S6 400+ hp project

[Petya]

My project in finish, here are some picture, engine bay still not ready, i have many little work to do, cleaning, make airbox for airfilter, fix cables, etc..

- full custom made exhasut system, custom made tubular manifold, KKK26/27 hybrid turbo, ported head with 7a exhaust cam, and S6 intake cam, 460cc injectors, big home made intercooler, rebuiled cooling system with electric fans, DTA pro 8 engine managment system, Vems round Wideband and EGT, brake system rebuilded with original parts

First time we have tryed to program what engine can do with still original bottomend. In first programming session we end up the work on 1.5 bar boost, because of some problem with original ingnition colis. (thx Aronmatic to borrowing other coils ), I ordered new ones, and we tryed with borrowed coils to program higher boost. On low rpm range engine can produce much higher boost as in old state (without head porting, and big cooler, and 7a cam). Engine died on 3500rpm on 1.8 bar boost when we gived more fuel to make good AFR.
5. cylinder rod broked, all other slightly (2. cylinder harder than others) bowed. Fine Engine can produce some high torque

I have bought new forged rods, new bottomend rebuilded with new RS2 bearings, new rings, original pistons. New engine run,everything seems ok, entrance still in progress.

Next week we will try to reprogram again. I will post some new picture from engine bay, and from killed rods, and if everything goes fine, some video from car.

[Mihnea]

Looks good to me but broken/bent rods at only 1.8 bar sounds like pinging/detonation to me honestly.

I've done more than 1 S6 running 2 Bar+ on stock bottom ends and no bent/broken rods whatsoever, but that's with 0 pinging and knock sensor activity! (touch wood)

Nice work though! Congrats!

Mihnea

[Billman]

Very nice. Nice intercooler also.

What injectors do you run?

[Mihnea]

Very nice. Nice intercooler also.

What injectors do you run?

460cc injectors

Doh.

[Billman]

Doh.

Appart from Flowrate the injectors have also more specs like flowrate@Pressure, maker...

Doh.

[merlin's S4]

Nice prodject! Does that intercooler fit behind the stock bumper? Did you have to loose the aircon??

[Jucca]

I'm sure he have to cut bumper and remove AC as well. We tryed to put similar IC to my S6, and I give up, because don't want to lose AC. I'm living at sea, where during summer can be 40 degreed C

[Petya]

Slightly modded stock bumper fit fine. Aircon now removed, because we had some engine heating problem, after i removed aircon cooler, and fit big and small one electric fan, but we have found why engine overheated. (waterpump was bad) So, now i can refit aircon, and fit again two small electric fan before intercooler.

Mihnea: i dont think it was knocking, but whoknows... Block wall, and pistons not damaged, only 5. rod broked, all other bowed.

Bill: about injectors i dont know more thing, i have bought as 440cc, after i cleaned it and checked flow rate, and they told me it is about 460cc.

[Petya]

On picture maybe not clear, but everything goes back 15cm, we cut 15cm from car front, water cooler goes back, original fans removed, brake bomb goes back too...to make space for intercooler.

[Jucca]

Please, keep us informed with pics too, as I'm thinking to upgrade my IC too.

[Mihnea]

@Petya: cylinder and piston damage only appears after long term pinging, pinging a few times won't get you that, but it could bend and break your rods! I probably have around 20-30 S4/S6 AAN customers in the US running 1.8-1.9 Bar even on 91 octane and none has ever had bent or broken rods (touch wood).

HTH,

mihnea

[Petya]

In thursday we started to reprogram engine, but on 5500rpm original fuel pump can't deliver more fuel. In friday i have bought Bosch "044" fuelpump, we programmed again. I wanted to reach 2 bar, but the maximum pressure only 1,75-1,8 bar because of my injectors.

Feeling is very good, serius power come from 3500rpm, and go up till 7200. I change gear now on 7200.

I was at sunday on drag race, to check what we have done. From 3 race, my best
60 feet: 1.885 1/8mile 7.9364/145km 1/4 mile 12.3006/183km. I think it is not bad from 1800kg car.

I will upload tomorow some video, and picture.

Big thx to our new member Micky B, who programmed my car, and build the bottom end! He had done excellent job!

[Micky B]

Thanks a lot Petya!!!

Ps:

Test shows when detonation occurs, the first week point fails in the 4-5 cyl audi/ww
engine is the spark plug, earth electrode flies off, or porcelan breaks, next is the piston ring land melts and holds the top or second ring or both, next week point is the rod. Rod fail is more common when bearing fails(bad oil,2 much fuel in oil), but this case
no problem with them.
We had more con rod problems, because with 98 ron gas you dont have to reduce ign and boost in low and mid rpm + headporting,cams etc inproove
cyl filling and this little more torque kills the rods!

[Petya]

I was in dyno today.

431hp/7120rpm 529nm/4745rpm

I check now the printed paper, and log, and i see, Dyno Man pushed full throthle only form 4700rpm. Dont know, but maybe torque maximum little higher about 4200rpm.

Intake air (DTA sensor in intake manifold) 34celsius (on the road maximum 27), pressur 1,7 bar.

Car can do constatly 146km/h at 1/8mile, 183km/h at 1/4mile, weight is 1785kg with me, so i think project ready.

[Billman]

can you post the Dyno ?