[Author Prev][Author Next][Thread Prev][Thread Next][Author Index][Thread Index]

S4 rebuild latest



After my recent catastrophic failure (I knew that the turbo was on its
way out when I bought the car) the S4 has now been just about finished
and out on the rollers.

Due to the failure, I have had to have new pistons and 20V head
(debris!). I've had a new hybrid K26, RS2 Manifold, hi-flow cats and SS
system (from the US), adjusted WG, AmD remap, Ram Air filter, new cams.
It still has the previous 2.5bar PT and factory IC.

It was found on the rollers that the standard S4 intercooler isn't up to
the job. Maybe not due to its construction, but that very little air can
get to pass through it due to its location and the proximity of other
rubbish i.e washer bottle etc. Fitting a larger IC may not help. The
intake charge was running around the 85-95 deg C on boost which Aelred
suggested was way high. Due to the heat, they restricted the max boost
at 1.2bar.

They took green injectors but didn't fit them as the engine did not
require any additional fuelling (maybe it will if they increase the
boost?)

I guess that I have two options, one to charge cool or to set up a water
spray system (as suggested in the archives...not that I have much room
for an additional tank!)

Anyway, some numbers;

The standard S4 gives 230bhp with 258/280 lb/ft @1950rpm. With my
previous GTI Engineering Phase II conversion (K26 hybrid and remap) gave
around 270bhp and 280/300 lb/ft at *4000rpm*.  The latest rework gives
323bhp with 402 lb/ft at 2896rpm. This is a huge increase on the
previous configuration. I assumed that they meant Nm rather than lb/ft
but no, they have the graphs as proof! I'm still not sure that the
figures can be right as that's around 8bhp and *100 lb/ft* more than a
standard RS2 setup!

Any other recommendation on getting the air charge cooled some more? Any
one used Pace charge coolers? Also, any recommendations of temp
gauge/thermistor to permanently monitor the charge temp? Any other
useful sensors I should invest in to keep an eye on things in general?

Regards, Malcolm

P.S I pick the car up in a couple of hours so I haven't got to drive it
just yet! :-)