Since there has been a lot of demand for more information regarding our B7 A4 Big Turbo Kit, I’ve done my best to compile some technical information obtained from our engineering department.


Some kit highlights:


A Garrett Turbo custom built to our specifications. We are one of the select few Garrett Turbo Kit Manufacturers, recognized officially by Garrett Turbo. This gives us direct access to their technical information and engineering services. We consulted Garrett to make this turbo with unique materials that are able to withstand the extreme exhaust gas temperatures the 2.0T engine develops.





A cast exhaust manifold designed and developed in house made of a state of the art high temperature resistant stainless steel.





Over the years, OEMs have been raising operating temps of their engines to achieve better efficiency and improve emissions. They have also begun using new materials that are able to deal with the added stress of these high temperatures, especially with diesel applications where exhaust temperatures can really elevate.


The rough prototype manifold installed on car:





We are using a modern 347+ stainless steel alloy (also knows as CF8C-Plus) that features the strength of more exotic alloys, but at a fraction of the cost. This material is truly a product of technological advancements made over the last few years in the exhaust manifold industry. See this .pdf link for a quick overview of this revolutionary material:

http://www.google.com/url?sa=t&ct=re...M6bXV9bYsqDSaQ


Here is a picture of our SLA model and production quality manifold:




A patent pending high pressure fuel pump designed and developed in house, and high flow fuel injectors. We have had several dozen current design pumps in long term use on several cars with zero issues. The pump will be released as a stand alone option in the next few weeks. Injectors were developed on our in house FSI injector test stand.






A 200 Cell HJS metal core catalytic converter, proprietary silicone turbo inlet and outlet hoses, and a mechanical diverter valve design.






Approximate power levels:


This is a dyno chart of the kit while still in prototype form. The power levels are close to the production numbers, but will be slightly detuned to run safely on stock internals.





The production kit will produce around 375 crank horse power and 330 crank torque on stock internals.



As you can see from some of the photos I posted, that besides the OEM cat, our kit does not remove any of the factory emissions equipment. It does not feature special programming tricks to bypass the OEM O2 sensors. It was developed with the mindset of delivering BIG Power without fooling the ECU into not throwing CELs, featuring cutting edge software from GIAC.


Time frame for release :

With a project such as this it’s difficult to nail down an exact time frame for release, but we are estimating the release date to be about 3 months from now due to lead times on some of the components that are made for us by subcontractors. Expect pricing to be around $5400.


I think that should cover most or all of the bases, but if there’s anything else you would like to know just ask and I will do my best to answer.

 

Which is the installation time of this kit?

 

Since the kit is yet complete, we don't have a finalized install time just yet.

That being said, the install doesn't require a ton of work. The installation won't be much more difficult then our GT28RS Kit for the B6. You can see the instructions for that kit here: B6 GT28RS Kit Instructions.

 

This is why I love A.W.E. They go over the top to help the customer decide on products for their vehicle. Alex, thank you very much for posting this. When I get my A4, I'm handing the keys over to you guys for a turbo, exhaust, ecu, and anything else I have money for lol.

 

Im sure this is way too soon to ask, but if audi brings us the 2.0tsi in the a5, will this kit work?

 

Thanks for the kind words! It's comments like that that make all the effort we put into our work worthwhile.

From what I remember reading, the 2.0T in the A5 is the next generation TSI motor with 211bhp and 258lb ft from the factory. In all honesty, we have no idea if it will work yet.

If that changes between the FSI-> TSI is anything like it has been with the VW Mk5s, it will require a complete redesign on all of our products for the motor. We recently purchased a 08 GTI equipped with the new TSI motor and are currently in the process of redesign all of our products to work with the new motor, everything from exhausts and Center Vent Gauges to our K04 Turbo Kit. The ECU is also completely different then the previous generation car.

Once we have a chance to inspect the new TSI motor, we will be able to have more concrete information.

 

I'm looking forward to your findings Alex (and if they really do decide to bring this motor to the US).

I've been a big AWE fan ever since Todd & co. installed my DSR 256 cams and AWE short shifter in my '98 GTI VR6 back in the old shop!!

 

The motor will probably be coming our way, but maybe not in the A5. I kind of hope it does, it would definitely make for an enticing package.

Haha, that was a while ago. Glad to see your still a supporter of ours.

 

While I'm here, I'll share some information regarding our High Flow Fuel Pump for our 2.0T FSI Turbo kits. This same pump will work for both the B7 A4 Kit as well as our Mk5/Audi A3 K04 Kit.

The final production parts are scheduled to arrive next week. We then need to do some batch QC spot checks and then do a formal release. Here is a picture of the pump and injector kit:



Some details on the pump and what makes it unique:

Patent pending high pressure pump design, suitable for all 2.0T FSI engines.

Specialty tools included for pump component swap.


Extensively street and dyno developed.


Coating -
PVD (Plasma Vapor Deposition) application of a DLC (Diamond Like Coating) - Low friction, extreme hardness and durability. Critical for long lasting performance


Tolerances -
Piston and bore are precision ground and matched to within microns (1 micron = .00004")


Manufacturing -
5 separate manufacturing steps including, machining, heat treatment, grinding, and coating


QC-
Each set is checked with precision digital gauges with a resolution of .00001"

Further-
Our design uses the factory fuel pump spring retainer not a generic valve spring retainer like the other pumps.

The factory retainer has smooth beveled edges and a mirror surface finish. Pumps not using the factory retainer have sharp edges and are slightly concave in the center, resulting in less load bearing area and the potential for stress concentrations from minor piston side loads. That type of design has been attributed to increased wear on cam followers by some experts.

Pricing will be ~$400 for the pump, as a do-it-yourself install kit, complete with specialty tools (pictured) to ensure install success.

 

They are bringing the new 2.0T, but it will be in the new A4.

 

Whats the turbo lag like? if any.

 

Look like a great kit, but I would be too worried about blowing my engine

 

We have designed this kit with the longevity and safety of the engine in mind. We didn't want to design a kit that would require new engine internals or anything of the sort. Our kit was engineered from the beginning to be a safe, reliable bolt on kit that would give the owner the horsepower they want every time they turn the ignition.

 

Pleeease be less than $5k

 

Great turbo kit..
Alex would you happen to know what the cpi of the oem cat is?