Posts Tagged ‘fsi tuning’
Achtuning presents the APR 2.0T FSI Stage III GTX Turbocharger System & Upgrade Kit! (EA113-K03 Vehicles)
Building upon over a decade’s worth of experience with turbocharged Audi and VW engines, including over half a decade with direct injected engines, APR’s Engineers have taken the 2.0T FSI to ground breaking levels of performance without compromise.
APR has introduced the 2.0T FSI Stage III GTX Turbocharger System. Producing over 405 horsepower on 93 (R+M)/2 octane and 449 HP in racing configurations, Stage III GTX places the 2.0T FSI’s accelerative performance in the same league as that of large V8 supercharged muscle cars and sub $400,000 exotic sports cars.
The new APR Stage III GTX Turbocharger System represents a large leap in technology over our previously available GT Turbocharger System. The new system’s response is much quicker, spooling hundreds of RPM sooner thanks to the latest in Garrett turbocharger technology and advancements in the ECU Upgrade. Further refinement of the fueling system increases the vehicle’s reliability and drivability to levels only matched by the OEM. A substantial increase in horsepower and torque results in roughly a 30-50 HP gain in the area under the curve over the previous system. As you hear a new exotic growl from your exhaust system, expect exhilarating g-force levels sure to put a huge grin on your face!
To learn about many component included in the APR Stage III GTX Turbocharger System, see below. For previous owners of the older APR Stage III GT Turbocharger System, an upgrade package is available.
APR Stage III GTX Components
At the heart of Stage III GTX is a GTX2867R turbocharger, consisting of the latest technologies from Le Mans’ winning turbo manufacturer, Garrett Honeywell. The internally gated unit features a fully-machined, ten-blade billet compressor 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. The newly developed compressor housing utilizes anti-surge porting, which greatly complements the lightning fast spool characteristics of this unit and grants APR’s Engineers the ability to deliver massive levels of torque inducing boost pressure, even in the lower RPM range.
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.
APR Stage III GTX Software
The factory Bosch MED 9 engine management system is responsible for proper operation of the engine in all 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 marks.
With the significant amount of changes included in the APR Stage III GTX Turbocharger System, APR’s Engineers spent months recalibrating the engine management system to operate smoothly as if intended by the OEM. 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.
APR’s EMCS program switching technology puts control of the ECU in your finger tips allowing you to access modes for standard pump fuel, high output race fuel and even reduced output valet modes to protect your 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!
*Note* Exiting APR Software customers will receive a fully loaded ECU. New Customers will receive 1 program and may purchase additional programs al la cart. Please check for EMCS availability.
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, Inconel is a very high temperature resistant material designed to withstand extreme exhaust gas temperature changes without expanding, contracting, melting or cracking under stress. 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 exhaust velocity high. Ensuring each exhaust pulse arrives at the collection point without collision is critical to producing lightning fast response and immediate torque delivery. Using 3D modeling and computational fluid dynamics software, APR’s Engineers designed varying short runner lengths calibrated to deliver sequential exhaust pulses without collision. A reduction in backpressure from the high flow design directly enhances power delivery.
Each manifold is investment-cast in the United States of America and machined in house on APR’s CNC machines to ensure high casting tolerances, repeatable results and strict quality control. The thick casting material reduces unwanted exhaust noise leaving behind a powerful and exotic growl.
All of these characteristics result in a manifold designed without compromise backed by a confidence inspiring lifetime warranty.
Induction and Charge Piping
Wire reinforced, multi-ply silicone hoses provide an unrestricted path for airflow to enter and exit the turbocharger at over 1,000 kilograms per hour. 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.
Turbo Outlet Pipe
To provide unrestricted and smooth airflow from the turbocharger to the intercooler, the APR Stage III GTX Turbocharger System includes a cast enlarged turbo outlet pipe to properly deliver the additional airflow from the larger turbocharger.
Mass Airflow Housing
The vehicle’s engine management relies on load calculations to accurately control the engine. Calculations are made by measuring airflow across the Mass Airflow Sensor and this is a critical component of the APR Stage III GTX Turbocharger System.
The small and restrictive factory unit is removed and replaced with the much larger housing. To ensure accuracy, APR’s MAF housing is cast in the United States of America and CNC machined in house at APR to ensure repeatable results. The long, precision-machined housing features a honeycomb airflow straightener to further aid in accurately reading airflow levels. Simply enlarging the MAF housing is not permissible without accurate adjustments to the factory engine management system, which is included with APR Stage III GTX Turbocharger System.
Oil and Coolant Lines
APR’s oil and coolant lines are specific to the vehicle’s Stage III GTX System and provide years of leak free operation. The oil lines feature flexible braided stainless steel with CNC mandrel bent hard-lines for specific and clean hose routing as if intended by the OEM.
Low Pressure Fuel Pump System
The APR Low Pressure Fuel Pump System is a complete, OEM style, PWM controlled drop in fuel pump and controller solution designed to fit cleanly in the OEM location. The upgraded pump provides adequate low-pressure fuel to the APR High Pressure Fuel Pump to support the power levels produced by the APR Stage III GTX Turbocharger System.
High Pressure Fuel Rail Valve
The factory vehicle’s gasoline direct injection injectors require higher than factory fuel rail pressure to achieve targeted air fuel ratios under high load, wide open throttle operation. APR’s Low Pressure Fuel Pump delivers the desired volume of fuel to the APR High Pressure Fuel Pump, which provides increased fueling headroom over the factory unit. However, the factory High Pressure Fuel Rail Valve limits maximum rail pressure below the desired level. The included APR High Pressure Fuel Rail Valve is calibrated to increase the maximum rail pressure to levels necessary for proper operation.
In doing so, APR’s able to support far higher horsepower levels than achievable on the existing APR Stage III GTX Turbocharger Systems without the need to alter the factory, correct spray pattern, injectors. This results in smoother part throttle operation, factory-like cold starts and fewer unburnt hydrocarbons emitted from the tailpipe under all conditions compared to other fueling options.
Cast Downturn and Downpipe
The GTX2867R internally gated turbocharger unit features a Garrett five-bolt flange, which differs from the OEM turbocharger flange. To support this design, the APR Stage III GTX Turbocharger System includes cast stainless steel exhaust downturn and downpipe, which mates directly to an APR Midpipe, Downpipe or Turboback Exhaust System.
Nuts, Bolts, Gaskets, Washers, Clamps, Fittings, etc
Every APR Stage III GTX Turbocharger System includes all necessary components for a complete install.
No matter how small the part, each piece of the APR Stage III GTX Turbocharger System oozes with quality evident in pieces like the Stage III GTX’s laser cut ancillary brackets and carriers.
Proper temperature range spark plugs are included with each APR Stage III GTX Turbocharger System.
Stock – (VAG’s Published Ratings)
207 FT-LBS of Torque
Stock – (APR’s Rating on 93)
222 FT-LBS of Torque
APR Stage III GTX – 91 (R+M)/2 or 95 RON
346 FT-LBS of Torque
+187 HP Gain over Stock at 7100 RPM
+140 FT-LBS Torque Gain over Stock at 6800 RPM
APR Stage III GTX – 93 (R+M)/2 or 98 RON
363 FT-LBS of Torque
+205 HP Gain over Stock at 7100 RPM
+153 FT-LBS Torque Gain over Stock at 6750 RPM
APR Stage III GTX – 100 (R+M)/2 or 104 RON
376 FT-LBS of Torque
+259 HP Gain over Stock at 7100 RPM
+192 FT-LBS Torque Gain over Stock at 7100 RPM
More Dyno Charts:
- APR Stage III GTX – 91 (R+M)/2 or 95 RON – At the Wheels
- APR Stage III GTX – 91 (R+M)/2 or 95 RON – At the Crank
- APR Stage III GTX – 93 (R+M)/2 or 98 RON – At the Wheels
- APR Stage III GTX – 93 (R+M)/2 or 98 RON – At the Crank
- APR Stage III GTX – 100 (R+M)/2 or 104 RON – At the Wheels
- APR Stage III GTX – 100 (R+M)/2 or 104 RON – At the Crank
2.0T FSI & 2.0 TFSI – EA113 – Transverse – AXX, BWA & BPY
- Audi A3 (MK2) – 6MT & S-Tronic
- Audi TT (MK2) – 6MT & S-Tronic
- Volkswagen Eos – 6MT & DSG
- Volkswagen Golf/GTI (MK5) – 6MT & DSG
- Volkswagen Jetta/GLI (MK5) – 6MT & DSG
- Volkswagen Passat (B6) – 6MT & DSG
Part Numbers & Prices (Prices applicable to the USA only):
T3100051 – $6,649.99 – APR Stage III GTX Turbocharger System – Including Software
T3100048 – $2,674.99 – APR Stage III GTX Turbocharger System – Including Software – (Upgrade System only. See online store for details.)
Existing APR software customers will receive a fully loaded ECU. New customers will receive one program and may purchase additional programs al la cart. Please check for EMCS availability. Software only included in upgrade kit for customers previously equipped with an APR Stage III GT2871R Turbocharger System.
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.
- 5 Liters of Motul Specific 505.01, 502.00 & 505.00 SAE 5w40 Oil
- 1 Oil Filter
- 4 Liters of Inugel Optimal Ultra (Concentrated) – Organic
MO00002 – $70.00
- 6 Liters of Motul 300V Power 5W40
- 1 Oil Filter
- 4 Liters of Inugel Optimal Ultra (Concentrated) – Organic
MO00006 – $100.00
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APR has just released an intake manifold Runner Flapper Delete System for 2.0T FSI (EA113) OEM intake manifold.
The APR Runner Flap Delete System (RFD) is a motorsport inspired upgrade designed to eliminate airflow restrictions within the factory intake manifold. This product is for anyone looking to maximize performance on highly tuned engines.
The runner flaps are individual plates, much like a throttle body flap, located within the intake manifold runners. Unfortunately even when opened to the maximum position, the flaps still represent an airflow restriction as illustrated in the graphic below.
The APR RFD System fills the voids in each runner after removing the runner flaps. Each piece is precision CNC machined from billet aluminum on APR’s live tooling in-house lathe.
Simply removing the runner flaps can cause adverse running conditions during cold start. However through proper ECU recalibrations, APR’s able to provide RFD specific software for all APR software stages to eliminate this harsh running condition. This is a free software upgrade for all existing APR ECU Upgrade customers, however an installation fee may apply. (contact us for details)
Power Gains: At Stage 3 airflow levels, typical results showed a decrease in turbocharger lag, more than a 10 ft-lbs of torque gain and more than a 10 horsepower gain.
Recommendations: This modification is recommended for APR Stage 2+ and higher modified engines.
Application: For all 2.0T FSI (EA113) factory intake manifolds. If you’re unsure which you have, please call for assistance.
Part Number: MS100033
We will be adding this to the Achtuning online catalog shortly.
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Check out the largest OEM Bosch HDEV 1 2.0T FSI Injectors on the market at a price point 30-40% lower than other retailers!
The factory injectors found in the Audi S3, Audi TTS, VW Golf ED30, VW Golf ED35, VW Golf Pirelli, VW Golf R & VW Scirocco R, Seat Leon Cupra & Seat Leon Cupra R K04 based vehicle are the largest Bosch HDEV 1 gasoline direct injection injectors currently available for the VAG 2.0T FSI EA113 engine platform. Capable of supporting over 500 HP in extreme applications, these gasoline direct injection injectors feature the proper spray pattern designed to support reliable operation in all normal conditions.
These injectors are approximately 13% larger than the standard injectors supplied on K03 based vehicles and are required for any APR 2.0T FSI K04 customer sourcing injectors from the kit. They are currently used in APR Australia’s Record Setting 10 Second Quarter Mile Golf R!
The injectors are sold individually or in sets of four. OEM Injector install kits are also available as it’s not uncommon for the factory install kits to become damaged during removal.
OEM Part Number:
06F 906 036 F
OEM Direct Replacement (Engine Codes):
BHZ, BWJ, BYD, BZC, CDL & CDM
OEM Compatible Upgrade (Engine Codes):
AAX, BGB, BPG, BPJ, BPY, BUL, BWA, BWE, BWT, BYK
Please note specific ECU software is required to run these injectors on engines not originally equipped with these injectors. If you have any doubt if these injectors are correct for your vehicle, or any APR turbocharger system, please contact an APR representative.
VW/Audi List Price – $214
Typical Online Price – $190
Achtuning Retail Price – $129!!
VW/Audi List Price – $856
Typical Online Price – $650
Achtuning Retail Price – $499!!
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APR K04 and Stage 3 turbo kits for the 2.0T FSI are IN STOCK here at ACHTUN!NG, including high-pressure fuel pumps!! There is apparently an International back-order on the HPFP so a few of you might have back-orders for turbo kits in place that are waiting for fuel pumps… Don’t bother waiting and order your APR 2.0T FSI turbo kit from ACHTUN!NG and take advantage of our FREE SHIPPING (within the Continental US) offer while you’re at it!!!
Click the images below to begin shopping online:
APR K04 Turbo Kit:
APR Stage 3 Turbo Kit:
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