APR’s 4.0T Cast Downpipes and Stage 2 ECU Upgrade

Posted on March 28, 2016 – 9:00 am

The APR 4.0T Cast Downpipe Exhaust System replaces the restrictive factory catalyst cross pipes and resonators with an upgraded 76mm stainless steel mandrel-bent system, featuring port-matched cast inlets, high-flow catalysts and various other features. Expect better throttle response, more horsepower and an intoxicating exhaust note, while remaining civilized during normal daily driving. It’s the best performance upgrade for the 4.0 TFSI following the APR ECU Upgrade and it’s all designed and assembled in-house, using premium materials and world-class manufacturing techniques few can match.


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Quick Facts

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More power and better response
Expect a decrease in turbo lag with power and torque gains as high as 49 HP and 95 FT-LBS of torque over APR Stage I!

Full 76mm downpipe system
The APR system is a full downpipe upgrade as it replaces the kinked 60mm catalyst cross pipes and resonated midpipes with straight through, 76mm mandrel-bent tubing.

Port-matched investment-cast downpipe inlets
The factory inlets are restrictive. APR’s cast system allows for massive, port-matched inlets that smoothly neck down over a long distance. The result is improved flow, better response and more power.

Dual, high-flow catalysts
GESI’s encapsulated catalysts are known for their strength and performance. Expect lower emissions, reduced noise and less exhaust smell compared to catless setups, all without negatively impacting performance to over 1,000 HP. Furthermore, with the catalyst moved, expect a cooler engine bay!

T304L stainless steel construction
Premium grade T304L stainless steel resists corrosion and stands the test of time.

Argon back-purged TIG welding
Clean, strong and attractive welds both inside and outside the pipes.

OEM-style low-profile slip-on clamps
The APR slip-clamps are easy to use, resist leaks and pipe deformation better than swedged setup, are lower profile than vbands and flanges and don’t require replacement gaskets.

OEM-style internally-corrugated flex sections
APR’s flex sections are internally corrugated to increase flow and prevent failures common with braided flex sections.

Investment cast secondary oxygen sensor bungs
APR’s obsession to details resulted in investment cast oxygen sensor bungs that sit on top of the piping, preventing material from protruding into the exhaust stream, disrupting flow.

Compatible with the OEM catback exhaust
Bolt-on and go! The system is fully compatible with the factory catback exhaust.

Designed, assembled and quality controlled in-house
All critical aspects of the system are handled internally to ensure the highest quality fit and finish.

All hardware and instructions included
New OEM gaskets, oxygen sensor harnesses, clamps, brackets and install instructions are included to make the install as headache free as possible.

APR Stage II ECU Upgrade price waived
With every APR downpipe purchase comes a free upgrade to Stage II from Stage I, saving consumers hundreds of dollars!

Limited lifetime warranty
The best system on the market also carry the best warranty in the industry!

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Cast Downpipes Inlets with 76mm Tubing

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The factory downpipes are less than desirable from a performance standpoint. Both pipes quickly neck down from the massive turbocharger outlet to small and resistive 60mm pipes that are kinked in many areas before twisting and dumping into catalytic converters. APR greatly improved upon this design through the use of investment-cast and port-matched downpipe inlets. Each pipe gradually reduces to the larger and straighter 76mm piping, with the hot catalyst moved further down the exhaust stream to keep under hood temperature down. The photos illustrate the differences between the factory and APR exhaust system inlets.

The cast inlets, piping and other components are made from the the high-nickel content, premium-grade stainless steel known as T304L. This material was chosen for its excellent corrosion resistance, strength and appearance. The castings are tumbled to smooth and de-burr any imperfections, and all piping is brushed clean before entering the CNC controlled mandrel benders. TIG welding is used at all connection points, and was chosen for its strength and appearance. Each weld is argon back purged during assembly to increase strength and consistency of the welds. The gusseted brackets are CNC laser cut and bent to provide strong mounting points to the factory mounting hardware.

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76mm Midpipes with Catalyst

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The APR midpipes replace the kinked factory 60mm resonator pipes with new, 76mm mandrel-bent T304L stainless tubing, complete with OEM style low-profile flex sections, GESI catalysts, investment cast O2 sensor bungs, and reducers. The pipes mate perfectly to the factory catback exhaust system without any modification necessary. All connection points use APR’s OEM style slip clamps providing the ultimate in compatibility, performance and easy of install compared to flanges, v-bands and pipe deforming sedges and slip fits common on other systems.

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Flex Sections

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The APR midpipes use OEM-style flex sections that are fully sealed with a corrugated inner lining to improve flow and reliability. The low profile design and minimal use of bradding material eliminates clearance issues common with other designs that can billow, rub, rattle and fray over time. Each flex section is constructed from T304L stainless steel.

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Catalytic Converters

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APR’s engineers specified high-quality and high-flow GESI metal 300-cell catalysts ideal for forced induction application. During dyno testing, the 100mm x 100mm design showed no measurable loss in power, thanks to the catalyst’s specifications.

Internally the catalytic converters feature a proprietary wash coat that helps to reduce emissions and smell common on cat-less setups. With performance in mind, the catalysts are placed far away from the turbo outlets to reduce turbulence in the downpipes and to help reduce under-hood temperature. The low-profile catalysts feature fully captured substrate bricks, which are furnace braised to the outer mantles and physically captured by the diffuser cones preventing rattling, rotation, and damage to the substrate. Subsequently, a byproduct of running the catalysts are a reduction in noise, making the system as a whole more pleasing to the ear.

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Clamps

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APR’s engineers specified a T304L stainless steel, OEM-style exhaust clamp designed to eliminate the need for flanges, swedging, or slip fittings. By using this low profile design, the exhaust system can be positioned higher in the exhaust tunnel and away from the ground with better clearances compared to flanged setups. Each clamp allows for less turbulence and greater accuracy at the connection points as the pipes simply butt up to one another rather than the ambiguity and voids associated with swedged slip fittings. Furthermore, the clamp doesn’t rely on deforming the pipe to provide a tight seal, making install and removal more convenient.

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Oxygen Sensor Bungs

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APR’s Engineers paid special attention to the details when designing the APR Cast Downpipe Exhaust System all the way down to the oxygen sensor bungs. APR’s O2 bungs are investment cast from T304L stainless steel and are curved to perfectly fit on 76mm piping, without protruding into the pipe, as this would further impede airflow beyond the sensor itself. The bungs are TIG welded to the piping and back-purging is used to ensure the interior surface is smooth and clean.

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Oxygen Sensor Harness

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Two high quality oxygen sensor extension harness are included as the catalysts and sensor bungs are relocated further away from the turbochargers.

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Gaskets

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Included with each system is an OEM gasket, designed to mate between the downpipe and the turbocharger.

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Dyno Testing

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APR saw gains ranging from +25 to +71 Horsepower and +32 to +95 FT-LBS of Torque, depending on application and octane, over the APR Stage I ECU Upgrade.

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The APR Difference: The Engineering and Designing Phase

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In the past APR worked with other manufacturers to develop a limited range of private-label exhaust systems outside the scope of APR’s internal development and manufacturing capabilities. Understanding the limits of such a program, combined with APR’s desire to deliver higher-quality products in a timely manner with better customer support, APR invested in internalizing the program. With the release of this exhaust system and the others like it, APR is pleased to present our first systems fully designed and engineered in-house from the ground up!

Design and development begins with the use of APR’s professional grade in-house coordinate measuring machines. APR’s engineers have full access to a Romer Absolute arm with integrated laser scanner, FaroArm and Creaform 3D laser scanner for collection of special constraints surrounding the factory exhaust system. The engineers scan the vehicles and create detailed 3D maps of their design environment while designing each system in PTC Creo 3.0 CAD software.

Using APR’s in-house stereolithography 3D printer, rapid prototypes are created for fitment on the vehicle. The design is easily and quickly verified, and if necessary, changes can be made. Once adequate clearances and fitment is confirmed, especially in areas that move under load, physical quick-cast prototypes are created and fitted for final verification through real-world use.

APR’s world-class manufacturing partners from around the globe are responsible for manufacturing each component that falls outside of APR’s internal capabilities. Working closely with each manufacturer, APR’s engineers supply CAD models, materials specs, and other design specifications and work hand-in-hand with the manufacturer to develop the components. The end result is a collection of components, wholly unique to the APR name, awaiting final finishing, assembly and quality control at APR’s 78,000 square foot facility in Opelika, Alabama in the USA.

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The APR Difference: The Fabrication, Finishing and Assembly Phase

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Manufacturing takes place both internally and externally to APR while finishing and assembly is completed in-house. APR’s fabrication team sends each cast component through the ceramic vibrating tumblers to smooth and de-burr surface imperfections. Each component is then cleaned by hand and prepared for assembly.

APR’s fabrication experts TIG weld each component, creating reliable, high quality and attractive welds. Each component is back-purged with argon during the process ensuring the weld is strong and consistent, as well as clean throughout. With this process complete, the APR Cast Downpipe Exhaust System is born!

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The APR Difference: Final Quality Control

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APR has placed a large emphasis on improving quality control across various product lines, and the exhaust program is not excluded. To ensure the systems are delivered as advertised, APR’s engineers have taken a multi-step approach that encompasses many techniques that go beyond the industry standard.

Metallurgy Testing
APR’s engineers request full metallurgy reports with each batch of components to ensure the components are made with the T304L stainless steel grades specified on the original design prints. This information is then cross-referenced against randomly selected and independently tested samples before the components are released for assembly.

Dimensional Inspection
Great designs only matter if the manufacturer delivers the components as expected. To help ensure the designs are as specified, APR’s engineers randomly select components and conduct full dimensional inspections using in-house 3D laser scanning equipment. Tolerances are digitally checked against the original specifications and passed or failed based on the results.

Fixtures
Operating in an environment designed for accuracy and repeatability, APR’s fabrication experts leave little room for error during the final assembly phase. Jigs and fixtures, created in-house, live on custom-specified fabrication tables. This working environment ensures the highest level of quality control during the assembly process and safeguards against dimensional variations potentially created during the manufacturing process. The end result is a system that fits every time as it’s true to the original design specifications.

Visual Quality
When hand-building the products in-house, an extra level of control takes place. Components are visually checked for imperfections, and items that fall out of quality standards are rejected. The products are then packaged with care before being distributed across the world.

APR’s confidence in the system’s quality allows for a limited lifetime warranty.

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Videos

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Hardware Application Guide

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Audi S6 / S7
Audi RS6 / RS7

A8/A8L/S8 – In development

DPK0014

$1,999.99

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Software Application Guide

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For the best results, APR recommends installing the APR Stage II ECU Upgrade. The upgrade price is waived for APR Stage I ECU Upgrade customers with purchase of the APR downpipes.

$374.99 – Audi S6 / S7
$749.99 – Audi RS6 / RS7
$499.99 – Audi S8

Audi A8 / A8L – In development

IMPORTANT PRICING AND AVAILABILITY DETAILS:
– Availability and ECU Compatibility: Stages, programs, and features may not be available for all ECUs.
– ECU Revision Notice: Multiple ECU revisions exist for each platform. APR software may be temporarily unavailable when factory updates are applied. Achtuning can check availability in person, or over the phone if the ECU boxcode/revision is known.
– Stage II Pricing: Customers who have purchased an APR ECU Upgrade before February 16th, 2015 are exempt from upgrade fees.


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APR’s ECU Upgrade Now Available for Facelifted Audi (C7.5) S6 and S7 4.0 TFSI!

Posted on September 8, 2015 – 10:00 am

Achtuning is pleased to present APR’s ultimate engine control unit (ECU) upgrade for the Audi (C7.5) S6 and S7 4.0 TFSI V8. APR’s ECU upgrade is available in octane-specific variations, including and is conveniently flashed to the vehicle’s factory ECU through the OBD-II port without any physical modification to the factory ECU. APR’s EMCS functionality puts the control of the engine’s operation at your fingertips and allows for additional features and options to be installed to the OEM ECU.

The ECU’s 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.

APR’s Calibration Engineers spent months calibrating the engine management system, including many hours of chassis dyno development. With a thorough understanding of the ECU’s torque structure, APR’s Calibration Engineers properly increased engine load to produce more power and torque across the entire power band. APR’s ECU Upgrade increases boost pressure, optimizes ignition timing, cam timing, lambda and more to produce higher output!

APR’s ECU Upgrades provides an excellent leap in horsepower and torque while retaining OEM knock control sensitivity and other built in safety features. This results in an exciting and powerful upgrade, optimized for various fuel grades found around the world!

The APR Stage I ECU Upgrade gives you higher peak numbers of 574 HP/638 FT-LBS on 93 (R+M)/2 octane and up to 597 HP/668 FT-LBS on 100 (R+M)/2 octane race fuel! As much as 186 HP and 243 FT-LBS of torque are available through the power band! APR’s latest ECU Upgrade is fully loaded with APR’s EMCS Program Switching and is compatible with APR Mobile.

Application Guide:

Audi C7.5 S6 and S7 4.0 TFSI.
$1,499.99 – Fully loaded.


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S-FLO Carbon Intake for Audi S6 & S7

Posted on December 3, 2014 – 11:00 am

Introducing AWE Tuning’s S-FLO Carbon Intake for Audi’s (C7) S6 and S7!

Power. Fitment. Perfection. The trifecta our Audi S6 and S7 customers are looking for.

  • Max gains of +20 hp and +21 ft-lbs of torque at the crank.
  • Perfect fitment, perfectly engineered.
  • Mounts to factory locations – Fitment Guaranteed.
  • Fully enclosed carbon fiber air box ensures maximum efficiency
  • Features high flow AWE Tuning S-FLO Filter.
  • Designed, engineered, and tested in-house at AWE Tuning.

The AWE Tuning S-FLO Carbon Intake was engineered in house to draw in large volumes of cool air to produce impressive power gains and look good doing it.

 

The line up:
AWE Tuning S-FLO Carbon Intake
The AWE Tuning S-FLO Carbon Intake is the complete suite, containing the AWE Tuning S-FLO Carbon Airbox, the AWE Tuning S-FLO Filter, our engineered Nomex® reinforced silicone hose, and all necessary brackets and mounting hardware. The airbox is high grade 2×2 carbon fiber, and encompasses a full carbon fiber air inlet and lid, both of which mount directly in the stock locations.

AWE Tuning S-FLO Filter
The AWE Tuning S-FLO Carbon Intake employs the proprietary AWE Tuning S-FLO Filter, which is also available separately. The AWE Tuning S-FLO Filter is the largest that can fit within the air box, and is a washable, oiled, large cylindrical filter.  The AWE Tuning S-FLO Carbon Intake and S-FLO Filter are two key under-the-hood upgrades highly recommended for S6 and S7 drivers.

 

AWE Tuning S-FLO Carbon Intake, SKU: 2660-11016 – $995.00

AWE Tuning S-FLO Filter, SKU: 2710-11012 – $79.00


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Audi S6 and S7 4.0 TFSI ECU Upgrade Now Available!

Posted on February 19, 2013 – 9:53 am

Achtuning is pleased to announce APR’s release of the ultimate ECU Upgrade for the Audi S6 and S7 4.0 TFSI V8!

After months of long nights and many hours of testing, developing and more testing, APR is pleased to offer you an ECU recalibration that is second to none. APR’s extensive research and development provides you with a powerful ECU upgrade with no loss of drivability or reliability. Expect faster acceleration, improved throttle response and more power across the entire power band.

APR’s 4.0 TFSI V8 ECU Upgrade is an expertly recalibrated engine control strategy that primarily remaps the engine’s operating parameters, within the factory ECU, to provide smooth and reliable power as if intended by the OEM. APR’s ECU Upgrade is developed to work within the OEM and Tier 1 Supplier specifications for engine component stress tolerances and performance specifications. Available in octane-specific variations, APR’s calibrations allow you to take advantage of fuel quality available in your area. APR’s patented EMCS functionality puts the control of your engine’s operation at your fingertips and allows for additional features and options to be installed to your OEM ECU.

APR Stage I ECU Upgrade

The APR Stage I ECU Upgrade gives you higher peak numbers of 560 HP/580 FT-LBS on 93 (R+M)/2 octane and up to 569 HP/605 FT-LBS on 100 (R+M)/2 octane race fuel. As much as 124 HP and 163 FT-LBS of torque are available through the power band! APR’s ECU Upgrade is the best power per dollar modification for the new 4.0 TFSI V8 and gives it just the extra edge these cars lack from the factory without pushing the limits. With factory-like smoothness and drivability, APR’s ECU upgrade will fill the void in an otherwise excellent car.

Acceleration Enhancements:

Beyond power and torque enhancements, APR’s Calibration Engineers were able to increase the acceleration rate of the S6 and S7 through other calibrations changes. Ignition delay is reduced resulting in a more responsive pedal without altering overall throttle sensitivity.

Launch Control:

APR’s Engineers paid particular attention to torque delivery when using launch control. Through specific ECU calibration and code changes torque delivery is limited until the clutches are fully engaged. This results in blistering acceleration without suddenly over-stressing the S-Tronic clutch packs.

Increased Fuel Economy:

APR’s Calibration Engineers paid close attention to several parameters directly related to fuel economy, especially while cruising at highway speeds. Depending on your driving style and fuel quality, you may see better miles per gallon!

Speed Limiter:

APR’s ECU upgrade increases the vehicle’s top speed limiter for blistering sprints around the track or across the Autobahn without the speed limiter shutting down your fun!

Left Foot Braking:

APR’s Left Foot Braking feature allows more control over the vehicle’s throttle. The factory equipped S6 and S7’s throttle input is disabled while pressing the accelerator and brake at the same time. Left Foot Braking, a common motorsport driving technique, allows the driver complete control over the vehicle’s throttle and braking system, which may give the S6 and S7 the edge it needs at the track. As is with all features APR adds to the ECU, this feature may be removed upon request.

Dyno Charts

APR Stage I ECU Upgrade Calibration Report

Horsepower

  • 420 HP – Stock reported by Audi
  • 480 HP – Stock measured by APR
  • 552 HP – APR Stage I 91 (R+M)/2 or 95 RON
  • 560 HP – APR Stage I 93 (R+M)/2 or 98 RON
  • 569 HP – APR Stage I 100 (R+M)/2 or 104 RON

FT-LBS of Torque

  • 406 TQ – Stock reported by Audi
  • 464 TQ – Stock measured by APR
  • 564 TQ – APR Stage I 91 (R+M)/2 or 95 RON
  • 580 TQ – APR Stage I 93 (R+M)/2 or 98 RON
  • 605 TQ – APR Stage I 100 (R+M)/2 or 104 RON

Horsepower Gain over Stock

  • +90 HP @ 3,900 RPM – APR Stage I 91 (R+M)/2 or 95 RON
  • +102 HP @ 3,950 RPM – APR Stage I 93 (R+M)/2 or 98 RON
  • +123 HP @ 4,250 RPM – APR Stage I 100 (R+M)/2 or 104 RON

FT-LBS of Torque Gain over Stock

  • +126 TQ @ 2,450 RPM – APR Stage I 91 (R+M)/2 or 95 RON
  • +138 TQ @ 3,750 RPM – APR Stage I 93 (R+M)/2 or 98 RON
  • +163 TQ @ 3,700 RPM – APR Stage I 100 (R+M)/2 or 104 RONAcceleration Times – Stock vs APR Stage I 93 (R+M)/2 or 98 RON Software:

0-60 MPH – 4.06 sec vs 3.52 sec

0-100 MPH – 9.24 sec vs 8.32 sec

62-124 MPH – 9.56 sec vs 8.51 sec

60-130 MPH – 11.32 sec vs 9.93 sec

Data collected at the same location via a Racelogic P-Box with launch control, ESP/ASR off, Dynamic mode and Sport mode. May not be comparable to data collected in other locations.

Quarter Mile Testing – Stock vs APR Stage I 93 (R+M)/2 or 98 RON Software:

Best 60′ Times – 1.713 sec vs 1.656 sec
Best 1/4 Mile ET – 12.216 sec vs 11.628 sec
Best 1/4 Mile Trap Speed – 112.42 MPH vs 117.83 MPH

APR EMCS Programs and Features

APR’s patented EMCS, Enhanced Modular Chipping System, brings selectable programs and features to your factory ECU, all without the need to purchase external hardware. Other companies have attempted to imitate EMCS with clumsy external switching devices that only replace or multiply portions of a “base” calibration. However, EMCS has the ability to completely rewrite the entire operating map data, giving each map a complete set of calibration changes. APR’s EMCS features and programs modes are activated via your OEM cruise control buttons. Your cruise control will continue to function as normal.

Program Switching:

Program switching allows the user to cycle through up to four different engine calibrations and operating modes all without the need for external hardware.

Stock Mode:

By selecting stock mode, the ECU calibration is reset to the factory calibration. The engine will run exactly as it did before purchasing APR software.

APR Performance Modes:

APR’s octane-specific calibrations are available for various premium and race fuels around the world. Each performance mode is a completely new calibration, altered specifically for the characteristics of the fuel quality selected.

Valet Mode:

APR’s Valet Mode protects your vehicle from becoming an expensive toy for unauthorized individuals. By enabling Valet Mode, the vehicle’s performance is extremely limited. Launch control is uneventful, the vehicles top speed is limited to roughly 40 MPH and the engine’s redline is reduced to nearly 5,000 RPM!


Fault Code Erase:

Fault code erase allows the user to erase and reset engine related trouble codes and ECU adaptation data without using a specialty tool.

The APR Development Difference

APR ECU Explorer:

APR’s proprietary ECU Explorer gives APR’s Calibration Engineers unparalleled access to the vehicle’s entire engine management system. Typical commercially available data logging tools, used by most tuners, only allow logging up to 12 engine-operating variables at extremely low data rates. These tools are also limited to a small, specific list of variables. APR’s ECU Explorer is capable of logging every variable found within the ECU. It’s capable of logging well over 100 variables at once with data rates as high as 100 samples per second. Synchronous data logging is available for fine-tuning.

APR ECU Composer with APR Live Tuning:

APR’s proprietary ECU Composer is used for altering the engine management system. With full access to every table, map and variable within the ECU, APR’s Calibration Engineers are not limited to a handful of maps as is common for most tuning companies. ECU Composer takes calibration to a new level on the 4.0T with APR’s Live Tuning. APR’s Calibration Engineers can test calibration changes with a single click of a button to instantly monitor the changes, rather than spending several minutes shutting down the vehicle to reflash the ECU. This allows a level of fine-tuning unmatched in the market.

APR ECU Assembly:

APR’s Electrical Engineers have the ability to alter the code structure of the ECU to add features not available from the factory. Through code levels changes, APR’s Engineers are able to add features designed to protect the gearbox during launch control. Other changes allow higher torque limit than those achievable through only modifying calibration data or using piggyback devices as is the case for many tuners. On the highly modified end, this allows APR to make Stage III Turbo Upgrades operate as if intended by the OEM. For most 4.0 TFSI owners, the advantage of this ability is the addition of APR’s patented EMCS Functions. EMCS puts the control of the engine’s operation at your fingertips and allows for additional features and options to be installed to your ECU.

Pricing and Application Guide

Audi C6 S6 and S7 4.0 TFSI – $1,499.00 – Includes 4 Programs (Stock, 91, 93, 100 or Valet), and Fault Code Erase

Security, Warranty and Money Back Guarentee

All APR ECU Upgrades are fully encrypted to prevent theft of our valuable and proprietary coding information by lesser companies.

30 Day Money Back Guarantee:

All APR ECU Upgrades include a 30-day money back guarantee with no questions asked. If for any reason you are dissatisfied with the APR ECU Upgrade, return to Achtuning for a full refund, provided you are within the 30 day period from the time of your initial purchase. Labor or shipping charges are not included in the guarantee.

Limited Lifetime Warranty:

All APR ECU Upgrades include a limited lifetime warranty against defects in the software, and to provide free updates and re-flashes as they become available. Labor or shipping charges are not included in the warranty.


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