RS6/RS7/S6/S7/4.0 TFSI induction kit

[Stuart SWA]

Hi All

I have today mocked up an induction kit for the 4.0 TFSI on my 2016 RS6 engine based on the information from K&N filters and there flow rates based on the standard airbox and filter, I have made this using 2 480cfm inverted filters and 76mm pipework as there stock direct replacement is only capable of 308cfm free air flow yet the standard RS6 engine can easily consume over 600cfm. I have for over 16 years specialised in high power turbo engines and after this mock up I will be posting direct internal of the filter induction temps live as I drive my car in real time situations so please keep an eye on this thread for updates.

Pics below of the current mock up before any heat reflection, mounting brackets etc, I will be testing this first before any other mods as the temps at present on the aluminium intake pipes are well below my stock airbox plastic dual pipes after traffic journeys and open road scenarios.

Please remember even Audi use twin airboxes on the S8 that makes less power before anybody goes off about air intake flow/temps, they have obviously struggled to fit 2 air boxes in the RS6/RS7/S6/S7 cars.

Thanks Stuart SWA.

[MikeFish]

Hi Stuart
What were the intake temps for the standard air intake?

[Zeebuilder]

Looks the biz

[Zeebuilder]

Very similar to the one I purchased what do u think of the sound?

[Stuart SWA]

Hi Stuart
What were the intake temps for the standard air intake?

Hi Mike

The basic data was as follows but today I have received 2 temp probes and gauges with 1 second update times that I will be mounting in the end of my new induction kit filters and then mounting inside the stock air box so that the real time differences can be measured.

Stock air box, warm car and 10 minutes of repeated full throttle pulls resulted in an external intake pipe temperature of 41c ( measured at the plastic intake pipe just external of the air box ).
Stock air box, warm car and my journey home of 15 miles in traffic max speed 40mph but most of it stop start traffic was 54c.

Intake kit scenario 1 was 18c.
Intake kit scenario 2 was 22c.

The aluminium intake pipes seem to dissipate the heat much better than the stock plastic but I will confirm this with further testing.

We are currently running 2 cars both RS6 one 2015 and one 2016, one on the induction kit and one on the stock air box with a pipercross filter.

I will be measuring the temps over the next few days as above and I will post it asap.

Thanks Stuart

[Stuart SWA]

Very similar to the one I purchased what do u think of the sound?

The sound is awesome but as I am an engineer I am mainly interested in real world benefits and hope to confirm my thoughts with further testing.

[MikeFish]

After reading this this morning I plugged in my bluetooth OBD dongle into the RS6 and got my tablet out to log some intake temps on the way to work (I have the AWE tuning carbon air intake for looks rather than performance). Unfortunately it doesn't seem to log either the intake temp or the mass air flow on the 6. The other data seemed to work OK (speed, coolant temp, timing etc).

[Bit_evl]

"The aluminium intake pipes seem to dissipate the heat much better than the stock plastic but I will confirm this with further testing.
"
I don't see this as good but am happy to be corrected. Source of heat is engine, air need to be cool for best density. Metal pipes will absorb heat from the engine and then disipte it but this will create a hot cavity. Plastic will not conduct it to the same level and so will not create the same temperature lift ?

[Stuart SWA]

After reading this this morning I plugged in my bluetooth OBD dongle into the RS6 and got my tablet out to log some intake temps on the way to work (I have the AWE tuning carbon air intake for looks rather than performance). Unfortunately it doesn't seem to log either the intake temp or the mass air flow on the 6. The other data seemed to work OK (speed, coolant temp, timing etc).

Hi Mike

Unfortunately the RS6 C7 uses Bosch MED17 as it's control unit and this system does not have any MAF sensors it uses MAP sensors so you will not see them, They do however have 1 Air intake temp sensor and 2 charge cooler intake temp sensors that are not readable by most generic OBD code readers. We use the genuine VAS5054a as we are approved by Audi UK as an independent repairer and with this tool we can view all the sensors via live data ( VAG-COM may do the same but I have not tried ).

We also have access to all the information on ELSAWIN and if you would like a copy of the self study program for the 4.0TFSI engine just PM me your email and I will send you a copy? Although this is not RS6 specific it explains the fundamental's of the engine and system used to run it.

Thanks Stuart

[Stuart SWA]

"The aluminium intake pipes seem to dissipate the heat much better than the stock plastic but I will confirm this with further testing.
"
I don't see this as good but am happy to be corrected. Source of heat is engine, air need to be cool for best density. Metal pipes will absorb heat from the engine and then disipte it but this will create a hot cavity. Plastic will not conduct it to the same level and so will not create the same temperature lift ?

Hi

I totally agree, I would expect to see higher cavity temps after heat soak using the aluminium unless the actual external under bonnet temps are colder than we all think? hence why I will be carrying out further testing. Also keep in mind that if the stock cold air feed cannot not flow enough air then ultimately air will be drawn in from under the bonnet anyway.

All I can say at present is 2 identical cars, running the same custom software from us right down to the same software version, same fuel from the same station, both full, same nitrogen tyre pressures and the exact same journey, we found the following:

Side by side before the intake they were virtually identical in performance.

Now the intake kit car can pull away by 1-2 lengths from the other.

I plan to place my intake temp sensors in numerous places to see if it's ultimate airflow, Intake temps or both which is making the difference.

Starting at the filter, then after the filter and ultimately then at the stainless intake pipes on the engine. As the sensors are heat resistant stainless and the wiring is small I will actually place them inside the pipes for a true reading. I will also be taking some external of the filter under bonnet temps as I believe that once moving, a huge volume of external cold air is pushed into the under bonnet area through the grill and other inlets.

Thanks Stuart

[MikeFish]

After reading this this morning I plugged in my bluetooth OBD dongle into the RS6 and got my tablet out to log some intake temps on the way to work (I have the AWE tuning carbon air intake for looks rather than performance). Unfortunately it doesn't seem to log either the intake temp or the mass air flow on the 6. The other data seemed to work OK (speed, coolant temp, timing etc).

Hi Mike

Unfortunately the RS6 C7 uses Bosch MED17 as it's control unit and this system does not have any MAF sensors it uses MAP sensors so you will not see them, They do however have 1 Air intake temp sensor and 2 charge cooler intake temp sensors that are not readable by most generic OBD code readers. We use the genuine VAS5054a as we are approved by Audi UK as an independent repairer and with this tool we can view all the sensors via live data ( VAG-COM may do the same but I have not tried ).

We also have access to all the information on ELSAWIN and if you would like a copy of the self study program for the 4.0TFSI engine just PM me your email and I will send you a copy? Although this is not RS6 specific it explains the fundamental's of the engine and system used to run it.

Thanks Stuart

Ah, that explains it then. And it's very kind of you to offer r osend me the self stufy guide. I believe I already have a copy though. I seem to recall it was based on the S8 ans S6/7 engines.

The testing you are doing is really interesting though and I'm keen to see what your findings are.

[Stuart SWA]

After reading this this morning I plugged in my bluetooth OBD dongle into the RS6 and got my tablet out to log some intake temps on the way to work (I have the AWE tuning carbon air intake for looks rather than performance). Unfortunately it doesn't seem to log either the intake temp or the mass air flow on the 6. The other data seemed to work OK (speed, coolant temp, timing etc).

Hi Mike

Unfortunately the RS6 C7 uses Bosch MED17 as it's control unit and this system does not have any MAF sensors it uses MAP sensors so you will not see them, They do however have 1 Air intake temp sensor and 2 charge cooler intake temp sensors that are not readable by most generic OBD code readers. We use the genuine VAS5054a as we are approved by Audi UK as an independent repairer and with this tool we can view all the sensors via live data ( VAG-COM may do the same but I have not tried ).

We also have access to all the information on ELSAWIN and if you would like a copy of the self study program for the 4.0TFSI engine just PM me your email and I will send you a copy? Although this is not RS6 specific it explains the fundamental's of the engine and system used to run it.

Thanks Stuart

Ah, that explains it then. And it's very kind of you to offer r osend me the self stufy guide. I believe I already have a copy though. I seem to recall it was based on the S8 ans S6/7 engines.

The testing you are doing is really interesting though and I'm keen to see what your findings are.

Hi Mike

Yes you are correct they are based on the S8/S6/S6 platform, the only RS6 specific guides are videos and they are not very informative from a technical point of view. I do however have all the workshop manuals and access to all TSB's on any Audi if you ever need my help?

Glad you are interested in my findings and I will update them as I carry out further testing.

Thanks Stuart

[Marcus_RS4]

Watching this one with intrigue.

#subscribed

[Stuart SWA]

Just a quick update, We have a very intermittent running issue with one of our current the test cars ( belongs to a customer and numerous Audi dealers cannot fix at present ). As soon as it is fixed we will post the results.

[kavbhamra]

watching this thread as I'd like an induction kit on my RS6. Keep hearing mixed reviews but lets see what this thread turns up. Great work so far