MembersPage/MarcellGal/PowerAndTraction (2007-05-22 09:01:05)

Having seen MembersPage/NanassyPeter/CloneInstall it became apparent that it's possible to make something for appr. 8000 EUR that leaves most Ferraris, BMWs and factory Subarus behind (in normal road circumstances or even during drag-races).

TODO: cleanup and move stuff from this page to the relevant subpage: only leave overview here

[gallery] (more pics will be uploaded)


Factory manuals needed

Thinking about getting the 1989 audi100-200 repair manuals. Not only engine, but the whole car (owner's manual is not enough!). I prefer digital to paper (I can print the parts that I need, maybe 10% at max.

Unfortunately not all that I need is available at this time. I'd be happy to pay 49 USD for the 3 day ebahn licence. If someone needs same set of docs, and willing to click (to print pages to pdf via pdf995 driver), possibly for hours (not sure how big chunks it's possible to print), let me know here.

Audi people suggested that I get etka, so I can look up part numbers. They said something about emule/bittorrent... I haven't investigated this at all.


I got a AAN (with K24 turbo) audi quattro running with PNP VEMS box (with motronic-55 connector) on [this config and tables]. That is not my engine, although very similar. My (old) harness is 3B (with lotsof small leafs hanging that I have no idea where to connect; and injector part had to be remade because of flaking insulation; guess it didn't like the heat for 18 years).

My 3B engine is running with PNP VEMS box and 1.1.23 firmware. While the HALL sensor was bad, it started appr every 2nd try, now fixed

Many thanx to


Project plan with parts and costs

See old photos, clutch, flywheel and enginebay [pics].

The clutch looked burnt (and weak anyway).

Since I have no mechanical installation experience (especially with this 5cyl engine), I made a spreadsheet to track the parts necessary for install. It would be nice to prevent major stalls due to the lack of small gaskets or bolts or other accessories.

See [project plan audi-costs.xls] and add your hints below.

The car should preferrably come out from the assemly shop on it's own power. Even if in NA form (with turbo+oil installed, but wastegate open and perhaps without charge-cooler to throttle tube, with improvised air-filter)

Add your hints here (anything missing from the spreadsheet, or errors, bad concepts, etc...):

1.1.x firmware for InputTrigger/AudiTrigger will have some advantages over the old 1.0.x (especially above 7000 RPM). But 1.1.x had problems with auditrigger, all these problems must evaporate this weekend.


[pictures about the engine pieces]


We accept that the max power of this engine will be limited by the following parts:

Effectively, max power (on the crank) that can ideally be achieved with this setup is estimated max 380 .. 400 HP.

We don't want to stress it further because:

Engine specs

As you see, this is inhomogeneus. Sounds stupid to use those pistons and rods (good for 600..900 HP) when the turbo limits power to appr 400 HP. However, we had a short timeframe and limited supply. So we chose a built (by experienced parties) bargain engine for appr 2500 EUR instead of a used "junkyard-engine" for 1600 EUR (though that had more spare parts). This way we can reduce the risk of wasting (more!) time because of mechanical problems. And possibly have some room for more HP for future upgrades.


The 20VT (5 cyl, 20 valve turbo) engine is quite amazing

We purchased a

We understand the potential in these engines and want to support tuners around the world who chose this engine.

The most important target of this install is to get the InputTrigger/AudiTrigger install procedure as simple, painless and reproducible as possible

Near-future plans with this install

K26-6/27 turbo, the K27 compressor looks like (cm scale):

K26_27_compressor_m.jpg


Exhaust and turbo - advice accepted, I have no experience here

We missed a nice looking 500 EUR exhaust manifold (auctioned 2007-03-29 on ebay.de)

A friend purchased [187 USD RS2 exhaust manifold] from [ebay]


Turbo (compressor side) upgraded

to K26/27 (appr 6xx EUR). Good for max appr 400HP. Minor compromise is that it is now an oil-only turbo (=> no watercooling: if I understand right, keeping watercooling would require some overpriced factory parts that just aint worth it).

The K26 turbo was upgraded by http://www.ahturbo.hu/ with instructions:

K26-6 turbine housing (cm scale):

K26-6_turbine_27_compressor_m2.jpg


Later

You can find some pictures under [files], including


Links