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034 Motorsport - 800hp Audi Build-Up Part 2

PART 2

Jul 1, 2008
Eurp_0807_01_z+audi_engine_build_up+engine_bay Photo 1/14   |   034 Motorsport - 800hp Audi Build-Up Part 2

In case you've missed it, Eurotuner is part of the Castrol Syntec Top Shop Challenge (www.SyntecTopShop.com), in which several magazines have teamed up with a reputable engine builder to produce the best all-around engine. The contest has been bringing out the best and worst of everybody involved. From our perspective, rivalries have been blown out of proportion and we're lucky the cops haven't shown up to settle these disputes. However, let it be said: we won't be beaten by the imports!

Eurp_0807_02_z+audi_engine_build_up+engine_cover Photo 2/14   |   034 Motorsport - 800hp Audi Build-Up Part 2

On the tuning side, the entrusted engine shops have had no time to respond to our shin-kicking, hair-pulling tactics. These guys are pushing the limits in power and reliability, and are further challenged by having to create the best possible power curve. Suffice it to say, building the most impressive all-round motor isn't easy, and we're glad 034 Motorsport has taken charge of our fate in this competition. And don't forget, you could win this engine at the end of it all, so check out the website (www.SyntecTopShop.com).

Eurp_0807_03_z+audi_engine_build_up+oil_lines Photo 3/14   |   034 Motorsport - 800hp Audi Build-Up Part 2

In the first part of our Audi 80 2.3-liter engine build (et 5/08) we focused on 034's assembly of the stout bottom end, followed by various tricks of the trade performed on the head to flow more air and because the area under the curve is also important getting it in the combustion chambers faster. This month, we'll show how 034gets copious amounts of air and fuel into the combustion chambers, and with a massive spark causing a cylindrically confined fireball powerful enough to interest the military.

Eurp_0807_04_z+audi_engine_build_up+dynograph Photo 4/14   |   034 Motorsport - 800hp Audi Build-Up Part 2

Starting with the fuel system, 034 installed its dual 044 fuel pump kit with an accumulator tank. The pump pushes fuel into a -10 feed line and through a -10 Aeromotive fuel filter. Pressure to the 034EFI 20v fuel rail is controlled by a Fuel Lab pressure regulator before feeding the hose-like1250cc injectors. The unsquirted fuel returns through a -6 line to the stock fuel tank.

Eurp_0807_05_z+audi_engine_build_up+garrett_turbo Photo 5/14   |   034 Motorsport - 800hp Audi Build-Up Part 2

A fuel system of this magnitude commands a psychotic amount of air in order to ignite. And while we won't reveal our turbocharger of choice for fear of tipping off the competitors too soon, the engine's fared well with its temporary GT42RSturbo during initial testing. The massive snail is fitted to an 034 Audi i-5 header featuring 1.5" runners made from 321 stainless steel to handle the heat. Boost is controlled with a 44mm Tial external wastegate.

Eurp_0807_06_z+audi_engine_build_up+radiator Photo 6/14   |   034 Motorsport - 800hp Audi Build-Up Part 2

Before intercooling, the heavily compressed air from the turbo travels through a 3" outlet that splits into dual 2.5" piping. With both pipes feeding the intercooler, 034 reports better distribution of flow across the intercooler core, which measures19x17x3" , yet fits behind a stock bumper.

Eurp_0807_07_z+audi_engine_build_up+breathers Photo 7/14   |   034 Motorsport - 800hp Audi Build-Up Part 2

Passing through 3" piping, the chilled air meets 034's big-bore throttle body and cast intake manifold, which reportedly flows 30% more than stock, with only a 2-3% variance between runners (as opposed to the factory manifold's fluctuations of around 25%). To save the turbo, a 50mm Tial blow-off valve relieves boost when the 70mm throttle closes.

Eurp_0807_08_z+audi_engine_build_up+turbo_piping Photo 8/14   |   034 Motorsport - 800hp Audi Build-Up Part 2

With the exhaust as a potential bottleneck, 034 took no chances and fabricated a 4" downpipe. They then merged it into the3.5" exhaust piping that remains sans muffler. We're glad there are no decibel limitations on this contest.

With air and fuel taken care of, 034 chose its own 034EFI stage IIc engine management system to control the sparks. The programmable unit offers degree-based timing calculations that give 0.25" accuracy. The unit also has built-in, 20 amp ignition drivers that directly fire the 034EFI ignition coils, allowing over 8 milliseconds of dwell at40psi boost levels for optimum spark ionization in the highly pressurized cylinders.

Eurp_0807_09_z+audi_engine_build_up+ignition_system Photo 9/14   |   034 Motorsport - 800hp Audi Build-Up Part 2

034 is also proud of the fact its EMS system features sequential valve-timed injection, sequential ignition, and boost control with compensation for all environmental variables.

Given the 100-octane fuel rule, all the tuners involved in the Castrol Syntec Top Shop Challenge are limited to an extent. After all, at these power levels, being able to run a higher octane fuel would make a world of difference. But after lots of dyno tinkering, 034 has so far managed to extract760hp at the wheels and 560 lb-ft of torque from the 2.3-liter engine running the GT42RS turbo.

Eurp_0807_10_z+audi_engine_build_up+throttle_body Photo 10/14   |   034 Motorsport - 800hp Audi Build-Up Part 2

That's an impressive number, to say the least. But we can't wait to see what they have got up their sleeves for the final challenge!

In the meantime we'll be doing our part, standing guard outside 034's shop, armed with an arsenal of water balloon launchers and Roman candles to counteract any form of espionage.

Eurp_0807_11_z+audi_engine_build_up+braided_lines Photo 11/14   |   034 Motorsport - 800hp Audi Build-Up Part 2

These other rags are playing dirty.

So if you want to get in on the action, pay a visit towww.SyntecTopShop.com where you can vote for your favorite builder (us!) and enter the sweepstakes to win the best engine.

Confused? In a matter of months, the seven engines built for the Castrol Syntec Top Shop Challenge will gather for a dyno shoot-out. The winning engine will then be up for grabs to anybody who entered the sweepstakes and chose that motor as their favorite.

You can also follow the build online, where you'll find video from each of the teams, as well as our articles and blogs.

Together with Castrol Syntec and 034Motorsport, we aim to challenge the import and domestic magazine titles and show them what raw, European turbo horsepower is all about! Don't miss our update in next month's issue.

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