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I've been driving my RS4 for over 8 years now. Very happy with it. Had MTM remap, later corrected by VTG company. 398 HP. Not much, seemed perfectly fine. Faster than my friend's E92 M3 or other friend's B7 RS4. Not by REAL much but quicker.

3 months ago I started to hear weird noise. It turned out to be a crack in one exhaust manifold.

Engine went out. Then we discovered that not only manifolds were dead but my turbos were also on the way out.

After a bit of thinking the decision was made to tweak it all a bit once the engine was already out and I had to do something with these parts anyway.

So I ended up getting custom made exhaust manifolds:




Light K04 Hybrids:





Everything got cleaned nicely



And with gutted pre-cats, middle silencer removed and a custom remap... here is the result:



I have to say I am very happy, I expected to get like 430 HP and surprise surprise - a bit over 460HP!

Car seems MUCH more powerful. It is a shame everything is covered in snow here so I can't really experience everything right now.

Got also noticeably louder but still acceptable.

Al in all, after 8 years I think my car deserved it. It also got new clutch along the way, new engine mounts, new trasmission mounts, drivetrain stabiliser etc etc etc.

I love it just as much as the very first day I got it... if not more.

B5 RS4s do ROCK!

460bhp from hybrid K04s + manifolds + de-cat DPs + map.

Standard/OEM exhaust? Air filter?

Should be seeing closer to 500 I would have thought?

Looks nice though, and massive improvement over stock!

Well I am not sure how it works but it looks like you guys get 460 and up much easier. Different dyno settings maybe?

This company that took care of mine also just finished another one, a bit more hardcore RS4 with GT25R Turbos, FMIC, 630cc injectors, custom intake etc etc etc and it ended up with 543 BHP and 662 Nm of torque.



I have a feeling it would show much more at your dynos somehow when it looks like you can get over 460 BHP and 745 (!!) Nm of torque (if I converted 525ft/lbs to Nm right) from just remap and catback??

I am sorry but I do not understand this phenomenon.

Anyway, figures aside car seems much more powerful, gives amazing smile on my face once again so I guess main point of it all has been achieved!

Oh and one more thing.

Think about MTM Stage I, promising 420 BHP.

We had 3 B5 RS4s around here with this remap and results were between 394-398 BHP. You can actually see MTM Stg I results on my graph posted in first post as well, we left it for comparison.

This alone means something as MTM is not a custom remap and should give more or less similar measureable results - somehow it doesn't.

I wonder if there is a person here with MTM Stg I measured at dyno - would be cool to find out the result.

That spec set up properly should be around 500bhp

Maybe Dyno results/calibration...?

Some pics... just because







And with my friend's E92:

nice!!

Can you post some VCDS logs on here - maybe a FATs run, logging boost and MAF to start with?

I'd be interested to see what how the boost comes on with those hybrids.

Thanks.

lovely car, Nice one

Oh man, I got a hint of green (envy) on me to have the RS from the beginning...

I reckon the reason for not going over 460 is in the exhausts. How is your set-up actually? OEM after de-catting (and which of the cats, by the way)?

And yes, I've understood also the dynos are not that accurate.

Nice pics!

Right now my exhaust is almost stock - with just pre-cats and middle silencer removed.

I will end up getting a Milltek cat-back or maybe something custom made for my car.

I also need to do something with my intercoolers. Temperature was high and the guy who worked on my car told me I may have problems in summer. So it will be FMIC or bigger SMICs soon.

It is interesting though how opinions differ from one forum to another. Here people say that with such mods it should be nearing 500 hp. On polish forums people say that with stock RS4 injectors even this result of 461 is not possible, that in their opinion it probably has around 420-430 hp. Do you guys change injectors to achieve 460 hp?

Makes me wonder who is right.

Maybe when car is finished with new coolers and exhaust I will try to go to nearest located dyno outside of my country, maybe in Germany somewhere just to have comparison.

Right now my exhaust is almost stock - with just pre-cats and middle silencer removed.

You will get a better flow (and thus allows for more power) when replacing with larger diameter "pipes" and ..hmm.. non-OEM main cats, for example. Your ECU may need a remap again.

It is interesting though how opinions differ from one forum to another. Here people say that...

Yes, and I've heard pushing past 480-490 requires new injectors. Somebody knows, who's done it

My opinion for your dyno test after more mods - to do it in the same place as now (at least there). Thereby you will get your references correct.

Still, thumbs up for your work so far with your ride....

I've ran an RS4 engine in my S4 for 8 months back in 2007, the mods were as follows:

bone stock RS4 engine
MRC tubular exhaust manifolds
MRC big diameter intake pipes
MRC FMIC kit modified to fit the RS4 engine and pipework
oil cooler kit
modified RS4 airbox
full dual 70mm exhaust with no cats.

Running boost pressure of up to 1.8 bar peak and dropping to 1.55 bar at redline, I've dynoed 540 PS/700Nm of torque. The stock injectors were going to 95% duty cycle at around 6100 RPM, however, I didn't need more fuel, because the engine was running relatively cool as it was, so I didn't need extra fuel for cooling.

I've had the car on DynoDynamics and Cartec 4WD dynos to confirm the 540 PS, so it's not like it was the dyno in one country that was more optimistic than the one in the other country, the DD being in the UK and the Cartec in Germany. I too have heard the hearsay stories of injectors being too small and so on, the truth is however, once you know what to do to an RS4 engine and what it needs in order to run happily, then it'll do so and produce all the power you want. Also, making sure that the engine is in top condition is more than mandatory, as in no boost leaks, check valves in a good shape, WG control hoses with no leaks in them, recent fuel filter etc etc etc. I'm not bashing your tuners in Poland, but trust me, if an RS4 couldn't do 500 PS on the stock turbos (even though they are not going to last for 20.000 miles when ran at this sort of boost), then I wouldn't have that this sort of power in my own car.