Audi Tuning | VW Tuning

2014 Port Townsend Cruise Raffle Winners

Posted on April 9, 2014 – 12:07 pm

 

On Saturday, April 5th we had 242 European car enthusiasts gather at Pacific Raceways in preparation for the 2014 Port Townsend Cruise.  Participants were encouraged to bring a minimum cash donation of $10 benefiting Seattle Cancer Care Alliance in exchange for raffle tickets.  Available prizes included a set of H&R “Street Performance” coilovers, a set of H&R front and rear sway bars, a free APR ECU upgrade, a set of front and rear StopTech “Street Performance” brake pads, and some FREE services from Achtuning including TWO free wheel alignments, a free brake fluid flush, and a free oil change with tire rotation!  A big “Thank you!” to our supporting vendors/sponsors – APR, H&R, and StopTech – who have thrown in so much for the sake of our European enthusiast community!!  Between those 242 cars, $4915 was collected for Seattle Cancer Care Alliance!!  We can’t thank you Pacific Northwest enthusiasts enough for your generosity.  We hope everyone had a great time and look forward to next year’s event.

And now, our PTC2014 Raffle Winners:


* ticket #7114597 – a FREE set of H&R “Street Performance” coilovers!


* ticket #7114610 – a FREE set of front/rear H&R sway bars!


* ticket #7114463 – a FREE APR ECU upgrade!


* ticket #7114573 – a FREE set of front/rear StopTech brake pads

FREE wheel alignment #1:
* ticket #7112424

FREE wheel alignment #2:
* ticket #7112381

FREE brake fluid flush:
* ticket #7114438

FREE oil change & tire rotation:
* ticket #7114620

Winners, please contact Achtuning staff immediately and be prepared to present your raffle ticket when you come to claim your prize. Keep in mind the H&R gift certificates expire at the end of May this year so don’t wait to claim your prize!!


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APR K04 Turbo

Posted on April 9, 2014 – 9:00 am

APR’s Engineering Teams have finished final testing of new “version 3.0″ K04 Turbocharger software for the 2.0 TSI/TFSI EA888 Gen 1 engine.  The new ECU Upgrade improves upon power deliver on top of what was previously a tremendous upgrade over stock!  Amidst addressing all previous concerns, additional motorsport features were added to further enhance your driving experience. Updates are now available here at Achtuning and is offered as a FREE software update for APR K04 Turbo Upgrade customers!

  • Please call to check file availability before booking an appointment! 
  • An OEM Bosch 3-Bar Map sensor is REQUIRED to run this software. 

Presenting the APR 2.0 TSI EA888 Gen 1 K04 Turbocharger System!

For the budget minded individual, APR is pleased to offer software and hardware utilizing an APR proprietary customized version of the factory Borg Warner K04-64 turbocharger. Originally equipped on VAG’s high output models, such as the Golf R and S3, the APR K04 Turbocharger System offers a substantial leap in power and torque all with excellent response in a reliable and stealthy, compact design. Expect lightning fast response, smooth daily driving and power that transform the vehicle into a new class of enjoyment.

The APR K04 Turbocharger System features many upgrades over the 2.0T’s factory equipped IHI turbocharger, making it an excellent upgrade. The integrated turbofold design features a cast stainless steel exhaust manifold and turbine housing, integrated into one single unit. This design aids in turbocharger spool while the stainless steel construction is capable of withstanding higher exhaust gas temperature for longer periods of time than lesser materials, such as cast iron. The CNC-machined, billet aluminum compressor wheel and higher flow exhaust turbine wheel expand the turbo’s efficiency range, allowing for higher output across a wider RPM range.

True to APR’s mantra of Performance without Compromise the days of shredding tires on front wheel drive vehicles are rapidly disappearing thanks to the new Gold Standard in ECU torque management calibration strategies only APR can deliver. Compressor surge is avoided to increase the reliability of the system without limiting the area under the curve typically experienced during a top speed acceleration run. APR’s endless pursuit of perfection has resulted in the most comprehensive 2.0 TSI K04 turbocharger system and tuning package in the world.

Using 93-octane fuel, the APR K04 Turbocharger System produces an astonishing 360 horsepower and 382 ft-lbs of torque. Unlike the factory turbocharger, power stays strong and doesn’t dramatically taper towards the vehicle’s new 7,100 RPM redline. Switching to APR’s 100 octane race fuel mode, peak power and torque climb further to 375 horsepower and 408 ft-lbs of torque. APR’s calibration experts have safely maximized the full power potential of the turbocharger unit, while keeping reliability at the forefront of their calibration strategies.

APR K04 Turbocharger System Components

Turbocharger

 

At the heart of the K04 Turbocharger System is an APR proprietary customized version of the factory Borg Warner K04-64 turbocharger originally equipped on VAG’s high-output models, such as the Golf R and S3. The turbocharger features a CNC-machined, billet compressor wheel and stainless steel exhaust turbofold.

Each turbocharger unit is machined, assembled and clocked in house at APR with the necessary brackets to ensure proper wastegate fitment and orientation. Each wastegate is then calibrated for precise operation and control to ensure seamless integration with the expertly recalibrated OEM engine management system.

Integrated DV Adapter

One of the greatest benefits to the APR K04 turbocharger system is its simple, yet elegant design. APR’s CNC-machined direct compressor recirculation port on the OEM compressor cover significantly reduces engine bay clutter and saves the end user from the hidden costs of purchasing extra throttle body pipes, hoses, clamps and DV mounts for recirculating boost pressure. The compact design also removes extra charge piping volume to allow for faster boost response and less locations for boost leaks. Furthermore, charge air pressure is directed directly at the compressor wheel which helps keep the turbo spooled upon lifting the throttle, minimizing turbo lag.

Turbo Outlet and Turbo Muffler Removal

The OEM k04 turbocharger features a turbo muffler designed to reduce turbocharger sound, but does so at the cost of ultimate performance. APR removes the turbo muffler not only to enhance the sound of the turbocharger, but to also provide a smooth airflow path across the previously baffled muffler section. A clean and simple CNC flange developed by APR’s Mechanical Engineers is bolted directly to the compressor cover in place of the OEM turbo muffler. A long mounting surface provides an excellent slip-proof surface for mounting the included APR EZ-Flow silicone discharge hose and an o-ring between the flanges ensures a life of leak-proof operation.

PCV Blockoff Plate

The K04 turbocharger was originally designed for an EA113 2.0T engine, and as such, includes items not present on the EA888 2.0T engine. The compressor cover features a port used in the EA113’s PCV system, but on the EA888’s this same port is located higher up on the intake tubing. APR has provided a gasket-sealed laser-cut port cover to block off this part to ensure no unmetered air enters into the system. The design is clean and simple and never requires maintenance.

Engine Management

The factory Bosch MED 17 engine management system is responsible for proper operation of the engine during constantly changing environmental and load conditions. With built in compensational data for environmental variables and varying load conditions, the factory ECU is far more complex and intelligent than units found in other vehicle makes and marques.

With the significant amount of changes included in the APR K04 Turbocharger System, APR’s Engineers spent months calibrating the engine management system, including hundreds of hours of in-house chassis dyno development. Drivability, gear changes, cruising and part throttle operation were tuned to operate smoothly as if intended by the OEM through proper torque management. Further development was performed putting the vehicle through performance evaluation and durability testing at the drag strip and road course. APR’s Electrical Engineers built new coding functions, strategies and routines into the ECU to control conditions normally unseen at factory power levels. Thanks to APR’s incredible proprietary calibration suite, data logging software and full access to the coding structure of the ECU, appropriate and intelligent changes are made to ensure flawless drivability and excellent performance without compromise.

Engine Calibration:

APR’s Calibration Engineers restructured the engine’s volumetric efficiency (VE) model to correctly determine the ECU’s calculated load and deliver proper torque management. Thanks to APR’s patented boost control coding and the addition of a 3-Bar MAP sensor, the ECU is able to perform closed loop boost control well beyond relatively low limits dictated by the factory MAP sensor. This directly translates to safer and more predictable operation while additionally producing more power and torque across the entire power band.

Additionally, through the properly reconstructed VE model, accurate open loop fueling is achieved, translating to insignificant fuel trim adjustments. Closed loop fueling is calibrated to control lambda perfectly under all operating conditions. Furthermore, compensations, such as ones related to intake air temperature, exhaust temperature, and altitude, are adjusted to handle the larger variances compared to the factory, low-output setup.

APR’s Calibration Engineers have optimized cam timing, ignition timing, engine load and lambda to provide tremendous leaps in power while retaining the OEM knock control strategy. The result is safely achieved power, optimized for various fuel grades found around the world from low-quality pump fuel, all the way to high-quality, oxygenated race fuels.

Compressor Surge Avoidance:

To aid in turbocharger reliability and longevity, APR’s engineers carefully studied the turbocharger’s compressor maps to avoid regions where compressor surge may be experienced. The K04 turbocharger has fantastic response characteristics and is able to produce incredibly high pressure at low airflow levels, but in doing so, the turbocharger runs into issues of compressor surge. In the area between 3000-4000 RPM, APR’s Calibration Experts have elected to limit boost pressure. During testing, with the limits removed, APR’s engineers were able to easily achieve over 400 ft-lbs of torque with 93 octane fuel, but doing so could result in damaging the turbo’s reliability. Back-to-back testing was conducted with and without the limitation and despite the reduction in torque in this range, APR’s engineers were unable to record a measureable difference in accelerative performance.

Torque Management and Traction Control:

Torque management plays a big role in how the vehicle feels and performs, especially during moments of low gear, rapid acceleration. Typically front wheel drive vehicles suffer from excessive wheel spin during these moments due to the massive torque on tap from the K04 Turbocharger System. Some drivers can find themselves in situations where they are fighting against wheel spin and traction control when they are simply interested in going forward as quickly as possible. This is further compounded by the fact that the factory traction control (ASR) system was designed for vehicles producing far less power and torque, resulting in overcompensated ASR interventions.

APR’s Calibration Engineers set out to perfect torque management and traction control by minimizing wheel spin as much as possible without neutering the driving experience. A multi-step approach was taken to achieve appropriate control. With ASR enabled, forward movement wheel spin will trigger appropriate torque intervention levels to minimize spin without hurting forward acceleration. On top of this, the torque management system is fine tuned to deliver only as much torque as the tires can take. In normal conditions the tires will only slightly break loose under full acceleration, resulting maximum acceleration. In higher traction situations, or with ASR disabled, all of the system’s torque is directly on tap!

While the end goal is similar, APR’s torque management system differs greatly from archaic “boost-by-gear” strategies. “Boost-by-gear” strategies rely on a static limitation of boost in an effort to minimize wheel spin, but to work properly they must be dialed in for every situation. The same boost levels in different weather conditions, such as a hot summer day and a cold winter month, can produce vastly different torque levels. Since APR’s torque management system relies on the engine management’s phenomenal torque reporting abilities, it is able to adjust to every environmental situation it encounters. To achieve a targeted torque level, the ECU applies the appropriate changes to mass airflow and ignition.

Acceleration Enhancements:

Through further calibration changes APR’s Calibration Engineers were able to increase the acceleration rate of the vehicle. Ignition delays are reduced resulting in a more responsive pedal without altering overall throttle sensitivity and resolution. Drivability was greatly improved by reducing the throttle lag commonly noticed at slow speeds and while reapplying throttle after decelerating. APR’s Motorsport Rev Limiter allows power to climb all the way to redline without dropping off several hundreds of RPM earlier. Lastly, APR’s tried and tested Motorsport Launch Limiter allows the driver to focus on launching the vehicle, rather than controlling the engine speed.

Part-Throttle Drivability:

Beyond wide-open throttle performance, APR’s Calibration Engineers spent countless hours optimizing vehicle drivability under daily, part-throttle, driving. The vehicle fully retains its impressive daily driver status and simply has more power on tap should the driver request more with his or her right foot!

APR EMCS and APR Mobile:

APR’s EMCS program-switching technology and APR Mobile put control of the ECU in the operator’s hand to access modes for standard pump fuel, high-output race fuel and even reduced-output valet modes to protect the vehicle against improper use by other individuals. This technology is patented by APR and is found nowhere else in the world. It’s Performance Without Compromise only APR can deliver!

Manifold Absolute Pressure Sensor

To provide closed-loop boost control at absolute pressure levels above 2.5 bar, APR’s K04 Turbocharger System features an OEM Bosch 3 bar MAP sensor.

Altering the ECU to understand the engine is equipped with a 3 bar MAP sensor is a trivial task. The sensor and proper calibration settings come standard on many factory VAG vehicles, but even these vehicles only provide proper closed loop boost control up to 2.5 bar absolute.

APR’s electrical engineers went many steps beyond the norm and recoded the factory ECU to deliver closed-loop boost control up to 3-bar absolute. This ability, combined with proper torque management, results in safe, reliable, and predictable performance at higher power levels without the need for clumsy and archaic external boost controlling devices.

Silicone Hose


A wire-reinforced, multi-ply silicone hose provide an unrestricted path for airflow exiting the turbocharger. The hose is engineered to properly connect the turbo’s outlet to the factory charge piping system.

APR’s Easy-Flow Silicone Hose design features stepped mounting surfaces for smooth transitions from one pipe to another. Traditional designs simply sit on top of each other, often resulting in a disruptive airflow path. By using the stepped design, hoses fit properly without airflow restrictions, resulting in the most ideal path for moving air through the turbocharger and into the engine.

Gaskets and Hardware

APR doesn’t cut corners even with the most mundane details of the kit. Every nut, bolt, stud, washer, clamp, and gasket necessary for the install is included with the kit.

Dyno Testing

Horsepower and torque were measured in APR’s in-house, Soundmaster dyno cell, using a Dynapack all-wheel dynamometer. Multiple stock and modified runs were conducted and the SAEJ1349 corrected results were averaged together to represent the differences between a stock and APR K04 2.0 TSI. Crank power figures were estimated based on VAG’s factory advertised results.

Click through the tabs below to view output using various fuel grades, power measured at all four wheels, estimated at the crank, and the absolute gain over stock.

91 Octane | 93 Octane | 100 Octane - Measured Front Wheel Horespower
91 Octane | 93 Octane | 100 Octane - Estimated Crank Horsepower
91 Octane | 93 Octane | 100 Octane - Gain over Stock

Calibration Report

Output:

200 HP & 207 FT-LBS of Torque – Stock as Rated by VAG
221 HP & 220 FT-LBS of Torque – Stock as Measured by APR
346 HP & 360 FT-LBS of Torque – APR K04 with 91 AKI or 95 RON fuel
360 HP & 382 FT-LBS of Torque – APR K04 with 93 AKI or 98 RON fuel
375 HP & 408 FT-LBS of Torque – APR K04 with 100 AKI or 104 RON fuel

Max Gains over Stock (based on APR’s CCTA/CBFA measured output):

+133 HP @ 6,700 RPM & +143 TQ @ 4,400 RPM – APR K04 with 91 AKI or 95 RON fuel
+144 HP @ 6,700 RPM & +164 TQ @ 4,400 RPM – APR K04 with 93 AKI or 98 RON fuel
+166 HP @ 4,450 RPM & +191 TQ @ 4,450 RPM – APR K04 with 100 AKI or 104 RON fuel

Requirements and Recommendations

Intake System
APR’s software is designed to utilize the factory mass airflow (MAF) sensor and housing. The Carbonio Stage I and II Intake System is highly recommended and required to meet the advertised power output.

Exhaust System
The APR Downpipe Exhaust System is required if the vehicle is not currently equipped with the APR Turboback Exhaust System. APR Recommends the APR Catback Exhaust System for maximum performance.

Intercooler System
The APR Intercooler System is required to meet the advertised power figures.

Transmission
The K04 Turbocharger System greatly increases torque over the factory output levels and as such, an upgraded clutch may be necessary to transmit power to the ground. APR highly recommends upgrading the factory clutch to one that suits the operator’s intended driving style.

Exhaust Valve Springs
APR has discovered some engines experience exhaust valve float at high RPM at the advertised horsepower levels due to excessive exhaust backpressure caused by K04’s relatively small turbine wheel. In such cases, APR recommends upgrading the factory valve springs. However, upon request, lower output software capable of producing 321 horsepower and 310 ft-lbs of torque on 93 octane is available.

Tires
APR recommends Michelin PSS and PS2 tires as well as BFGoodrich Rivals and GForce Sport Comp 2 tires.

Fluids
APR recommends Motul Fluids and Lubricants.

Application Guides

Vehicles
Audi A3 (MK2)
Audi Q3
Audi TT (MK2)
Volkswagen Beetle
Volkswagen CC
Volkswagen Eos
Volkswagen Golf / GTI (MK5 / MK6)
Volkswagen Jetta / GLI / Bora / Vento / Sigitar (MK5 / MK6)
Volkswagen Passat / Magaton (B6)
Volkswagen Scirocco
Volkswagen Tiguan
Seat Altea
Seat Leon (MK2)
Seat Toledo (MK2)
Skoda Octavia / VRS (MK2)
Skoda Superb (B6)
Skoda Yeti

Engines
CAWA 2.0T EA888 Gen 1 Transverse (Pending: Beta Testing)
CAWB 2.0T EA888 Gen 1 Transverse (Pending: Beta Testing)
CBFA 2.0T EA888 Gen 1 Transverse
CCTA 2.0T EA888 Gen 1 Transverse
CCTB 2.0T EA888 Gen 1 Transverse
CCZA 2.0T EA888 Gen 1 Transverse (Pending: Beta Testing)
CCZB 2.0T EA888 Gen 1 Transverse (Pending: Beta Testing)
CCZC 2.0T EA888 Gen 1 Transverse (Pending: Beta Testing)
CCZD 2.0T EA888 Gen 1 Transverse (Pending: Beta Testing)

Transmissions
6 Speed Manual
S-Tronic
DSG
Tiptronic

Drivetrains
Drivetrain
Front Wheel Drive
All Wheel Drive

APR K04 Turbocharger System – Includes Software
Part Number: T2100016
Price: $2,749.99
SALE: $2,474.99 <— Sale till May 4th

APR’s K04 Turbocharger System includes APR software, but for customers without APR’s Turbocharger System, who are looking to optimize their driving experience with the best engine management strategy available, APR’s K04 software is available separately. This software requires an OEM Bosch 3-bar map sensor and an OEM Borg Warner K04-64 turbocharger with no modifications to the turbo other than the required fitment aspects. All other requirements and recommendations above should be followed to ensure compatibility.

Software Only

Existing APR Software Customers – $499
New APR Software Customers – $899

Motul Oil, Coolant and Oil Filter

Part of the APR Turbocharger System install process requires removal of the OEM Turbocharger. During this process, oil and coolant must be drained and should be replaced to offer superior performance and protection. The APR Turbocharger Systems are now complete turn-key solutions, including everything you need down to the oil, coolant and oil filter. During checkout you’ll be given the option between Motul Specific 502.00, 505.00 & 505.01 5W40 or Motul Power 300V engine oil as well as Motul Inugel Optimal Ultra Coolant and an OEM oil filter. The Premium Motul lubricant package is included at a much lower than retail price point and the costs are listed below.

Motul Specific Lubricant Install Package

5 Liters of Motul Specific 505.01, 502.00 & 505.00 SAE 5w40 Oil, Oil Filter & 4 Liters of Inugel Optimal Ultra (Concentrated) – Organic
Part Number: MO00003
Price: $75.00

Motul 300V Lubricant Install Package

6 Liters of Motul 300V Power 5W40, Oil Filter & 4 Liters of Inugel Optimal Ultra (Concentrated) – Organic
Part Number: MO00007
Price: $105.00


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APR: 2.0 TSI “Stage 3″ GTX Turbocharger Kit Released!

Posted on April 7, 2014 – 12:31 pm

Achtuning is excited to announce APR’s release of the 2.0 TSI EA888 Gen 1 Stage III GTX Turbocharger System!

In 2008, shortly after the worldwide release of the 2.0 TSI engine, Volkswagen of America commissioned APR to build the Stage III GT Turbocharger System for their SEMA concept cars. Successes of these concept cars lead to the first release of the APR Stage III Turbocharger System, based on the then available Garret GT turbocharger, and became a worldwide phenomenon. In the years since, APR has continued to work with VWoA, Volkswagen GmBH, VWVortex and BFGoodrich to deliver more concept cars for SEMA, Wörthersee in Austria, as well as other events around the world, while APR continued testing the latest in turbocharger technology.

With the introduction of the Garret GTX2867R Turbocharger, APR has raised the bar further and redefined the standard by which the VAG community measures performance, reliability, drivability and quality. Gone are the days of compromise where low-end response meant excessive backpressure, compressor surge, and extremely limited top end performance. True to APR’s mantra of Performance without Compromise the days of shredding tires on front wheel drive vehicles are rapidly disappearing thanks to the new Gold Standard in ECU torque management calibration strategies only APR can deliver. APR’s endless pursuit of perfection has resulted in the most comprehensive 2.0 TSI turbocharger system in the world.

The 2.0 TSI is completely transformed the second it meets an APR Stage III GTX Turbocharger System. Power immediately jumps to 423 horsepower with 387 ft-lbs of torque on tap using 93 octane fuel on a completely stock and unmodified factory fueling system. Switching to APR’s 100 octane race fuel mode, power shoots up to 458 horsepower with 409 ft-lbs of torque all at the driver’s command. This level of extreme performance is just a taste of the system’s full performance capabilities. APR’s Stage III+ GTX fueling system (Coming Soon!) increases performance further by simply adding a few bolt-on APR fueling components.

APR Commissioned Stage III Vehicles

APR Stage III GTX Turbocharger System Components

Turbocharger

At the heart of Stage III GTX Turbocharger System is a GTX2867R turbocharger, which is capable of flowing nearly 50 lbs/min of corrected air flow. This directly translates to large power gains on the 2.0 TSI that continue to grow all the way to redline. The GTX Turbocharger consists of the latest technologies from Le Mans’ winning turbo manufacturer, Garrett Honeywell, and has a track record of reliability and repeatability worthy of complementing an APR Turbocharger System.

The internally gated turbocharger features a fully-machined, ten-blade billet 49.7 mm compressor wheel, Inconel 53.9 mm turbine wheel and a dual ball bearing oil and water-cooled CHRA.

APR’s Engineers spent countless hours testing turbine inlet and A/R sizes in order to decrease turbocharger lag without negatively impacting peak power. Complementing the turbo’s lightning fast response characteristics is a newly developed anti-surge housing, which enables APR’s Calibration Engineers to deliver massive low-end torque without experiencing compressor surge.

Each turbocharger unit is assembled and clocked in house at APR with the necessary brackets to ensure proper wastegate fitment and orientation. Each wastegate is then calibrated for precise operation and control to ensure seamless integration with the expertly recalibrated OEM engine management system.

Engine Management

The factory Bosch MED 17 engine management system is responsible for proper operation of the engine during constantly changing environmental and load conditions. With built in compensational data for environmental variables and varying load conditions, the factory ECU is far more complex and intelligent than units found in other vehicle makes and marques.

With the significant amount of changes included in the APR Stage III GTX Turbocharger System, APR’s Engineers spent months calibrating the engine management system, including hundreds of hours of in-house chassis dyno development. Drivability, gear changes, cruising and part throttle operation were tuned to operate smoothly as if intended by the OEM through proper torque management. Further development was performed putting the vehicle through performance evaluation and durability testing at the drag strip and road course. APR’s Electrical Engineers built new coding functions, strategies and routines into the ECU to control conditions normally unseen at factory power levels. Thanks to APR’s incredible proprietary calibration suite, data logging software and full access to the coding structure of the ECU, appropriate and intelligent changes are made to ensure flawless drivability and excellent performance without compromise.

Engine Calibration:

APR’s Calibration Engineers properly restructured the engine’s volumetric efficiency (VE) model to properly determine the ECU’s calculated load and deliver proper torque management. Thanks to APR’s patented boost control coding and the addition of a 3-Bar MAP sensor, the ECU is able to perform closed loop boost control well beyond relatively low limits dictated by the factory MAP sensor. This directly translates to safer and more predictable operation while additionally producing more power and torque across the entire power band.

Additionally, through the properly reconstructed VE model, accurate open loop fueling is achieved, translating to insignificant fuel trim adjustments. Closed loop fueling is calibrated to control lambda perfectly under all operating conditions. Furthermore, compensations, such as ones related to intake air temperature, exhaust temperature, and altitude, are adjusted to handle the larger variances compared to the factory, low output setup.

APR’s Calibration Engineers have optimized cam timing, ignition timing, engine load and lambda to provide tremendous leaps in power while retaining the OEM knock control strategy. The result is safely achieved power, optimized for various fuel grades found around the world from low quality pump fuel, all the way to high quality, oxygenated race fuels.

Torque Management and Traction Control:

Torque management plays a big role in how the vehicle feels and performs, especially during moments of low gear, rapid acceleration. Typically front wheel drive vehicles suffer from excessive wheel spin during these moments due to the massive torque on tap from the Stage III GTX Turbocharger System. Some drivers can find themselves in situations where they are fighting against wheel spin and traction control when they are simply interested in going forward as quickly as possible. This is further compounded by the fact the factory traction control (ASR) system was designed for vehicles producing far less power and torque, resulting in overcompensated ASR interventions.

APR’s Calibration Engineers set out to perfect torque management and traction control by minimizing wheel spin as much as possible without neutering the driving experience. A multi step approach was taken to achieve appropriate control. With ASR enabled, forward movement wheel spin will trigger appropriate torque intervention levels to minimize spin without hurting forward acceleration. On top of this, the torque management system is fine tuned to deliver only as much torque as the tires can take. In normal conditions the tires will only slightly break loose under full acceleration, resulting maximum acceleration. In higher traction situations, or with ASR disabled, all of the system’s torque is directly on tap!

While the end goal is similar, APR’s torque management system differs greatly from archaic “boost-by-gear” strategies. “Boost-by-gear” strategies rely on a static limitation of boost in an effort to minimize wheel spin, but to work properly they must be dialed in for every situation. The same boost levels in different weather conditions, such as a hot summer day and a cold winter month, can produce vastly different torque levels. Since APR’s torque management system relies on the engine management’s phenomenal torque reporting abilities, it is able to adjust to every environmental situation it encounters. To achieve a targeted torque level, the ECU applies the appropriate changes to mass airflow and ignition.

Acceleration Enhancements:

Through further calibration changes APR’s Calibration Engineers were able to increase the acceleration rate of the vehicle. Ignition delays are reduced resulting in a more responsive pedal without altering overall throttle sensitivity and resolution. Drivability was greatly improved by reducing the throttle lag commonly noticed at slow speeds and while reapplying throttle after decelerating. APR’s Motorsport Rev Limiter allows power to climb all the way to redline without dropping off several hundreds of RPM earlier. Lastly, APR’s tried and tested Motorsport Launch Limiter allows the driver to focus on launching the vehicle, rather than controlling the engine speed.

Part Throttle Drivability:

Beyond wide open throttle performance, APR’s Calibration Engineers spent countless hours optimizing vehicle drivability under daily, part-throttle, driving. The vehicle fully retains its impressive daily driver status and simply has more power on tap should the driver request more with his or her right foot!

APR EMCS and APR Mobile:

APR’s EMCS program switching technology and APR Mobile put control of the ECU in the operators hand to access modes for standard pump fuel, high output race fuel and even reduced output valet modes to protect the vehicle against improper use by other individuals. This technology is patented by APR and is found nowhere else in the world. It’s Performance Without Compromise only APR can deliver!

Turbocharger Manifold

Attached to the turbocharger is APR’s investment-cast, super alloy, nickel-chromium-based Inconel 625 Manifold featuring APR’s Sequential Exhaust Pulse runner lengths. Unlike hand welded tubular manifolds and other cheap cast materials such as iron, Inconel is a very high temperature resistant material designed to withstand extreme exhaust gas temperature changes without expanding, contracting, melting or cracking under stress. Furthermore, the thick casting material reduces unwanted exhaust noise. This material is typically found only at the highest levels of professional motorsport racing where reliability is essential to success.

Investment-cast Inconel features heat retention characteristics, which aid in turbo response by keeping the exhaust velocity high. APR’s Engineers designed variable runner lengths calibrated to deliver sequential exhaust pulses without collision. Along with the manifold’s T25 outlet, this aids in turbocharger spool, producing excellent response for immediate torque delivery. A reduction in backpressure from the high-flow, collision-free design directly enhances power delivery far beyond that of the OEM turbocharger manifold and other less effective designs. Backpressure reduction also alleviates most common valve float issues associated with high output factory s3gtx turbo upgrades and so called small “hybrid” s3gtx turbochargers.

Each unit undergoes strict quality control checkpoints to ensure ultimate reliability each step of the manufacturing process. The unit is CNC machined to tight tolerances and inspected for defects before being packaged and shipped to customers around the world.

All of these characteristics result in a manifold designed without compromise backed by a confidence-inspiring lifetime warranty.

Manifold Absolute Pressure Sensor

To provide closed loop boost control at absolute pressure levels above 2.5 bar, APR’s GTX Turbocharger System features an OEM Bosch 3 bar MAP sensor.

Altering the ECU to understand the engine is equipped with a 3 bar MAP sensor is a trivial task. The sensor and proper calibration settings come standard on many factory VAG vehicles, but even these vehicles only provide proper closed loop boost control up to 2.5 bar absolute.

APR’s electrical engineers went many steps beyond the norm and recoded the factory ECU to deliver closed loop boost control up to 3 bar absolute. This ability, combined with proper torque management, results in safe, reliable, and predictable performance at higher power levels without the need for clumsy and archaic external boost controlling devices.

Mass Air Flow Sensor Housing

The factory engine management relies on load calculations derived from the mass airflow (MAF) sensor to properly control the engine. All too often this critical component is eliminated from turbo upgrade kits as the factory unit is small and can easily become saturated. The alternative of upgrading the unit is often not used due to the complexity of doing so. However, no task is too large for APR’s Engineering Teams when the sake of reliability is brought into question, and as such APR has engineered a larger housing for use in the Stage III GTX Turbocharger System.

To aid in accurate airflow readings, the APR MAF housing features a long, precision-machined tunnel with a honeycomb airflow straightener. APR’s Electrical Engineers make appropriate coding changes to the ECU to understand the larger MAF housing while the calibration experts update the ECU with all of the necessary calibration data surrounding the larger housing’s physical properties. The end results are accurate readings and a further refined driving experience.

The MAF housing includes a CNC-bent mounting bracket for a sturdy connection to the engine bay and additional wiring and couplers are included to extend the factory MAF sensor’s harness.

Silicone Hoses

 

Wire reinforced, multi-ply silicone hoses provide an unrestricted path for airflow to enter and exit the turbocharger. The ultra rigid design ensures boost and vacuum piping will not swell or collapse causing leaks and restrictions in the induction and charge piping system supporting boost response and turbo recovery. Each hose is engineered to fit properly into the vehicle’s engine bay with all necessary emissions and reference ports securely affixed.

APR’s Easy-Flow Silicone Hose design features stepped mounting surfaces for smooth transitions from one pipe to another. Traditional designs simply sit on top of each other, often resulting in a disruptive airflow path. By using the stepped design, hoses fit properly without airflow restrictions, resulting in the most ideal path for moving air through the turbocharger and into the engine.

Oil and Coolant Lines

APR’s oil and coolant lines are specific to the APR Stage III GTX Turbocharger System and provide years of leak free operation. The lines feature a flexible braided stainless steel construction with CNC mandrel bent hard-lines for specific and clean routing as if intended by the OEM. Every detail is important, and APR goes the extra mile to ensure any possible weaknesses are eliminated.

Downturn and Downpipe

An investment cast 3” stainless steel downturn provides a smooth and uninterrupted path for exhaust gases existing the turbocharger at high velocity. The high temperature resistant stainless steel design increases the components strength without fear of component failure even under the most grueling environments.

APR’s 3-inch T304 stainless steel downpipe connects seamlessly to the supplied downturn and is fully compatible with APR’s turboback exhaust system, full downpipe, or midpipe exhaust system.

Diverter Valve Housing and Wastegate Solenoid Bracket

The factory turbocharger features a diverter valve (DV) and wastegate solenoid (N75) directly mounted on the compressor housing, which is removed for the more powerful APR Stage III GTX Turbocharger Unit. As such, APR provides a CNC-machined billet-aluminum DV housing and CNC-bent N75 bracket to conveniently relocate these items within the engine bay.

The DV housing is anodized clear to protect against corrosion and the internal mounting surface is precision machined identically to the OEM unit, to ensure a proper, leak proof design.

Vacuum Lines

APR provides new vacuum lines and T-junctions. Leak proof connections are easily achieved thanks to the included OEM style crimp clamps.

Gaskets

APR doesn’t cut corners even with the most mundane details of the kit. Every nut, bolt, stud, washer, clamp, and gasket necessary for the install is included with the kit.

Spark Plugs

To cope with raised cylinder pressure and temperature, four NGK Laser Platinum Premium plugs are included. The plugs operate at a heat range colder than stock, which results in better pre-detonation resistance under extreme conditions. With these spark plugs in, APR’s calibration engineers were able to safely achieve more power, especially in extremely demanding conditions.

Install Manual

Dyno Testing

Horsepower and Torque was measured in APR’s in-house, soundmaster dyno cell, using a dynapack all-wheel dynamometer. Multiple stock and modified runs were conducted and the SAEJ1349 corrected results were averaged together to represent the differences between a stock and APR Stage III GTX 2.0 TSI. Crank power figures were estimated based on VAG’s factory advertised results.

Click through the tabs below to view output using various fuel grades, power measured at all four wheels, estimated at the crank, and the absolute gain over stock.

91 Octane | 93 Octane | 100 Octane - Measured Front Wheel Horespower
91 Octane | 93 Octane | 100 Octane - Estimated Crank Horsepower
91 Octane | 93 Octane | 100 Octane - Gain over Stock

Calibration Report

Output:

200 HP & 207 FT-LBS of Torque – Stock as Rated by VAG
221 HP & 220 FT-LBS of Torque – Stock as Measured by APR
409 HP & 374 FT-LBS of Torque – APR Stage III GTX with 91 AKI or 95 RON fuel
423 HP & 387 FT-LBS of Torque – APR Stage III GTX with 93 AKI or 98 RON fuel
458 HP & 409 FT-LBS of Torque – APR Stage III GTX with 100 AKI or 104 RON fuel

Max Gains over Stock (based on APR’s CCTA/CBFA measured output):

+199 HP @ 6,700 RPM & +159 TQ @ 4,150 RPM – APR Stage III GTX with 91 AKI or 95 RON fuel
+212 HP @ 6,700 RPM & +174 TQ @ 4,150 RPM – APR Stage III GTX with 93 AKI or 98 RON fuel
+244 HP @ 6,700 RPM & +194 TQ @ 4,200 RPM – APR Stage III GTX with 100 AKI or 104 RON fuel

Requirements and Recommendations

Intake System
The Carbonio Stage I Intake is required.

Exhaust System
The APR Midpipe Exhaust System is required if the vehicle is not currently equipped with the APR Downpipe Exhaust System or APR Turboback Exhaust System. APR Recommends the APR Catback Exhaust System for maximum performance.

Intercooler System
The APR Intercooler System is required to meet the advertised power figures.

Transmission
The APR Stage III GTX Turbocharger System greatly increases torque over the factory output levels and as such, an upgraded clutch may be necessary to transmit power to the ground. APR highly recommends upgrading the factory clutch to one that suits the operator’s intended driving style.

Engine Internals
For increased reliability and longevity, especially on vehicles running race fuel and heavily tracked, APR recommends APR Connecting Rods and APR Mahle Pistons.

Tires
APR recommends Michelin PSS and PS2 tires as well as BFGoodrich Rivals and GForce Sport Comp 2 tires.

Fluids
APR recommends Motul Fluids and Lubricants.

Application Guides

Vehicles
Audi A3 (MK2)
Audi Q3
Audi TT (MK2)
Volkswagen Beetle
Volkswagen CC
Volkswagen Eos
Volkswagen Golf / GTI (MK5 / MK6)
Volkswagen Jetta / GLI / Bora / Vento / Sigitar (MK5 / MK6)
Volkswagen Passat / Magaton (B6)
Volkswagen Scirocco
Volkswagen Tiguan
Seat Altea
Seat Leon (MK2)
Seat Toledo (MK2)
Skoda Octavia / VRS (MK2)
Skoda Superb (B6)
Skoda Yeti

Engines
CAWA 2.0T EA888 Gen 1 Transverse (Pending: Beta Testing)
CAWB 2.0T EA888 Gen 1 Transverse (Pending: Beta Testing)
CBFA 2.0T EA888 Gen 1 Transverse
CCTA 2.0T EA888 Gen 1 Transverse
CCTB 2.0T EA888 Gen 1 Transverse
CCZA 2.0T EA888 Gen 1 Transverse (Pending: Beta Testing)
CCZB 2.0T EA888 Gen 1 Transverse (Pending: Beta Testing)
CCZC 2.0T EA888 Gen 1 Transverse (Pending: Beta Testing)
CCZD 2.0T EA888 Gen 1 Transverse (Pending: Beta Testing)

Transmissions
6 Speed Manual
S-Tronic
DSG

Drivetrains
Drivetrain
Front Wheel Drive
All Wheel Drive*

*Please note, AWD vehicles require an alternative AWD downpipe system and modification to the oil and coolant lines at the owner’s discretion.

System

APR Stage III GTX Turbocharger Systems
Part Number: T3100061
Price: $5,399.99
SALE: $4,859.99 <— Until May 4th.

APR Stage III GTX Turbocharger Upgrade System (For Existing APR Stage III GT2860RS or III+ GT3017R Customers) – Includes Software (REQUIRES 3BAR Map Sensor)
Part Number: T3100059
Price: $2,699.99
SALE: $2,429.99 <—- Until May 4th.

Motul Specific Lubricant Install Package

5 Liters of Motul Specific 505.01, 502.00 & 505.00 SAE 5w40 Oil, Oil Filter & 4 Liters of Inugel Optimal Ultra (Concentrated) – Organic
Part Number: MO00003
Price: $75.00

Motul 300V Lubricant Install Package

6 Liters of Motul 300V Power 5W40, Oil Filter & 4 Liters of Inugel Optimal Ultra (Concentrated) – Organic
Part Number: MO00007
Price: $105.00


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APR Spring Sale: April 7th – May 4th

Posted on April 7, 2014 – 9:00 am

The annual APR Spring Sale is upon us! Just about everything from APR featured in the Achtuning online store is ON SALE and IN STOCK now through May 4th, READY TO SHIP!! Begin shopping online or give us a call at 425-895-0000 to place your order. Immediate shipping/tracking results will be shared with you since we’re ready to ship your IN STOCK APR orders!!


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2014 Port Townsend Cruise Raffle Prizes

Posted on April 4, 2014 – 4:11 pm

Are you joining us THIS SATURDAY for the 2014 Port Townsend Cruise benefiting Seattle Cancer Care Alliance?

HANG ON to those 2014 Port Townsend Cruise raffle tickets that you pick up during the 9am roll-in at Pacific Raceways tomorrow morning! You will get one raffle ticket for every $10 donation towards Seattle Cancer Care Alliance. Raffle winners will be announced the following Wednesday, April 9th, right here as well as on the Port Townsend Cruise Facebook Page so STAY TUNED!

Raffle prizes include:
* APR ECU upgrade for Audi or Volkswagen (valued up to $1000!)
* H&R “Street Performance” Coilovers for Audi or Volkswagen
* H&R Front & Rear Anti-Sway Bars for Audi or Volkswagen
* StopTech Front & Rear “Street Performance” Brake Pad Set
* A FREE wheel alignment from ACHTUN!NG (x2)
* A FREE brake fluid flush from ACHTUN!NG
* A FREE oil change & tire rotation from ACHTUN!NG

… AND MORE STUFF STILL COMING!!

(Not sure what we’re talking about? Click here to learn more!)


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PTC2014: FREE swag from APR

Posted on March 19, 2014 – 9:00 am

APR just sent us this image of some APR goodies they are sending our way to hand out for FREE to 2014 Port Townsend Cruise participants!

Be sure you’re at Pacific Raceways at 9am on Saturday, April 5th for the pre-cruise activities! Achtuning will be handing out FREE swag from several of our favorite vendors just before the 10:15am driver’s meeting. See you there and GO APR!!


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PTC2014 Raffle Prize: APR ECU Upgrade!

Posted on March 18, 2014 – 9:00 am

ACHTUNING is giving away an APR ECU upgrade to one of our 2014 Port Townsend Cruise raffle winners, up to a $1000 value!!

Your minimum $10 cash donation benefiting Seattle Cancer Care Alliance will be collected by Port Townsend Cruise volunteers at Pacific Raceways as you enter Lot C, the start of the event. For every $10 cash donation you will receive a raffle ticket. PTC2014 raffle winners will be announced shortly after the cruise right here on porttownsendcruise.com so stay tuned! Can’t make the event but still want to donate for a chance to win? You can mail in your donation to Achtuning but it must be post-marked by the date of the event to be included in the raffle!

(See our FAQ page for detailed info re: mailing in your donation.)


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Carbonio Intake From APR For Volkswagen’s EA888 Gen 3 1.8/2.0

Posted on March 3, 2014 – 9:00 am

While the EA888 Gen 3 1.8 and 2.0 TSI found in Volkswagen’s GLI, Passat, and Beetle is is still new, our performance partners at APR have already come up with an intake solution and they are IN STOCK here at Achtuning!  Expect an APR claimed 12hp and 11 ft-lb of torque, a good amount of bang for your buck and a great compliment to that APR tune you’re considering. ;)

Application Guide:

  • 2013.5+ VW (Mk6) Jetta GLI | 1.8 TSI & 2.0 TSI EA888 Gen 3
  • 2013.5+ VW Beetle | 1.8 TSI & 2.0 TSI EA888 Gen 3
  • 2013.5+ VW Passat | 1.8 TSI & 2.0 TSI EA888 Gen 3

Achtuning Price:  $344.98 SHIPPED!  (FREE SHIPPING within the “lower 48″)


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APR 2.5 TFSI Pistons & Connecting Rods

Posted on January 15, 2014 – 9:00 am

APR has just released their proprietary light-weight, high-strength forged OEM profile MAHLE pistons and connecting rods for the 2.5 TFSI engine!

 

As the leader in high performance engine products for the Volkswagen Automotive Group, APR is capable of creating horsepower and torque levels outside of the original equipment’s stress tolerances. In such cases, it’s highly recommended and in some cases necessary to upgrade additional engine components to cope with the increased load. APR’s Connecting Rods raise the engine’s stress tolerance levels to provide years of continued reliable operation without compromise.

APR’s proprietary connecting rods feature premium, certified USA-Made 4330 alloy, chosen for its lightweight and high-strength properties compared to 4340 or other inferior alloys sourced from undisclosed locations around the world. To ensure the highest level of quality control, the entire process from initial design to finished product, including materials, forging, treating and 100% CNC machining all take place in the USA. APR only uses strict manufacturing guidelines in some of the finest manufacturing facilities in the industry to deliver unmatched quality and integrity with each rod produced.

Quick Facts

 - Tapered H-Beam Design - Strong weight saving design
 - 4330 Alloy Construction - High strength and light weight alloy
 - AMPCO 45 Bushing - Exceptional wear resistance
 - Wrist Pin Oil Passage - Additional wear resistance
 - Magnaflux Tested - Casting quality control
 - Rockwell Tested - Hardness testing
 - Diamond Honed - Surface finishes with consistent RA
 - Balanced to +/- 1 Gram - Increased reliability & performance
 - Tolerances to Factory Specs - OEM quality fit
 - Double Re-Melt Forging - Improves metal quality
 - Vacuum Heat Treated - Improves strength
 - Surfaced Peened - Improves fatigue strength
 - Cryogenically Treated - Improves strength
 - 100% USA Certified Alloys - Improves quality and control
 - 100% Made In the USA - 100% Made In the USA
 - Tapered Wrist Pin - Additional weight savings
 - Drop-In Compatibility - Works with no other modifications
 - ARP2000 Hardware - High quality and strength bolts

The connecting rod is designed to handle power levels far beyond the original component’s ratings in order to ensure reliability with years of continued use. Increasing rod strength often comes at the expense of increased weight, which ultimately reduces engine efficiency. To generate a balance between strength and weight, APR tested and analyzed several designs in addition to using premium alloys, advanced forging techniques and multiple strengthening treatments. APR’s Engineering Team’s design requirements resulted in a tapered H-beam design, offering exceptional strength due to the H design and weight savings from tapering, a trait most commonly associated with an A design.

We call it Performance Without Compromise.

Weights and Application

MS100070 – 2.5 TFSI – CEP – 22mm Wrist Pin – 501g Including Hardware – Drop In Rod for OEM Piston or APR’s Mahle Motorsport Pistons

  

The wrist pin end of the rod features a wear resistant bushing material made from AMPCO 45 – a high strength alloy with mechanical properties beyond that of commercial nickel-aluminum bronzes. Wear reduction is further enhanced via a pin lubrication access point at the top of the rod, feed by the engine’s oil squirters. For further weight reduction and drop in rod compatibility with OEM and APR pistons, the wrist pin end is tapered.

When modifying an engine for strength and longevity, quality is of the utmost importance. APR’s Engineering teams have ensured each rod is created with absolute quality and control in mind each step of the way. Tolerances are kept to OEM specs and the rods are balanced to within +/- 1 gram. Furthermore the rods undergo rigorous tests to backup the entire manufacturing process. Rockwell testing provides a method for testing hardness while Magnaflux or Magnetic Particle Inspection, offers a method for detecting interruptions in the physical continuity of the casting. The result is a product you can trust.

Mahle Motorsport VP2 Rod Bearings

When upgrading connecting rods, it’s necessary to replace the existing connecting rod bearings. APR recommends using Mahle Motorsport VP2 rod bearings for their superior strength and wear resistance properties and attention to detail over the similarly priced OEM bearings.

Each bearing is capable of taking abuse in the magnitude of 14,500 psi while still offering superior conformability and fatigue resistance not commonly seen elsewhere in the market. This is partially due to the bearing’s high-grade hardened steel backing with bronze substrate and lead/indium overlay. Laser etched part numbers rather than typical stampings aid in significantly improved heat transfer and prevention of shell distortion. Formula 1 standards dictate extremely high tolerances, while Mahle’s attention to detail and chose of fine materials ensure worry free operation.

Mahle Motorsport German Tool Steel Wrist Pins

For ultimate strength and reliability, APR recommends upgrading to Mahle’s German tool steel wrist pins while upgrading connecting rods. If ordering APR’s Mahle Motorsport Pistons, wrist pins are included.

Application Guides

Connecting Rods Set – MS100070 – $1,299.99 – 2.5 TFSI – CEP – 22mm – 501g including hardware – Drop In for OEM Piston or APR’s Mahle Motorsport Pistons

Mahle Motorsport VP2 Rod Bearing Set – Z1002377 – $199.99

Mahle Motorsport German Tool Steel Wrist Pin Set – MS100074 – $159.99 – 22mm
Set of 5. If ordering APR Pistons, replacement wrist pins are included.

APR’s proprietary light-weight, high-strength forged OEM profile MAHLE pistons for 2.5 TFSI engines

The introduction of direct injection played a significant role in piston combustion bowl design. The profile ultimately affects the swirl and tumble of the air/fuel mixture making the design critical for the most efficient use of the fuel. APR worked with MAHLE, a VAG Tier 1 supplier for OEM pistons, to design a proprietary piston sharing the OEM profile along with other strength and weight saving properties.

Quick Facts

  • Forged pistons
  • Proprietary APR / MAHLE design
  • Proprietary MAHLE 142S alloy
  • Low noise materials
  • Low thermal expansion for tighter tolerances
  • OEM piston compression bowl profile
  • 83mm oversized design
  • 10.1:1 compression ratio
  • MAHLE 22mm German tool steel wrist pins included
  • MAHLE low-drag rings included
  • Top – Barrel-Faced Steel (File to Fit)
  • Second – Tapered Face Ductil Iron (File to Fit)
  • Oil Rings – 3 Piece Standard Tension
  • 320 grams per piston
  • Hard anodized top ring grooves to prevent micro-welding
  • MAHLE proprietary Grafal anti-friction coated skirts
  • OEM oil squirter notches
  • First landing accumulator grooves for top ring seal promotion
  • Ultra flat ring grooves for ring seal promotion

  

The piston is designed to handle power levels far beyond the original component’s ratings in order to ensure reliability with years of continued use. Increasing piston strength often comes at the expense of increased weight, which ultimately reduces engine efficiency. To generate a balance between strength and weight, APR pistons are forged from MAHLE’s proprietary 142S alloy and treated with other MAHLE proprietary coatings. This material is stronger than the common 4032 alloy, provides quieter operation than 2618 alloy and maintains tighter piston to cylinder wall clearances thanks to the material’s low expansion rates. The piston’s grey phosphate coating acts as a dry lubricant to protect against galling and micro-welding while MAHLE’s proprietary Grafal skirt coating reduces drag, scuffing, friction, wear and noise.

To maintain the OEM piston profile, compression is raised roughly .1 due to the half mm overbore. APR’s engineering teams chose the 10.1:1 compression ratio after spending several years testing the affects on knock tolerance and off-boost operation from different ratios on VAG direct injection engines. APR explored altering the compression ratio, but were unable to locate any advantages in doing so.

APR pistons are designed for 83mm bore diameter, a half millimeter over the OEM units and as such are not drop in compatible. The larger piston diameter provides in an increased engine displacement from 2,480 cc to 2,511 cc. The slight increase in displacement and reduction in friction provided by the included high-performance, low-drag rings frees up horsepower. To remove any imperfections in the cylinder walls and to provide a new, compatible sealing surface for the upgraded rings, a first overbore must take place. APR does not recommend drop in pistons at this level of internal engine modification.

APR pistons include upgraded 22mm German tool steel wrist pins for ultimate strength and reliability.

The pistons are fully compatible with APR’s MS100070 connecting rods.

APR Piston Application Guide

APR Mahle Piston Set – MS100069 – $1,099.99 – 2.5 TFSI – CEP – 22mm wrist pin – 320g – 83 mm diameter


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The NEW APR Stage 3+ Supercharger Kit for the B7 Audi RS4!

Posted on January 6, 2014 – 9:00 am

APR has debuted their Audi (B7) RS4 4.2L FSI V8 Stage III+ TVS1740 Supercharger System!

Achtuning is pleased to present APR’s NEW Audi (B7) RS4 4.2L FSI V8 Stage III+ TVS1740 Supercharger System!  Since the release of the B7 RS4, Audi’s technological advances on RS models have grown dramatically. However, this often came along with the removal of traditional manual 6-speed transmissions many RS owners have grown to love. APR quickly realized the RS4 represented one of Audi’s last great performance sedans and chose to continue advancing the platform more than half a decade after the last RS4 rolled off the production line.

APR’s technical reach has grown enormously since opening in the 1990’s and currently represents a force of unmatched performance without compromise in the performance enhancement sector for Audi vehicles. Their previously available APR Stage III TVS1320 Supercharger System found its way on to several hundred RS4s around the world, making it the most popular and reliable system on the market. With more than four years’ worth of RS4 supercharger engineering research, development and testing, APR’s new Stage III+ TVS1740 Supercharger System represents the pinnacle of Audi’s German engineering enhanced by APR’s American ingenuity.

In the factory form, Audi’s older high revving FSI V8 leaves much to be desired compared to some of the latest technological advances brought forth by Quattro GmbH in recent years. The APR Stage III+ TVS1740 Supercharger System fills the void by adding an average of roughly 40% more horsepower and torque across the entire power band. The results are nothing short of amazing; taking the RS4 from 414 horsepower to 626 horsepower on pump fuel and 688 on race fuel without breaking a sweat! With more than 500 FT-LBS on tap thanks to the TVS1740’s positive displacement supercharger expect instant acceleration with absolutely no lag commonly associated with other forms of forced induction.

APR Stage III+ TVS1740 Supercharger Components

Supercharger and Manifold

 

At the heart of the APR Stage III+ Supercharger System is Eaton’s latest Twin Vortices Series (TVS) supercharger unit, the TVS1740. The supercharger system is a positive displacement, roots style pump, utilizing Eaton’s lightweight, four-lobe 160 degree twisted rotors. Cast and assembled as a single, OEM-style-manifold and rotating group housing, the unit is quiet, compact, attractive, easy to install, and requires little to no extra maintenance to the unit itself.

The positive displacement supercharger offers power instantly as the throttle is pressed. Boost pressure builds with no perceived lag commonly associated with other types of forced induction, and provides a large increase in torque across the entire power band. Throttle control is linear and predictable and makes for an excellent driving experience both in daily driving and wide-open acceleration.

 

Since the supercharger does not compress air as it moves through the roots, it’s extremely efficient during light throttle and cruising situations. Unlike screw-type positive displacement superchargers that are always compressing, the TVS unit can internally bypass unwanted air, resulting in negligible parasitic loss during cruising and thus far greater fuel economy.

The single cast unit and appropriately sized rotating group eliminates potential leak points and allows for a slim, compact design without sacrificing key airflow design characteristics. The unit features a high velocity flow path through the supercharger rotors and an unrestricted discharge port into the appropriately sized plenum. The large plenum equalizes flow across all ports as air feeds evenly through the low-pressure-drop, dual-internal air-to-water heat exchangers. Finally, the ports are separated into individual runners, offering greater operation by eliminating cross talk.

Internally the dual heat exchangers offer technological advances shared by Formula 1 teams around the globe. Each unit features a louvered fin design, which minimizes pressure drop while achieving excellent cooling effectiveness. The extruded multi-rib tubing maximizes heat extraction to be carried away through the large bore coolant recirculation hard lines. Externally, supercharger coolant is pumped through a large front mounted heat exchanger where it’s cooled and circulated back through the charger again.

Engine Management

 

The factory Bosch MED 9 engine management system is responsible for proper operation of the engine during constantly changing environmental and load conditions. With built in compensational data for environmental variables and varying load conditions, the factory ECU is far more complex and intelligent than units found in other vehicle makes and marques.

With the significant amount of changes included in the APR Stage III+ TVS1740 Supercharger System, APR’s Engineers spent months calibrating the engine management system, including well over 100+ hours of in-house chassis dyno development. Drivability, gear changes, cruising and part throttle operation were tuned to operate smoothly as if intended by the OEM. Further development was performed putting the vehicle through performance evaluation and durability testing at the drag strip. APR’s Electrical Engineers built new coding functions, strategies and routines into the ECU to control conditions normally unseen at factory power levels. Thanks to APR’s incredible proprietary calibration suite, data logging software and full access to the coding structure of the ECU, appropriate and intelligent changes are made to ensure flawless drivability and excellent performance without compromise.

Adding forced induction to a naturally aspirated engine presents several challenges with regards to how the ECU operates. APR’s Calibration Engineers properly restructured the engine’s volumetric efficiency (VE) model to properly determine the ECU’s calculated load. Accurate open loop fueling is achieved, translating to insignificant fuel trim adjustments. Closed loop fueling is calibrated to control lambda perfectly under all operating conditions. Furthermore, compensations, such as ones related to intake air temperature, are adjusted to handle the large temperature variances compared to a factory naturally aspirated setup.

APR’s Calibration Engineers have optimized cam timing, ignition timing and lambda to provide tremendous leaps in power while retaining OEM knock control sensitivity. The result is safely achieved power, optimized for various fuel grades found around the world from low quality pump fuel, all the way to high quality, oxygenated race fuels.

 

Beyond power and torque enhancements, APR’s Calibration Engineers were able to increase the acceleration rate of the vehicle through other calibration changes. Ignition delays are reduced resulting in a more responsive pedal without altering overall throttle sensitivity and resolution. Drivability was greatly improved by reducing the throttle lag commonly noticed at slow speeds and while reapplying throttle after decelerating. APR’s Motorsport Rev Limiter allows power to climb all the way to the factory set redlines without dropping off several hundred RPMs earlier. And lastly, APR’s tried and tested 4,200 RPM Motorsport Launch Limiter allows the driver to focus on launching the vehicle, rather than controlling the engine speed.

Beyond wide open throttle performance, APR’s Calibration Engineers spent countless hours optimizing vehicle drivability under daily, part-throttle, driving. The vehicle’s pedal maps are recalibrated under both standard and sport mode, providing smooth part-throttle drivability without compromising the driveshaft windup protection. The vehicle fully retains its impressive daily driver status and simply has more power on tap should the driver request more with his or her right foot! We call it Performance Without Compromise.

Front Mount Heat Exchanger

APR’s supercharger system features a large, 310mm x 540mm x 42mm, front mount heat exchanger responsible for cooling coolant as it’s pumped out of the supercharger’s dual internal air-to-water heat exchangers. This is a critical component in any supercharged application to not only keep power consistent, pull after pull, but also to help keep IAT below dangerously high levels. The heat exchanger is specific to the RS4 platform, featuring a hand welded design and CNC, laser-cut brackets to provide a simple and clean method of mounting to the vehicle.

Coolant Pump and Harness

APR’s coolant pump connects to the supercharger coolant circuit and continuously circulates coolant through the supercharger’s dual internal air-to-water radiators and APR front mount heat exchanger. The pump provides adequate coolant flow through a system of this size. The pump seamlessly connects to the factory wiring harness through the included APR wiring harness with no wire splicing and is triggered by the included relay system. APR’s CNC, laser-cut bracket provides a simple and clean method of mounting the pump to the vehicle.

High Pressure Fuel Pumps

 

Sold separately as brand new pumps or rebuilds of the engine’s existing pumps, the APR High Pressure Fuel Pumps address fueling needs and leaves plenty of headroom for safety and further increased power levels. By increasing the pump’s internal capacity, the fueling system is capable of displacing a higher volume of fuel per minute at every RPM.

Coolant Expansion Tank

The APR coolant expansion tank is used for filling the supercharger’s cooling circuit and for handling liquid expansion under various operating temperatures. The tank is cut from a single block of aircraft grade 6061 aluminum billet, is anodized black and proudly displays the APR logo. APR’s CNC, laser-cut bracket provides a simple and clean method of mounting the expansion tank to the engine bay.

Throttle Body Hose and PCV Bracket

A wire reinforced, multi-ply silicon hose is provided to connect the throttle body to the intake housing. The ultra-ridged design ensures the hose will not collapse under the tremendous vacuum created by the supercharger system’s forced induction. The hose is engineered to fit properly into the engine bay with the necessary ports securely affixed by OEM style crimp clamps.

A laser-cut, CNC-bent, PCV hose bracket with retained fasteners is provided to secure the factory PCV pipe to the repositioned throttle body.

Fueling Hardware

 

APR’s supercharger system varies greatly from the OEM intake manifold design, and for fitment’s sake, the factory high pressure fueling system must be modified. The fuel rails and other high pressure and low pressure direct injection fuel lines are replaced with new, low profile, OEM parts. All OEM safety equipment remains intact.

An APR high-pressure rail relief valve allows the system to operate at greater rail pressures, resulting in a reduction of injection on-time which translates to more ignition advance and greater power.

The kit also includes all new high-pressure fuel pump low-pressure fittings, replacement injector O-rings, and OEM style extension harnesses requiring absolutely no splicing of the factory harness.

Spark Plugs

To cope with raised cylinder pressure and temperature, eight NGK Iridium IX spark plugs are included. The plugs operate at a heat range colder than stock, which results in better pre-detonation resistance under extreme conditions. With these spark plugs in, APR’s calibration engineers were able to safely achieve more power, especially in extremely demanding conditions.

Intake Air Temperature Sensor and Harness

The factory mass airflow sensor includes an intake air temperature (IAT) probe and is designed to provide the engine control unit (ECU) with air temperature information. Because the RS4 is converted from naturally aspirated to forced induction, the sensor must be relocated to ensure proper IAT measurement. The IAT sensor is absolutely critical for safe, reliable and powerful operation and as such, APR provides an OEM sensor and harness for placement just past the supercharger’s dual internal air-to-water radiators. The included harness allows for simple integration into the OEM wiring harness.

The sensor feeds correct IAT readings to the ECU, which provides closed loop control over various calibration decisions, such as desired ignition advance. This provides safe operation no matter what the condition. During a cold day, with lower supercharger coolant temperature, the ECU will safely increase engine output mainly through ignition. However, under hot conditions, such as a vehicle seeing plenty of track time, the ECU will compensate for these conditions, lowering output slightly to avoid dangerous premature detonation. These compensations result in only attempting to safely achieve the maximum amount of power capable during any given temperature related scenario.

Coolant Lines

 

The APR Supercharger System features dual internal air-to-water radiators designed to reduce intake air temperature, (IAT), before entering the cylinders. With cooler IAT, the ECU will request more ignition advance and result in more power.

APR reinforced rubber coolant lines feed the Supercharger’s internal cooling system, which provides a circuit between the included APR front mount heat exchanger, APR coolant pump and APR expansion tank.

All necessary brass connectors, spring-loaded clamps and OEM style crimp clamps are included.

Fuel Lines

To accommodate the large APR Supercharger, modifications are made to the low-pressure fueling system and evap lines. Each fuel line exceeds CARB and EPA ratings and includes a patent-pending GreenShield barrier. The multi-ply, reinforced rubber hoses are designed to protect against today’s modern deteriorating fuels and include a best-in-class working psi of 225.

OEM style spring clamps and crimp clamps are included to ensure a solid connection. To help provide a neat and appealing install and assist in abrasion resistance, nylon braid hose cover and shrink-wrap is included.

Vacuum Lines

To accommodate the transition from naturally aspirated operation to forced induction, APR provides new vacuum lines and T-junctions. Leak proof connections are easily achieved thanks to the included OEM style crimp clamps.

Pulleys and Belt

The supercharger system’s internal rotors are rotated via a belt and pulley attached to the engine’s accessory drive system. The included 5pk belt and OEM idler pulleys ensure a proper connection to drive the supercharger.

N80 Harness

Several OEM components are moved during the install of the supercharger system, and as such, APR provides an OEM style extension harness to connect components without modification to the factory wiring harness.

Gaskets

New OEM gaskets and bolts are provided to facilitate a leak proof connection between the cylinder heads and APR Supercharger unit.

Misc. Hardware

The included core support bolts allow the vehicle’s front end to be placed into the service position. In doing so, the install process is made much easier thanks to the added space in the engine bay.

The included factory style zip-ties aid in securing various lines moved during the install and to replace factory zip-ties removed during the install process.

Padding material protects items from damage during the install process.

Install Manual

APR has a worldwide network consisting of many professional shops capable of performing an APR supercharger system install. To accompany APR’s world-class technical support hot line, APR includes a full, printed, step-by-step install manual to make the install process smooth and simple!

Dyno Testing

Horsepower and Torque was measured in APR’s in-house, sounmaster dyno cell, using a dynapack all wheel drive dynamometer. Multiple stock and modified runs were conducted and the SAEJ1349 corrected results were averaged together to represent the differences between a stock and APR Stage III+ B7 RS4. Crank power figures were estimated based on Audi’s factory advertised results.

Click the links below to see power output at the wheels, estimated at the crank and with different octanes

91 Octane | 93 Octane | 100 Octane - Measured All Wheel Horespower
91 Octane | 93 Octane | 100 Octane - Estimated Crank Horsepower
91 Octane | 93 Octane | 100 Octane - Gain over Stock

APR Stage III+ TVS1740 Supercharger System Calibration Report

Output:

414 HP & 317 FT-LBS of Torque – Stock as Rated by Audi
418 HP & 322 FT-LBS of Torque – Stock as Measured by APR
606 HP & 515 FT-LBS of Torque – APR Stage III+ with 91 AKI or 95 RON fuel
626 HP & 529 FT-LBS of Torque – APR Stage III+ with 93 AKI or 98 RON fuel
688 HP & 562 FT-LBS of Torque – APR Stage III+ with 100 AKI or 104 RON fuel

Max Gains over Stock:

+223 HP @ 7,900 RPM & +215 TQ @ 4,400 RPM – APR Stage III+ with 91 AKI or 95 RON fuel
+243 HP @ 7,900 RPM & +228 TQ @ 4,300 RPM – APR Stage III+ with 93 AKI or 98 RON fuel
+305 HP @ 7,900 RPM & +261 TQ @ 4,350 RPM – APR Stage III+ with 100 AKI or 104 RON fuel

Acceleration Testing

All too often performance upgrades show improvements during a single dyno pull, but lack the ability to show the same performance in real world conditions. Furthermore the dyno may be unable to illustrate the system’s response and other tuning changes designed to make the system instantly react to the drivers input. Through acceleration testing, APR’s engineers were able to improve power delivery during launches, after gear changes and prove the cooling system was up to the task of sheading heat to keep power consistent.

APR’s local certified quarter mile drag strip is a perfect and safe testing ground for high speed, 130+ MPH sprints. Using Car and Driver magazine’s measured results as a benchmark, APR’s Engineers setout to prove the Stage III+ Supercharger System was capable of increasing the RS4’s performance substantially.

Car and Driver magazine measured the B7 RS4’s sprint from 30-130 MPH in an underwhelming 17.2 seconds. However, with the addition of the APR’s Stage III+ TVS1740 Supercharger System, the vehicle entered a league of performance often shared by exotic supercars. Using 93 octane fuel the same acceleration test was completed 6.64 seconds faster! Through testing higher octane fuels, and eventually weight reduction and tire changes, the gap grew even larger, ultimately resulting in an astonishing 48.2% reduction in time.

Many more acceleration tests were preformed, including record setting quarter mile passes, proving an APR Stage III+ TVS1740 Supercharger System is the ultimate upgrade for B7 RS4!

60-120 MPH

11.4 – Stock (Car & Driver Magazine)
6.91 – APR Stage III+ – Full Weight with Street Tires and 93 AKI Fuel
6.31 – APR Stage III+ – Full Weight with Street Tires and 100 AKI Fuel
5.93 – APR Stage III+ – Reduced Weight & Drag Slicks and 104 AKI Fuel

60-130 MPH

14.3 – Stock (Car & Driver Magazine)
8.62 – APR Stage III+ – Full Weight with Street Tires and 93 AKI Fuel
7.92 – APR Stage III+ – Full Weight with Street Tires and 100 AKI Fuel
7.37 – APR Stage III+ – Reduced Weight & Drag Slicks and 104 AKI Fuel

30-130 MPH

17.2 – Stock (Car & Driver Magazine)
10.56 – APR Stage III+ – Full Weight with Street Tires and 93 AKI Fuel
9.77 – APR Stage III+ – Full Weight with Street Tires and 100 AKI Fuel
9.08 – APR Stage III+ – Reduced Weight & Drag Slicks and 104 AKI Fuel

Quarter Mile Best Trap and ET

13.2 @ 109 MPH – Stock (Car & Driver Magazine)
11.1 @ 125 MPH – APR Stage III+ – Full Weight with Street Tires and 93 AKI Fuel
11.0 @ 129 MPH – APR Stage III+ – Full Weight with Street Tires and 100 AKI Fuel
10.6 @ 131 MPH – APR Stage III+ – Reduced Weight & Drag Slicks and 104 AKI Fuel

Requirements and Recommendations (Each Sold Separately)

APR High Pressure Fuel Pumps

The APR HPFPs expands the 4.2L FSI V8′s direct injection fueling capabilities to the levels required for proper operation with the APR Stage III+ TVS1740 System. Because the pumps are sold in two different forms, they are offerd seperately from the kit. Entirely new pumps can be purchased, or the vehicle’s existing pumps can be sent to APR for a rebuild at a discounted rate. This product is required.

Transmission

The APR Supercharger System greatly increases torque over the factory output levels and as such, an upgraded clutch may be necessary to transmit power to the ground. APR highly recommends upgrading the factory clutch to one that suits the operator’s intended driving style.

Induction System

The APR Supercharger System was designed using the factory intake system and OEM mass airflow sensor (MAF) housing. APR recommends a new OEM or high flow intake filter for optimal performance. An intake port carbon cleaning is necessary to meet advertised power levels.

Exhaust System

The APR Supercharger System was designed for operation with the either the factory exhaust system or a high flow exhaust system. APR recommends 2.75” high flow downpipes for optimal performance.

Motul Fluids and Lubricants

Maintaining the vehicle’s fluids and lubricants is necessary to enjoy years of worry free operation. APR highly recommends Motul’s product range.
Application Guide and Price

Vehicle – B7 RS4 4.2L FSI V8 (Sedan, Avant or Cabriolet)
System – APR B7 RS4 4.2L FSI V8 Stage III+ TVS1740 Supercharger System – Includes Software
Part Number – T3100052
Price – $17,749.99

Motul Oil, Coolant and Oil Filter

 

During the install, oil and coolant must be drained and should be replaced to offer superior performance and protection. The APR Supercharger Systems are now complete turnkey solutions, including everything you need down to the oil, coolant and oil filter. During checkout you’ll be given the option between Motul Specific 502.00, 505.00 & 505.01 5W40 or Motul Power 300V engine oil as well as Motul Inugel Optimal Ultra Coolant and an OEM oil filter. The Premium Motul lubricant package is included at a much lower than retail price point and the costs are listed below.

MO00004 – $95.00 – 10 Liters of Motul Specific 505.01, 502.00 & 505.00 SAE 5w40 Oil, Oil Filter & 2 Liters of Inugel Optimal Ultra (Concentrated) – Organic
MO00008 – $130.00 – 10 Liters of Motul 300V Power 5W40, Oil Filter & 2 Liters of Inugel Optimal Ultra (Concentrated) – Organic

 


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