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Audi Tech Letters

Nov 11, 2004

Audi Info Please
I have an Audi Quattro 1983 with an all-alloy engine. I would like a little history on these cars and how many of them were built with an alloy engine.
Dave McMillan
via the Internet

2018 Audi A4
$36,000 Base Model (MSRP) 27/37 MPG Fuel Economy

To our knowledge, the only production Audi Quattro that came from the factory with an all-alloy engine was the Sport Quattro. A total of 200 of the Sport Quattros were built, with 170 of those going to customers. These all-alloy engines were also subject to recall and most were replaced with cast iron block units, due to issues with oil consumption.


Letter to the Editor
I am looking for a V6 engine for my 1998 VW Passat, must be from a five-speed car, complete with harness, control module, mass airflow sensor and possibly an exhaust. Please provide price and availability. I drive a 1992 Audi 100 2.8 Quattro. I am looking for a little more power and I am considering an upgrade to the five-valve engine. I am not looking to go racing but I feel my engine is a little tired (200,000 miles) and a little more performance would be appreciated. I am assuming a five-valve Audi engine with a management system for a manual trans will be a little pricey and hard to find.

A seasoned Audi mechanic has suggested that we find a five-valve engine from a 1998-2000 VW Passat. The Passat engines are relatively plentiful, especially with manual trans EMS units. I realize that some wiring and mechanical hurdles may need to be overcome but overall the engine swap with a few modifications does not sound too daunting. I am assuming the block is the same so motor mounts, A/C compressor and trans should hook up. I am prepared to mount a different module, tap in a few wires, and modify an exhaust system and any other low-tech modifications that are required. First, will I feel that 20-30 hp gain? Second, am I missing something serious for the changeover? Do the Passat engines have similar engine management systems? Is it just a matter of locating the different EMC module and tracing out a few wires or will I be taking on a monster project?
Timothy Bailey

You are right on track. The newer 30V V6 engine in the Passat is in fact a newer iteration of the 12V V6 that's in your car. The newer engine would simply bolt right in. As you mentioned, in order to do the swap correctly, you would in fact need the ECU as well as the complete wiring harnesses.


2000-2001 Audi A4 1.8T; Differences?
I'm considering purchasing a 2000 or '01 AUDI A4 1.8T. Then, I'm going get a boost controller (about 35 hp gain) and change the CPU chip. I am aware that a '01 A4 has 20 hp more than '00. Where does this power gain come from? If it's boost, will these two models have the same hp after installing a boost controller? Also, is it redundant if I do both chip tuning and a boost controller?
Jay


via the Internet

The increase in horsepower is related to an increase in boost levels in the '01 engine. There are some other primary differences as well. The 170-hp version of the engine is a ULEV engine, and there were minor changes made to the engine internals, intake, fueling and exhaust systems to make it qualify for the ultra low emissions standard. If you want to increase power, both the 150-hp and 170-hp versions respond equally well to ECU modifications, or "chip" tuning. While some have added boost controllers, they simply take over the role of the N75 valve, which is the valve that controls the turbo's wastegate. If set up correctly, they can allow boost to last higher up into the rpm range.


Audi 20-Valve Engines
Is there a performance difference between the 3B series 20 valve turbo engine and the 20-valve engine installed in the S4/S6 cars built between 1992 and 1997?
R. Glenn
via the Internet

The 3B 20V engine as found in the early Audi 200 Quattros produced 217 hp and 228 lb-ft of torque in U.S. trim. The AAN 20V engine in the S4/S6 cars in U.S. trim produced 227 hp and 258 lb-ft of torque. The primary differences between the two, which account for the higher output levels, were a larger intercooler and higher boost levels for the AAN. There were other minor differences in parts as well such as different knock sensors and intake-to-intercooler pipe.


Australian Audi Transplant
I recently read the letter "Audi A4 Transplant" submitted by Karen Zimmer. In this you mention that the 30V V6 engine is a newer iteration of the 12V V6. You go on to suggest that the newer motor would simply just bolt right in but that the computer, wiring harness and fueling issues would need to be straitened out. My motor has recently had a major failure and the cost to repair sounds equivalent to replacing it with a good secondhand unit. My Audi is a 1997 A4 2.6-liter V6 Quattro (Australian model). If I were to go ahead with this, where can I find out more information on what needs to be done to the fuel rails and other fuel injection parts for the 30V motor to operate correctly?

What are the designations fo these engines? I have seen some three-letter codes (e.g. AAH etc) but no reference to model years.
Anonymous
via the Internet

The best advice I could give is to check with a qualified independent Audi shop. I'm not that familiar with the 2.6-liter V6, but it would most likely be very similar in terms of wiring, fueling, etc. If you were to get a complete 30V V6 with all the fuel rails, injectors, etc., it would make the swap much simpler. You would then need to just replace the ECU and harnesses and match up the wiring.


A4 Avante Upgrades
I'm the proud owner of a newly acquired single-owner 1999 Avante 1.8T. The car has never had any modifications and has been well maintained. I'm thinking of doing some simple upgrades such as a Wetterauer chip, K&N air filter, and APEX'i cat-back exhaust. I'm wondering if also doing a high flow catalytic converter will gain me anything else, and if you have any other recommendations.
Steven Hammons
via the Internet

The basic intake, chip and exhaust mods that you mentioned will indeed change the character of your A4. I would suggest looking into chips other than Wetterauer however, as they do not seem to produce the results that APR (www.goapr.com), GIAC (www.giac.com), Revo (www.revo-technik.com) or Neuspeed (www.neuspeed.com) are getting on the same engine. Another company to check out that has recently brought their tuning software to the U.S. is Dahlback Racing (www.tjmmotorsport.com). These companies also have much larger dealer networks and more likely to have someone close by. As for the K&N, you won't get much horsepower gain but it does indeed improve throttle response. I'd also replace the DV valve with a good aftermarket unit like the Forge 007. There are a number of good exhaust systems out there and if you go with a complete system with a downpipe, you really don't need to go with a high flow catalytic converter.


Audi Aftermarket? It Does Exist
I am the proud owner of a 2001 2.8-liter A4. There is only one problem I'm having with this car: I want it to go faster. Everyone that I've talked to about aftermarket parts for the engine either say it can't be done or that there are not parts for it. I think this is highly unlikely and know there must be some engine upgrades that will turn my car into the lethal street weapon that I know that it is capable of being.
Andrew Dwyer
via the Internet

I don't know who you are talking to, but there are definitely a host of performance parts available for your 2001 30V. Give the guys at PES Tuning a call (www.pes-tuning.com/). They can hook you up with their G2 supercharger system, which will put you near 300 hp. While it doesn't make supercar numbers, this kit will certainly make a significant difference in your current performance levels.


1991 Audi Coupe
I read an article on your Web site about the 1991 Audi Coupe and I want to know where I can find performance parts for this vehicle, exhaust, springs, etc.
Jack Griffiths
via the Internet

One of the best places to start with modifying your Coupe is with 2Bennett Automotive in Davis, Calif. (www.2bennett.com/). Perusing their site, you'll find everything you need and some things you will probably lust after and want to mortgage the house for, like their complete 300-hp 20V engine swaps.


Answers for an Audi Newbie
I just bought an Audi A4. I wanted to but aftermarket parts for my car but I do not know what is factory approved, like Dinan for BMWs and AMG parts for Benz.
Tim Zoellner
via the Internet

Unfortunately, here in the U.S. Audi does not provide any factory approved aftermarket parts, other than those that are sold through the dealer. However, all is not lost. There are a lot of companies that do provide aftermarket parts, although they may prove to be problematic if you should have any related warranty issues. Remember though that although companies like Dinan and AMG provide factory approved parts, they also have limitations on how they affect factory warranties. If you are going to modify your car, just remember that you are responsible for those modifications, and if there are problems associated with them that you might have to deal with them outside of warranty.


To: european.car@sorc.com

I have recently acquired a 2004 TT 3.2-liter Coupe and love the car now that I figured out how to disable the ESP. DSG is fun for an automatic but there seems to be some takeoff hesitation in certain terrain situations (uphill turning, etc.) and it has an annoying tendency to shift from first to second midway through a turn.

My car came with the 17-in. all season standard tires. They won't do for summer sport driving. What would be the widest tread and wheel I could put on this car to put the most tread on the road with the widest track? Audi dealer says check with the tire company, tire company says check with the dealer. Wheel company says check with dealer. Dealer, of course, will only recommend factory wheel-tire combo (225/45 WR18).

Finally, what tuner or supplier would you recommend for performance chips and other enhancements? I'm looking for just a few for more horses and lb-ft.
Tim
via the Internet

After having the opportunity to drive the TT 3.2-liter DSG for an extended period of time I can understand your excitement with the car. As for the shifting, if you are looking to hold the rpm between the one-two shift, keep it in sport mode. While it will still shift at redline it will hold the gears much better while attacking the turns. As for replacing the wheels and tires, I've seen as large as 10-in. wide wheels at the rear of the TT. However, understand if you want to go this wide in the rear you will induce more understeer in the car. While it looks good it's not the optimum performance solution. I would suggest using 8.5-in. wide wheels all the way around, and if you want the staggered look I'd go no larger than 9.5s in the rear. As for tires, I'd go for 235/45-18 on the fronts (or all around if you go with the 8.5s) and 265/35-18 on the rear if you decide you want the 9.5s in the rear. This stays within the parameters necessary for proper functioning of the haldex unit. This combo will give you about a 1.5% speedometer error over stock (speedometer will read just under 71 mph at 70mph), which is minimal. To combat the extra oversteer induced by the wider rear track, you could also add a larger rear sway bar, like Neuspeed's 22mm rear bar (www.neuspeed.com).

As for engine tweaks, currently due to the limitations of the DSG transmission most tuners aren't developing any performance options for the TT 3.2. AMD Technik in the UK (www.auto-amd.com) has developed three levels of tuning, from a simple ECU upgrade which provides an additional 15 hp all the way up to a 300 hp Stage III which includes an ECU upgrade, Milltek exhaust and cams. The torque levels are limited to protect the DSG transmission. Advanced Motorsport Solutions (AMS) (www.advancedmotorsport.com) also has programming available which will produce up to a 15 hp increase over stock. Please note that it isn't that the DSG can't handle the extra hp and torque, but the DSG's programming is such that it will reduce power levels if it senses the torque levels have exceeded specified parameters.


Audi TT Exhaust
I own a 2003 TT (225). I'm looking for a cat-back exhaust system. I want to stay away from systems that have that bumble-bee sound. I found a company that is working on a system ANSA, but they don't have it yet. Do you have any suggestions? It is for street use, I just want better sound and performance.
Michael Nalls
via the Internet

You have several options for exhausts for the TT 225. Some of the nicer sounding exhausts include Neuspeed, Forge, Milltek and Jetex. All of these systems provide a nice, deep tone at idle and provide no noticeable cabin drone at highway speeds. Milltek can be ordered from Stratmosphere (http://www.stratmosphere.com), the Forge system directly from Forge Motorsports (http://www.forgemotorsport.com), and you can find the Jetex exhaust from New Dimensions (http://www.newdimensions.com). Check the Neuspeed site for info on their exhausts and a list of retailers (http://www.neuspeed.com).

All three brake upgrade kits you mentioned will work very well on your S4. The StopTech kit is one of the most well thought out and well-engineered kits on the market and is very competitively priced, making it more to the top of the list in terms of price vs. performance. The similarly sized Brembo kit is also very nice but about $500 more. The MTM system lists for about $1000 more and utilizes a modified Brembo caliper designed originally for the RS2, as well as 330mm brake rotors. With no direct comparisons of the kits fitted to an S4, it's difficult to say which would offer the best braking. However, the laws of physics dictate that the StopTech and Brembo kits' 355mm rotors will offer superior braking--all things considered. One other thing to consider is that you'll need larger wheels to accommodate the significantly larger brakes.


Audi 80 Quattro
I currently own a 1988 Audi 80 Quattro. To increase performance would it be cheaper and more feasible to do an engine swap or install a turbo? If it's the turbo, does anyone make a kit? I would also like to know what I could do as far as weight reduction.
Mario Di Cesare
Lake Orion, Michigan

Engine swaps are generally not the cheapest thing to do, given the complexity involved. However, that being said, there are no commercially available turbocharger kits available for your car either, forcing you to consider a full custom solution, which is also relatively expensive and will require a significant amount of tuning. The 2.3-liter, inline five cylinder engine in your car had a fairly high compression ratio of 10:1, and although the internals are pretty stout, it wasn't designed for turbo applications. The turbocharged version of that engine, which was available in the Audi 5000 that year for comparison, had a compression ratio of 7.8:1. Given the fact that you'd be rebuilding the entire engine, an engine swap would probably be the way to go to get increased power. At that point you could look for a 20V version of the venerable inline 5 from an old 200, S4 or S6. While this wouldn't be a simple swap, it has been done and will yield the greatest results. Give the guys at 2Bennett Automotive (www.2bennett.com) a call as they have done these types of swaps before. As for weight reduction, the best place to start is the insulation in the car and trunk and removing the spare tire. The installation of lightweight seats also can shed a considerable amount of weight as well.


A4 2.8L Turbo: The Project Car
I own a '98 Audi A4 Quattro 2.8-liter V6. With intake and exhaust it produces around 210 hp. Since I'm installing a custom turbo on this engine I was told that I first need to get bigger exhaust manifold and maybe do some other modifications. I've been working on this project for quite some time, however I get a lot of negative feedback because I've heard that this is not a strong engine, and more than 0.3 bar (around 2 to 4 psi) of boost will break it.
Goran Rudich
Phoenix, Arizona

The 2.8-liter V6 has a relatively high stock compression ratio of 10.3:1. The engine internals are pretty strong, but the high compression ratio limits the amount of boost you can run. I wouldn't run more than 4-6 psi on that compression ratio and stock internals with91 octane pump gas. I'd look to find either a "spacer" style head gasket or lower compression pistons to bring compression to 9.0:1 or so. That would allow you to run much higher boost levels. Of course, you'd need custom exhaust manifolds and a custom exhaust system as well. The size and design of the manifolds would be dictated by the size of the turbo that you would be using. Your other option would be to use the Performance Engineering Systems (www.pes-tuning.com) G2 Supercharger. This kit is good for 295 hp and simply bolts on with no internal modifications necessary, due to the fact that it also runs a relatively low amount of boost.


Eurovan Hybrid
I have a 1990 Coupe Quattro with a 20V five-cylinder engine. I've heard you can build an engine with my head and a bottom end from a Eurovan 2.5- or 2.6-liter engine. Is this true? I want to build a normally aspirated engine with as much power as I can, within a budget of under $3,000.
Keith Johnson
via the Internet

It is definitely possible to convert your 20V from 2.3 to 2.6 liters using the larger displacement short block found in the Eurovan. Eurospec Sport (www.eurospecsport.com) sells the short block conversion $ 2,095. They also sell a stoker kit for your engine to enlarge the displacement from 2.3 to 2.6 liters as well for $1,895, if you want to save a few bucks and build it up yourself.


Turbo?
I drive a 1996 model 2.8L Audi A4 Quattro. I was wondering if you know where I could find a turbo kit for my non-turbo car?
Jonathan Rhea
via the Internet

I wish I could tell you that there are several turbo kits available for your car, but I simply cannot find any. I did find some other options, including a modified throttle body and camshafts from 2Bennett Automotive (www.2bennett.com), but these are far from a turbo kit in terms of horsepower potential. PES Tuning (www.pes-tuning.com) offers a supercharger for the 1998 and later 30V V6 but not for the 12V. You may want to contact them anyway and see if you can modify their kit to work on the 12V. If you do decide to go the turbocharging route, it looks like a custom setup is going to be your only choice.


Audi Tuner
I have a 1997 Audi A6 wagon and would like to find a source for an excellent aftermarket tuner in the same vein as Dinan for BMW, which manufactures tuning chips, low-restriction air filters and aftermarket exhausts that are refined and well-made. I just want to add another 20 hp to my output without going into the engine internals. There seems to be a lot available for the A4 but little for the A6. Any suggestions?
Doug Wells
via the Internet

I've searched high and low for some tuning products for the old 12V V6 found in your car and came up with only one source that provides a modified throttle body and a set of cams. Try contacting 2Bennett Automotive (www.2bennett.com) for these parts. It seems most of the development of aftermarket parts for the Audi V6 began when they released the 30V version in 1998.


S4 Brake Upgrade
I'd like to upgrade the brakes on my 2000 S4. I can't find any article giving the right answer. I've been considering kits from Brembo, Stoptech and MTM.
Dario
Montreal, Quebec

Unfortunately, while the BBS LM is an outstanding wheel in terms of looks and performance, the style of the wheel, with its relatively flat face and machined lip, limits its use with big brake kits. One of your options would be to get custom lips machined for your wheels, which would reduce the width to bring the wheel back into the wheel well. Try contacting BBS Germany (www.bbs-ag.com) to see if different width lips are available. AP Racing (www.apracing.com) may have suggestions as to which of their calipers are smaller or narrower which may work better for you in this situation.

Audi V6 Focred Induction
Does anybody out there make a forced-induction system for the Audi 3.0-liter V6 Quattro? Are there any companies that make any other performance parts for this car?
Sancho Au
via the Internet

The only forced induction system currently in production for the Audi 3.0-liter V6 is Performance Engineering Systems' (www.pes-tuning.com) G2 Supercharger. This kit is good for 295 hp and simply bolts on with no internal modifications necessary. This is due to the fact that it also runs a relatively low amount of boost. PES also has other things like ECU modifications and exhausts for this engine. Total Audi Performance at (www.tap1.com), 2 Bennett Automotive (www.2bennett.com) and Blaufergngen (www.audiquattroparts.com) all carry a variety of different modifications including throttle bodies, cams and suspension parts.


PES Tuning Alive and Well
I have a 1999 Audi A4 2.6-liter and wanted to put a supercharger system on it. After using a Web search engine I was directed to an old article you did about PES Tuning's supercharged A4 system. I called the number in the article and no one answered. I tried the PES Web site, and after the intro page the only thing that comes up is an "internal error." I tried e-mailing them to no avail. I was wondering if you have any knowledge if they are still around? And if not, is there someone else who carries a supercharger system for the Audi 2.6-liter motor?
Greg Lyon
via the Internet

I'm surprised you've had so much trouble getting in contact with PES. To my knowledge they're still alive and kicking and very busy. Try checking out their new Web site (www.pes-tuning.com), send another e-mail at info@pes-tuning or try giving them another call at either of these two numbers: (267) 288-0161 and (877) 697-1688, or fax at (267) 288-0165. As far as I'm aware, they are the only company in the U.S. that makes a supercharger for the Audi A4's V6.


97 Audi A4 2.8
I want to boost performance on my 1997 A4 2.8-liter, but I don't see anything for my car. Is there anything out there? Can I put twin turbo in, and how much does it cost?
Viradet Dem Phonthongsy
via the Internet

I guess you could say anything is possible with the right amount of money and patience, but you're going to spend a lot of money trying to develop a twin-turbo kit for your car. The engine is simply not designed to handle boost well due to its high compression ratio. I'd have to say that your best bet is to consider a 2.7-liter twin-turbo engine swap from a B5 S4. Although you would need the ECU and complete engine harnesses, this would be much simpler than designing, implementing and tuning a custom twin setup for the car. If you want to simply boost performance,

check with 2Bennett Automotive (www.2bennett.com)

Blaufergngen (www.audiquattroparts.com)

or Total Audi Performance at (www.tap1.com)

for the more common modifications such as modified throttle bodies, cams, exhausts and suspension parts for your car.


Audi 90: Help Required
I am a huge car fanatic but up until this point I have focused mostly on off-road and Japanese tuner cars. Recently I began looking for a new car to take me to school and work. I found a 1994 Audi 90 CS Quattro for a very agreeable price and I made the purchase. I bought the car with the intention of only buying it and driving it, without making any modifications, but that idea hasn't lasted very long. I don't want to go crazy or anything, mostly just replace worn-out stock pieces with better performing aftermarket pieces. For example, the struts are going to need replacing soon so I have begun looking for a nice suspension kit that will replace the old parts with sportier-than-stock pieces. Being somewhat new to European car tuning I didn't know where to look for parts so I picked up your magazine as a guide. I searched the Web sites of your advertisers and scoured the magazine for some info but found nothing. I can find barely a mention of my car anywhere and even searching for wheels on major Web sites leaves me with nothing. I was hoping you could give me some info. I was hoping to find a nice suspension kit that is more aggressive than stock but remaining very street-able, and some nice forged wheels like the new BBS RG-R. Is there some other car that my car shares a platform with that I should look for, or is there another way of identifying my car that I am unaware of?
Daniel Johnson
via the Internet

The 90 Quattro you purchased has lots of potential. For the suspension, you can opt for either Koni Adjustable or Bilstein Sport shocks mated with H&R Sport springs which will lower your car about 1.5-in. and really help handing. 2Bennett Automotive (www.2bennett.com), has a complete height- and dampening-adjustable coilover kit for your car as well, but it's a bit pricey at $1,600 and may be more than your looking for. They also have some performance suspension bushings to tighten up the steering response. As for wheels, you can't go wrong with the BBS RGRs, or any forged wheel for that matter. If you're looking for more general information on the car, check the historical model guides on Audiworld (www.audiworld.com) for complete specifications for your car.


A4 Quattro Bad Weather Instability
I was recently involved in a minor accident in my 1999 A4 1.8T Quattro. Someone nosed out from a traffic light and I just barely clipped them. The right rear wheel made contact but didn't appear to be damaged and the body shop that repaired the cosmetic damage said that the alignment was fine. However, the car is now unstable on slick roads. The back end tries to come around, requiring constant correction and causing the car to feel like it's wagging back and forth as it goes down the road. It seems like the torque distribution from the Quattro system has been thrown out of balance. My question is, can the Quattro system be damaged when it gets centerpunched? The car is dangerous on icy roads now and I need to know what to do.
Jim Whalen
via the Internet

It's highly unlikely that the torsen Quattro system was damaged in the accident. What it sounds like is that you have some damage to either the rear control arms or struts. Additionally, it's possible that the ABS sensor in the rear has been damaged, which could affect the rear EDL, or electronic differential locking system, as it is controlled through the ABS system. I would bring your car to an Audi specialist or your local dealer and have them check this out as soon as possible.


225-hp Audi TT
I was wondering if you could recommend some performance companies for my Audi TT, as well as who makes the best performance parts for Audis? I've been looking at many different brands of products but I just don't know which ones are best. For example, I have been looking at five different chips, eight exhausts, three intakes and intercoolers, but I just don't know which ones to pick. They don't have to be the same brand, just the best product from different companies.
Adrian Gonzalez
via the Internet

I wish it were as easy as listing all of the companies you mentioned and saying that one is the best, but that's simply impossible. As you have already found out, there are numerous companies producing performance-enhancing products for your TT. I think what it boils down to is that you need to ask yourself what you are looking for. Do you want the most performance out there at the possible risk of less reliability? Is the car going to be a daily driver and never see an autocross course or track time? Do you want an exhaust system that is quiet or not?

I would suggest the GIAC X-chip (www.giacusa.com) if you are looking to get the most power out of the engine and if you are going to get a FMIC, they make a specific chip for this combo. It will work fine with either the Forge Motorsports FMIC (www.forgemotorsport.com), which is a very high quality unit, or the OCT FMIC which is very similar to the Forge and is available from Stratmosphere (www.stratmosphere.com/index.htm). Both Forge and Stratomsphere offer excellent exhausts as well. While Forge produces their own, Stratmosphere carries the Milltek exhaust, which has a great tone, excellent fit and optional resonator to keep things quiet in the cabin. If you're looking for a quiet exhaust, Jetex makes an excellent unit, which is quiet when it needs to be, and has a nice deep tone when you open up the throttle. Check with New Dimensions (www.newdimensions.com) as they are the sole importers of Jetex exhaust systems here in the U.S.

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