorwerks.com/flywhee...heel_works.htm
-B6 S4 type brakes
-maybe some long tube headers if I have the time and money
ZINGO AIRBOX MOD
Basically, this involves sealing up some openings in the airbox with the intent of better airflow at speed to the engine. I also pulled the Hemholz resonator and fabricated a plug to go into the intake tract that leaves a smooth uninterrupted path for the air to travel through.
I didn't do any before or after logging, so I only have subjective impressions. Nothing huge, but for the price you can't go wrong. Power delivery felt a little more linear and it seemed to pick up a little bit when at highway speeds.
ZIMBU AIRBOX MOD
After experimenting with a CAI setup, I found that while it gave a little more on the very top, the losses at lower RPMs (likely a function of decreased intake air velocity through the larger CAI intake) offset the gains.
However, I did find that running a duct from the foglight to the stock airbox in addition to the stock snorkel provided noticable top end gains from 4000 RPM upwards without sacrificing any bottom end power.
RSR Ran-Up
I decided to test this one out after I saw the write up on Moto-IQ http://www.motoiq.com/MagazineArticl...-a-Bottle.aspx
Basically, it's a ceramic additive comprised of ceramic balls about 1/10 of a micron. It appears to function by way of reducing internal friction as well as sealing micro scratches in places like the cylinder walls. You may also want to try Liqui Moly Ceratec.
At $45 or so per container, it's not cheap as an additive (although the ceratec is half the price) but in my mind it was totally worth it. Consistent with other reports, my engine ran smoother, revs freer for things like rev-matching, and the engine did seem to pick up a modest HP gain (prob about 5-7 HP). Most importantly, I saw a consistent empirical MPG improvement of about 5-7%.
I think this last point is the most important. Not only was it an objective measure (taken at cruise on long stretches on flat highway), but it logically follows that for mileage to increase, there has to be an improvement in engine efficiency, either through friction reduction, cylinder sealing or both. As well, it would be logical to assume that increased efficiency = more HP/Tq.
I did the math and with a 5-7 % increase in fuel economy, even at $45 per bottle, the stuff pays for itself within 5000-7500 Kilometers. So IMO, adding it to your oil is a no brainer, especially considering the way the car felt afterwards. If Ceratec does the same thing, then you could actually come out ahead at a 5000-7500 km oil change interval.
Unitronic 93 Octane flash
****NOTE: I will add to this section with some more details and logs that I took****
So I'll begin by saying I know a lot of you have been swearing by the JHM flash and I would say you probably have good reason to. It seems like JHM did put a lot of work into it and I imagine it is probably the superior flash between the two.
That said, my budget for mods on this car is pretty tight. The Uni 91 octane flash is $350 and the 93 flash I paid $400 (Can $) for. If I were to get the JHM flash, I would be looking at $500 + $80 USD for a total of about $680 Canadian. As it stands, I managed to piece together the materials for a complete 2.5 in downpipe setup for $280. So in my case and budget: Uni 93 flash + 2.5 in downpipes > JHM flash alone.
As for my impressions of the tune, totally worth it. As others have mentioned, you likely won't pick up a ton of peak power, but that is most likely a function of the restrictive exhaust setup. Where you do make noticeable gains is in the midrange and other transient responses.
Overall I would describe it as the car feeling punchier and more nimble. I find that maneuvers like hitting the throttle to get into a space in traffic are much easier. Given that most of our driving is done at part throttle or using transient throttle applications, this type of reflash makes a substantial real world driving difference.
I should also add that it does feel like a 10-15 HP gain. Which may not seem like much, but when it comes to modding these engines, it's really about additive gains, not big one time power adders like a turbo car.
Where I think this mod will shine is when I add the 2.5 in downpipes. The combination of lower end response and torque from the flash between 3000-5000 RPM and the 5000-7200 RPM gain from the downpipes will be a sweet combo IMO.
2.5 in downpipes
As I just stated, I think this mod will compliment the Uni flash very nicely. With any luck I will have these done and on the car this weekend and will report back with some before and after logs.
NOVEMBER 10, 2014 EDIT
Well, after a combined 20 some hours fitting, checking, cutting welding, finding out I fitted it wrong, inventing new swear words and re-welding I did up my downpipes and all I can say is HOLY SHIT!!!!!!!!!!
Pulling the cats totally, totally changes how this car feels. I noticed that even with the tune, I made gains in midrange HP/Tq, but it still felt like after about 5000 RPM it just kind of petered out. Well no more, this engine would be happy to bang off the rev limiter now.
Also, throttle response is immensely improved as well, in fact, I found that when I rev matched for my downshifts I actually overshot the RPM on account of how easily and freely it reved.
Unfortunately, we've had a major dump of snow here and the roads are clogged with slow traffic so I haven't got a chance to make a pass through 1-2 and part of 3, however I will get a recording of it as soon as I can. (I do have a shot of 1st gear 2500-6500 RPM that I'll post as soon as I can get it downloaded.
If I had to describe how the engine feels, the words "It's a gem of an engine" comes to mind. For the first time I've actually found myself just wanting to get in it and bomb around town just to have some fun. Now, ask yourself "how many 3.0 drivers actually find the car to be fun:....
SUMMARY
All said, I would call this project a success so far. For around $750-$800 ($1500 if you go all out by replacing the entire exhaust), you can have a car that can hang w modded 1.8t's as well as having the instant torque and a crisp, linear powerband.
One thing I should add: if you're gonna change the downpipes out, you should seriously consider just buying them from JHM. While I did manage to make them for half the price, it was an intensely aggravating and a lot of hours. Plus, JHM's pipes are stainless steel whereas mine were aluminized steel. I would actually think that if I had made my downpipes out of stainless, I would probably be looking at $500-600 in materials alone.
So while there seemed to be a lot of complaining about what JHM charges for their downpipes, take it from me the $700 is actually a hell of a good price for something that will totally change your vehicle.
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