APR's Audi TT-RS Stage III GTX Turbocharger System from GMP Performance
APR's Audi TT-RS Stage III GTX Turbocharger System from GMP Performance
APR presents the TT RS 2.5 TFSI Stage III GTX Turbocharger System!
In the 1980s, an iconic legend was born as the world fell in love with Audi’s 5-cylinder engine’s unmistakable and intoxicating growl. To the Audi enthusiast, the light-weight, compact 5-cylinder engine represented the hallmark of Audi’s technical prowess and ability to emotionally captivate an audience with a driving experience unlike any other in its time.
APR’s technical reach has grown enormously since opening in the 1990s and currently represents a force of unmatched performance without compromise within the performance enhancement sector for Audi vehicles. The APR Stage III 2.5 TFSI Turbocharger System is a culmination of roughly two years worth of engineering research, development and motorsport testing unheard of in the market today. With brutal testing on multiple continents, the APR Stage III Turbocharger System is the pinnacle of Audi’s German engineering enhanced by APR’s American ingenuity.
The APR Stage III Turbocharger System is a turnkey solution designed to expand on the TT RS’s already stellar performance by increasing peak horsepower to roughly double that of the European model. Sitting at 665 horsepower and over 560 ft-lbs of torque on high octane fuel, the vehicle’s performance is transformed to that of a modern day equivalent of Audi’s motorsport 5-cylinder engines of yesteryear. APR’s advanced knowledge of engine management combined with an uncompromising selection of premium materials, access to the latest engineering equipment and techniques, as well as a highly educated and capable staff of engineers, resulted in a turbocharger system capable of delivering a truly exhilarating and fulfilling driving experience.
http://youtu.be/otiMH9uWSMs
Development
APR’s engineering teams use professional grade tools to aid in development of the APR Stage III Turbocharger System. Through the use of coordinate measuring machines, such as the Creaform 3D laser scanner and FaroArm, spatial constraints within the 2.5 TFSI’s engine bay were captured to give APR’s engineers a detailed map of their design environment. The 3D laser scanner allows for quick and easy modeling of static hard parts, such as the turbocharger unit. The modeled parts are placed within the mapped engine bay and development on the system begins using PTE’s Creo 2 3D CAD software. With such an unforgivingly tight working environment, this data is absolutely necessary to ensure every parts fits as intended.
Unfortunately an engine bay is not a fixed working environment. Under load the engine mounts allow for movement, ultimately changing and limiting the spatial constraints even further. Before production hardware is created, APR’s engineers print each part using an in house sterolithography 3D printer. Fitment is then tested and necessary changes are made before casting the final pieces.
Over the entire development period, APR’s Calibration and Electrical Engineering teams continued modifying the factory engine management system to provide a smooth and reliable driving experience. Particular attention was paid towards driving characteristics, ultimately increasing the responsiveness of the entire system through the reduction of turbocharger lag. Given that the system operates at such high levels of performance, it’s often outside of the scope originally intended by the factory ECU. As a result, APR’s Electrical Engineers added patented control strategies to the ECU to enable proper control in all situations.
Success of the system depended greatly upon the results of APR’s accelerated life testing. APR’s in-house TT RS as well as select APR Importers' vehicles from across the globe were chosen for their locations in harsh environments. From the Swiss Alps to the South African deserts, APR’s engineers spent over a year collecting data through normal daily driving and grueling motorsport events. As new design requirements arose during testing, changes were made and testing continued. The end result is an extremely powerful, yet reliable turbocharger system worthy of APR’s stamp of approval.
Stage III GTX Components
Turbocharger
At the heart of the APR Stage III GTX Turbocharger System is a GTX3576R turbocharger, utilizing the latest technologies from Le Mans winning turbo manufacturer, Garrett Honeywell. The turbo features a fully-machined, eleven-blade billet compressor wheel and a dual ball bearing oil and water-cooled CHRA. APR’s Engineers spent countless hours testing several turbocharger units to arrive at a configuration suitable for their power, reliability and drivability requirements. Testing began with smaller internally gated units and gradually increased over time until a balance was met within all categories. The result is a system that spools quickly with excellent response, even in the lower RPM range, while producing top end power figures beyond that of a Audi R8 LMS Ultra V10 FSI!
Turbocharger Compressor Cover
The turbocharger is fed through a massive 4-inch ported shroud compressor inlet. This newly developed compressor housing’s anti-surge porting greatly complements the 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. APR’s Engineers enhance the compressor cover by adding an OEM style clampless connection system for the large turbo inlet pipe. This ensures proper orientation of the pipe, ease of installation and a leak free operation.
Turbocharger Turbine Housing
APR’s Engineers tested several turbine-housing designs, both internally and externally gated, with a multitude of inlet and outlet styles as well as A/Rs before arriving at the Tial Sport stainless steel vband .63 A/R turbine housing.
The housing is an investment cast smooth 304L stainless steel design, which offers many benefits over traditional cast iron housings. The design is compact and lightweight, reducing weight by roughly 33% over the typical cast iron counterpart. Furthermore stainless steel features heat retention characteristics, which aid in turbo response by keeping exhaust velocity high. GTVFL3.0 Vband inlet and VBF300M vband outlets completely eliminate the need for exhaust studs, gaskets and bolts to provide a leak-proof sealing surface, all while remaining easy to install.
To aid in reducing temperature under the hood and area surrounding the turbocharger, APR’s Engineers modified the turbine housing with Swain Tech’s ceramic coating. No other ceramic coating on the market comes close to Swain Tech’s proven track record of high mileage, motorsport proven performance and is the industry standard for thermal barriers.
Engine Management
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 marques.
With the significant amount of changes included in the APR Stage III Turbocharger System, APR’s Engineers spent months calibrating 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. When necessary, APR’s Electrical Engineers are able to build new coding functions, strategies and routines into the ECU to control conditions normally unseen at factory power levels.
APR’s upcoming 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!
Exhaust 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, 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, leaving behind a powerful and exotic 5-cylinder growl Audi enthusiasts have come to love. This material is typically found only at the highest levels of professional motorsport racing where reliability is essential to success.
To provide smooth and leak-proof operation between the manifold, turbo and external wastegate, APR’s exhaust manifold features Vband connection points. This eliminates the need for exhaust studs, nuts and gaskets and introduces an easier install for the end user while increasing overall reliability.
Investment-cast Inconel features heat retention characteristics, which aid in turbo response by keeping the exhaust velocity high. With exhaust gas pulses occurring 144 degrees apart, APR’s Engineers designed variable runner lengths calibrated to deliver sequential exhaust pulses without collision. 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.
Each unit undergoes strict quality control checkpoints to ensure ultimate reliability each step of the manufacturing and treatment process. The unit is CNC machined to tight tolerances and inspected for defects before undergoing thermal treatments at Swain Tech. Swain Tech’s world-renowned ceramic material is used to provide a thermal barrier between the manifold and all surrounding components. Through exhausting motorsport-testing APR found this treatment not only necessary for sustained wide-open operation, but also a critical component in reducing intake air temperature for prolonged performance, lap after lap.
Wastegate
A wastegate is a valve that provides a means for controlling boost pressure on a turbocharged engine. The unit controls the amount of exhaust gasses passing over the turbine wheel as prescribed by APR’s Stage III ECU Software. There are two types of wastegate configurations, internal and external, and each have their own advantages depending on application. With the addition of a massive turbocharger unit, APR’s Engineers found external gating necessary.
APR’s Stage III Turbocharger System features a compact Tial Sport MV-S 38mm external wastegate with water-cooling and vband connection points. The unit is constantly subjected to extreme temperatures and as such features high temperature based materials for increased life and performance. The addition of water-cooling ensures reduced temperatures under extreme motorsport conditions.
Temperature resistant materials are used throughout the unit as evidenced by the 347 stainless steel housing. The wear resistant racing valve is based on NiCrFe alloys and mates to Nitronic 60 stainless steel valve seats and bushings. The valve is actuated by a high heat resistant 17-7 PH stainless steel spring between a Nomex reinforced silicon diaphragm.
APR treats the housing with Swain Tech’s premium ceramic coating to provide a thermal barrier between the wastegate and surrounding components. Each unit’s spring pressure is spec’d and set at APR prior to shipping to provide accurate control. Lastly, each unit is fitted with APR’s flexible braided stainless steel lines for integration into the turbocharger's water-cooling system via the included multi-ply high-temperature-silicone junction point.
Turbocharger Compressor Inlet Pipe
A cast aluminum induction system was created to support the Stage III Turbocharger systems massive airflow requirements without worry of collapsing under extreme conditions. The cast pipe smoothly transitions from the OEM intake connection point down to the turbocharger’s 4-inch inlet where it’s attached via a clampless OEM style connection. This provides leak proof operation and smooth transitional airflow at all junction points while remaining easy to install and maintaining compatible with OEM and upgraded intake systems.
To combat heat soak, neighboring high temperature items feature a Swain Tech ceramic coating while the compressor inlet pipe is wrapped with Reflect-A-Gold at critical points for additional heat protection. Extreme motorsport testing proved the design to be a success, even after hours of continued use.
Turbocharger Compressor Outlet Hose
Wire reinforced, multi-ply silicone hoses provide an unrestricted path for airflow existing the turbocharger. The ultra rigid design ensures piping will not swell or collapse causing leaks and restrictions in the charge piping system. The hose is engineered to fit properly into the engine bay with all necessary 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 system.
Turbocharger Exhaust Downturn
An investment cast 3” stainless steel downturn provides a smooth and uninterrupted path for exhaust gases existing the turbocharger at high velocity. Vband clamps make install a cinch, providing a leak proof connection point while removing the need for gaskets, studs and nuts. The high temperature resistant stainless steel design increases the components strength without fear of component failure even under the most grueling environments. A port is provided for the OEM primary oxygen sensor and a second Vband connection links the downturn to the rest of the exhaust downpipe system.
Exhaust Downpipe
APR’s 3-inch T304 stainless steel downpipe connects seamlessly to the supplied downturn and is fully compatible with APR’s RSC turboback exhaust system, full downpipe, or midpipe exhaust system. Vband clamps make install a cinch, providing a leak proof connection point while removing the need for gaskets, studs and nuts. The wastegate exhaust piping is fed back into the primary exhaust system far away from the turbine as to not disrupt flow.
Turbocharger Oil and Coolant Lines
APR’s oil and coolant lines are specific to the APR Stage III 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. FireFlex and DEI heat shrouding sleeves (not pictured above) protect the lines from surrounding high temperature components and reduce oil and coolant temperatures typically seen under extreme conditions. A multi-ply silicon junction point provides a means for neatly connecting coolant lines to the factory system. Every detail is important, and APR goes the extra mile to ensure any possible weaknesses are eliminated.
High Pressure Fuel Pump
Sold separately as a brand new pump or rebuild of the engine’s existing pump, the APR High Pressure Fuel Pump addresses fueling needs and leaves plenty of headroom for safety and further increased power levels in the future. By increasing the pump’s internal capacity, the fueling system is capable of displacing a higher volume of fuel per minute at every RPM.
Install Hardware
APR doesn’t cut corners even with the most mundane details of the kit. Every nut, bolt, washer, clamp and gasket necessary for the install is included with the kit.
Spark Plugs
Included with each kit are five Denso Iridium IKH24 (5346) spark plugs designed to operate properly and resist knock under the extreme cylinder pressures produced in the APR Stage III Turbocharger System.
http://youtu.be/Zty2dEXq0PU
APR Recommends:
When you're boosting your TT-RS this significantly, it's a given that some parts will need to be upgraded alongside the new addition. Here are some components and recommendations to get the most out of your new turbocharger system.
APR 2.5 TFSI Front Mount Intercooler System
The APR Intercooler System dramatically lowers charge air temperature and resists heat soak far better the TT RS’s factory intercooler system. Through a massively increased frontal surface area, superior intercooler core design and smooth, cast end tanks, APR’s engineers were able to create an intercooler capable of supporting power levels well beyond that of the factory unit. Expect increased horsepower and torque and dramatically prolonged performance.
· APR intercooler core dimensions: 3.00" x 12.70" x 22.25"
· OEM intercooler core dimensions 3.19" x 6.38x" x 21.75"
· 104% more frontal area and 92% larger core compared to stock
· Pressure tested for leak proof operation
· Smooth cast alumnium end tanks
· CNC machined hose connection points
· Integrated light weight support brace, horn and sensor brackets
· Stealthy black coating that does not alter thermal effectiveness
Each unit uses a high quality, bar and plate core with staggered and louvered fins. The Intercooler’s exceptionally tall design and fin structure exposes the core to a greater volume of airflow than possible with the factory or similar aftermarket short and thick core designs. With more of the intercooler directly exposed to the elements, cooling effectiveness dramatically increases.
The intercooler’s maximum size and frontal area is directly related to packaging constraints found at the front end of the vehicle. Intercooler units located in the factory location are design limited resulting in increased volume primarily through expanding the depth of the system. Unfortunately increasing depth only slightly increases the intercoolers effectiveness compared to increased frontal surface area. APR’s Intercooler System includes a reengineered front-end support brace constructed from billet aluminum to maximize packaging constraints. The low profile support brace resides near the factory location and no longer blocks the intercooler from front-end airflow. The bar’s inner design features a weight saving grid, which also aids in airflow through the core.
APR 2.5 TFSI High Pressure Fuel Pump
APR is a Tier-One OEM supplier of high pressure fueling components to VAG and has operated with a nearly perfect tract record since the program's motorsport backed inception in 2006. With thousands of pumps sold yearly, APR has a wealth of knowledge and manufacturing techniques utilized in the production of critical fueling components with exceptional reliability.
The engine’s fueling system is very capable without modification, even at high power levels generated using APR’s Stage II+ ECU Upgrade and exhaust. However, APR’s Stage III Turbocharger System is capable of generating significantly more power and requires modification to high pressure fuel pump to keep up with fueling demands.
The APR High Pressure Fuel Pump addresses fueling needs and leaves plenty of headroom for safety and further increased power levels in the future. By increasing the pump’s internal capacity, the fueling system is capable of displacing a higher volume of fuel per minute at every RPM.
The key to APR’s reliability comes in part by use of extremely high grade materials and manufacturing techniques. The most critical components within the HPFP are the enlarged plunger and barrel. Each matched set is created using medical grade precision machining techniques deeply quality controlled all within the USA with dimensional tolerances as tight as .0001” and geometric tolerances as tight as .00009”. The plunger and barrel are created from certified and heat-treated bearing-grade stainless steel and undergo a special diamond like coating process for exceptional surfaces hardness and ultra reliable operation. The seals used in the pump are made of a high-performance filled polymer with a high modulus spring to retain the seal forces throughout the life of the product. The cross section of the seal is also of a proprietary design to maintain integrity over many years of use. Finally, to prevent float associated with altering the plungers mass, APR supplies each unit with a properly spec’d spring.
APR Sachs 2.5 TFSI Clutch
The Sachs clutch upgrade for the 2.5 TFSI is capable of holding the torque and power produced by the APR Stage III Turbocharger System. This upgrade includes a new pressure plate and clutch disc as pictured.
For more information, click here!
http://youtu.be/7MZOa6fY_CA
In the 1980s, an iconic legend was born as the world fell in love with Audi’s 5-cylinder engine’s unmistakable and intoxicating growl. To the Audi enthusiast, the light-weight, compact 5-cylinder engine represented the hallmark of Audi’s technical prowess and ability to emotionally captivate an audience with a driving experience unlike any other in its time.
APR’s technical reach has grown enormously since opening in the 1990s and currently represents a force of unmatched performance without compromise within the performance enhancement sector for Audi vehicles. The APR Stage III 2.5 TFSI Turbocharger System is a culmination of roughly two years worth of engineering research, development and motorsport testing unheard of in the market today. With brutal testing on multiple continents, the APR Stage III Turbocharger System is the pinnacle of Audi’s German engineering enhanced by APR’s American ingenuity.
The APR Stage III Turbocharger System is a turnkey solution designed to expand on the TT RS’s already stellar performance by increasing peak horsepower to roughly double that of the European model. Sitting at 665 horsepower and over 560 ft-lbs of torque on high octane fuel, the vehicle’s performance is transformed to that of a modern day equivalent of Audi’s motorsport 5-cylinder engines of yesteryear. APR’s advanced knowledge of engine management combined with an uncompromising selection of premium materials, access to the latest engineering equipment and techniques, as well as a highly educated and capable staff of engineers, resulted in a turbocharger system capable of delivering a truly exhilarating and fulfilling driving experience.
http://youtu.be/otiMH9uWSMs
Development
APR’s engineering teams use professional grade tools to aid in development of the APR Stage III Turbocharger System. Through the use of coordinate measuring machines, such as the Creaform 3D laser scanner and FaroArm, spatial constraints within the 2.5 TFSI’s engine bay were captured to give APR’s engineers a detailed map of their design environment. The 3D laser scanner allows for quick and easy modeling of static hard parts, such as the turbocharger unit. The modeled parts are placed within the mapped engine bay and development on the system begins using PTE’s Creo 2 3D CAD software. With such an unforgivingly tight working environment, this data is absolutely necessary to ensure every parts fits as intended.
Unfortunately an engine bay is not a fixed working environment. Under load the engine mounts allow for movement, ultimately changing and limiting the spatial constraints even further. Before production hardware is created, APR’s engineers print each part using an in house sterolithography 3D printer. Fitment is then tested and necessary changes are made before casting the final pieces.
Over the entire development period, APR’s Calibration and Electrical Engineering teams continued modifying the factory engine management system to provide a smooth and reliable driving experience. Particular attention was paid towards driving characteristics, ultimately increasing the responsiveness of the entire system through the reduction of turbocharger lag. Given that the system operates at such high levels of performance, it’s often outside of the scope originally intended by the factory ECU. As a result, APR’s Electrical Engineers added patented control strategies to the ECU to enable proper control in all situations.
Success of the system depended greatly upon the results of APR’s accelerated life testing. APR’s in-house TT RS as well as select APR Importers' vehicles from across the globe were chosen for their locations in harsh environments. From the Swiss Alps to the South African deserts, APR’s engineers spent over a year collecting data through normal daily driving and grueling motorsport events. As new design requirements arose during testing, changes were made and testing continued. The end result is an extremely powerful, yet reliable turbocharger system worthy of APR’s stamp of approval.
Stage III GTX Components
Turbocharger
At the heart of the APR Stage III GTX Turbocharger System is a GTX3576R turbocharger, utilizing the latest technologies from Le Mans winning turbo manufacturer, Garrett Honeywell. The turbo features a fully-machined, eleven-blade billet compressor wheel and a dual ball bearing oil and water-cooled CHRA. APR’s Engineers spent countless hours testing several turbocharger units to arrive at a configuration suitable for their power, reliability and drivability requirements. Testing began with smaller internally gated units and gradually increased over time until a balance was met within all categories. The result is a system that spools quickly with excellent response, even in the lower RPM range, while producing top end power figures beyond that of a Audi R8 LMS Ultra V10 FSI!
Turbocharger Compressor Cover
The turbocharger is fed through a massive 4-inch ported shroud compressor inlet. This newly developed compressor housing’s anti-surge porting greatly complements the 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. APR’s Engineers enhance the compressor cover by adding an OEM style clampless connection system for the large turbo inlet pipe. This ensures proper orientation of the pipe, ease of installation and a leak free operation.
Turbocharger Turbine Housing
APR’s Engineers tested several turbine-housing designs, both internally and externally gated, with a multitude of inlet and outlet styles as well as A/Rs before arriving at the Tial Sport stainless steel vband .63 A/R turbine housing.
The housing is an investment cast smooth 304L stainless steel design, which offers many benefits over traditional cast iron housings. The design is compact and lightweight, reducing weight by roughly 33% over the typical cast iron counterpart. Furthermore stainless steel features heat retention characteristics, which aid in turbo response by keeping exhaust velocity high. GTVFL3.0 Vband inlet and VBF300M vband outlets completely eliminate the need for exhaust studs, gaskets and bolts to provide a leak-proof sealing surface, all while remaining easy to install.
To aid in reducing temperature under the hood and area surrounding the turbocharger, APR’s Engineers modified the turbine housing with Swain Tech’s ceramic coating. No other ceramic coating on the market comes close to Swain Tech’s proven track record of high mileage, motorsport proven performance and is the industry standard for thermal barriers.
Engine Management
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 marques.
With the significant amount of changes included in the APR Stage III Turbocharger System, APR’s Engineers spent months calibrating 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. When necessary, APR’s Electrical Engineers are able to build new coding functions, strategies and routines into the ECU to control conditions normally unseen at factory power levels.
APR’s upcoming 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!
Exhaust 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, 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, leaving behind a powerful and exotic 5-cylinder growl Audi enthusiasts have come to love. This material is typically found only at the highest levels of professional motorsport racing where reliability is essential to success.
To provide smooth and leak-proof operation between the manifold, turbo and external wastegate, APR’s exhaust manifold features Vband connection points. This eliminates the need for exhaust studs, nuts and gaskets and introduces an easier install for the end user while increasing overall reliability.
Investment-cast Inconel features heat retention characteristics, which aid in turbo response by keeping the exhaust velocity high. With exhaust gas pulses occurring 144 degrees apart, APR’s Engineers designed variable runner lengths calibrated to deliver sequential exhaust pulses without collision. 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.
Each unit undergoes strict quality control checkpoints to ensure ultimate reliability each step of the manufacturing and treatment process. The unit is CNC machined to tight tolerances and inspected for defects before undergoing thermal treatments at Swain Tech. Swain Tech’s world-renowned ceramic material is used to provide a thermal barrier between the manifold and all surrounding components. Through exhausting motorsport-testing APR found this treatment not only necessary for sustained wide-open operation, but also a critical component in reducing intake air temperature for prolonged performance, lap after lap.
Wastegate
A wastegate is a valve that provides a means for controlling boost pressure on a turbocharged engine. The unit controls the amount of exhaust gasses passing over the turbine wheel as prescribed by APR’s Stage III ECU Software. There are two types of wastegate configurations, internal and external, and each have their own advantages depending on application. With the addition of a massive turbocharger unit, APR’s Engineers found external gating necessary.
APR’s Stage III Turbocharger System features a compact Tial Sport MV-S 38mm external wastegate with water-cooling and vband connection points. The unit is constantly subjected to extreme temperatures and as such features high temperature based materials for increased life and performance. The addition of water-cooling ensures reduced temperatures under extreme motorsport conditions.
Temperature resistant materials are used throughout the unit as evidenced by the 347 stainless steel housing. The wear resistant racing valve is based on NiCrFe alloys and mates to Nitronic 60 stainless steel valve seats and bushings. The valve is actuated by a high heat resistant 17-7 PH stainless steel spring between a Nomex reinforced silicon diaphragm.
APR treats the housing with Swain Tech’s premium ceramic coating to provide a thermal barrier between the wastegate and surrounding components. Each unit’s spring pressure is spec’d and set at APR prior to shipping to provide accurate control. Lastly, each unit is fitted with APR’s flexible braided stainless steel lines for integration into the turbocharger's water-cooling system via the included multi-ply high-temperature-silicone junction point.
Turbocharger Compressor Inlet Pipe
A cast aluminum induction system was created to support the Stage III Turbocharger systems massive airflow requirements without worry of collapsing under extreme conditions. The cast pipe smoothly transitions from the OEM intake connection point down to the turbocharger’s 4-inch inlet where it’s attached via a clampless OEM style connection. This provides leak proof operation and smooth transitional airflow at all junction points while remaining easy to install and maintaining compatible with OEM and upgraded intake systems.
To combat heat soak, neighboring high temperature items feature a Swain Tech ceramic coating while the compressor inlet pipe is wrapped with Reflect-A-Gold at critical points for additional heat protection. Extreme motorsport testing proved the design to be a success, even after hours of continued use.
Turbocharger Compressor Outlet Hose
Wire reinforced, multi-ply silicone hoses provide an unrestricted path for airflow existing the turbocharger. The ultra rigid design ensures piping will not swell or collapse causing leaks and restrictions in the charge piping system. The hose is engineered to fit properly into the engine bay with all necessary 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 system.
Turbocharger Exhaust Downturn
An investment cast 3” stainless steel downturn provides a smooth and uninterrupted path for exhaust gases existing the turbocharger at high velocity. Vband clamps make install a cinch, providing a leak proof connection point while removing the need for gaskets, studs and nuts. The high temperature resistant stainless steel design increases the components strength without fear of component failure even under the most grueling environments. A port is provided for the OEM primary oxygen sensor and a second Vband connection links the downturn to the rest of the exhaust downpipe system.
Exhaust Downpipe
APR’s 3-inch T304 stainless steel downpipe connects seamlessly to the supplied downturn and is fully compatible with APR’s RSC turboback exhaust system, full downpipe, or midpipe exhaust system. Vband clamps make install a cinch, providing a leak proof connection point while removing the need for gaskets, studs and nuts. The wastegate exhaust piping is fed back into the primary exhaust system far away from the turbine as to not disrupt flow.
Turbocharger Oil and Coolant Lines
APR’s oil and coolant lines are specific to the APR Stage III 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. FireFlex and DEI heat shrouding sleeves (not pictured above) protect the lines from surrounding high temperature components and reduce oil and coolant temperatures typically seen under extreme conditions. A multi-ply silicon junction point provides a means for neatly connecting coolant lines to the factory system. Every detail is important, and APR goes the extra mile to ensure any possible weaknesses are eliminated.
High Pressure Fuel Pump
Sold separately as a brand new pump or rebuild of the engine’s existing pump, the APR High Pressure Fuel Pump addresses fueling needs and leaves plenty of headroom for safety and further increased power levels in the future. By increasing the pump’s internal capacity, the fueling system is capable of displacing a higher volume of fuel per minute at every RPM.
Install Hardware
APR doesn’t cut corners even with the most mundane details of the kit. Every nut, bolt, washer, clamp and gasket necessary for the install is included with the kit.
Spark Plugs
Included with each kit are five Denso Iridium IKH24 (5346) spark plugs designed to operate properly and resist knock under the extreme cylinder pressures produced in the APR Stage III Turbocharger System.
http://youtu.be/Zty2dEXq0PU
APR Recommends:
When you're boosting your TT-RS this significantly, it's a given that some parts will need to be upgraded alongside the new addition. Here are some components and recommendations to get the most out of your new turbocharger system.
APR 2.5 TFSI Front Mount Intercooler System
The APR Intercooler System dramatically lowers charge air temperature and resists heat soak far better the TT RS’s factory intercooler system. Through a massively increased frontal surface area, superior intercooler core design and smooth, cast end tanks, APR’s engineers were able to create an intercooler capable of supporting power levels well beyond that of the factory unit. Expect increased horsepower and torque and dramatically prolonged performance.
· APR intercooler core dimensions: 3.00" x 12.70" x 22.25"
· OEM intercooler core dimensions 3.19" x 6.38x" x 21.75"
· 104% more frontal area and 92% larger core compared to stock
· Pressure tested for leak proof operation
· Smooth cast alumnium end tanks
· CNC machined hose connection points
· Integrated light weight support brace, horn and sensor brackets
· Stealthy black coating that does not alter thermal effectiveness
Each unit uses a high quality, bar and plate core with staggered and louvered fins. The Intercooler’s exceptionally tall design and fin structure exposes the core to a greater volume of airflow than possible with the factory or similar aftermarket short and thick core designs. With more of the intercooler directly exposed to the elements, cooling effectiveness dramatically increases.
The intercooler’s maximum size and frontal area is directly related to packaging constraints found at the front end of the vehicle. Intercooler units located in the factory location are design limited resulting in increased volume primarily through expanding the depth of the system. Unfortunately increasing depth only slightly increases the intercoolers effectiveness compared to increased frontal surface area. APR’s Intercooler System includes a reengineered front-end support brace constructed from billet aluminum to maximize packaging constraints. The low profile support brace resides near the factory location and no longer blocks the intercooler from front-end airflow. The bar’s inner design features a weight saving grid, which also aids in airflow through the core.
APR 2.5 TFSI High Pressure Fuel Pump
APR is a Tier-One OEM supplier of high pressure fueling components to VAG and has operated with a nearly perfect tract record since the program's motorsport backed inception in 2006. With thousands of pumps sold yearly, APR has a wealth of knowledge and manufacturing techniques utilized in the production of critical fueling components with exceptional reliability.
The engine’s fueling system is very capable without modification, even at high power levels generated using APR’s Stage II+ ECU Upgrade and exhaust. However, APR’s Stage III Turbocharger System is capable of generating significantly more power and requires modification to high pressure fuel pump to keep up with fueling demands.
The APR High Pressure Fuel Pump addresses fueling needs and leaves plenty of headroom for safety and further increased power levels in the future. By increasing the pump’s internal capacity, the fueling system is capable of displacing a higher volume of fuel per minute at every RPM.
The key to APR’s reliability comes in part by use of extremely high grade materials and manufacturing techniques. The most critical components within the HPFP are the enlarged plunger and barrel. Each matched set is created using medical grade precision machining techniques deeply quality controlled all within the USA with dimensional tolerances as tight as .0001” and geometric tolerances as tight as .00009”. The plunger and barrel are created from certified and heat-treated bearing-grade stainless steel and undergo a special diamond like coating process for exceptional surfaces hardness and ultra reliable operation. The seals used in the pump are made of a high-performance filled polymer with a high modulus spring to retain the seal forces throughout the life of the product. The cross section of the seal is also of a proprietary design to maintain integrity over many years of use. Finally, to prevent float associated with altering the plungers mass, APR supplies each unit with a properly spec’d spring.
APR Sachs 2.5 TFSI Clutch
The Sachs clutch upgrade for the 2.5 TFSI is capable of holding the torque and power produced by the APR Stage III Turbocharger System. This upgrade includes a new pressure plate and clutch disc as pictured.
For more information, click here!
http://youtu.be/7MZOa6fY_CA
Now is the perfect time to take advantage of this and many other great offerings from APR as their Winter Sale runs from now until January 4th. If you have an Audi owner on your holiday gift list or if your own Audi is on your gift list, be sure to snag the great upgrades available from APR!
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