MTM500+ Engine Conversion

[Nige_RS4]

jr, do you have any pics of the old turbos to show if there was any damage to the internals? Something must've gone through the turbo to get into your inlet manifold OR something fell inside when the turbo was removed [img]images/graemlins/confused.gif[/img]

Over to the experts ....

p.s. I agree that turbos have a limited lifetime, but I would not expect them to destroy an engine unless you continued to drive for some time post-failure. Incidentally, what symptoms did you experience ?

[johneroberts]

So expect turbo failures they are looked upon as an expendable item in the car.

hmmm. A turbo going bust is one thing but if this causes internal engine damage as well - that could be costly as yours has proved. [img]images/graemlins/mad.gif[/img]

just a small question - how much power can the RS4 gearbox take (is it different to the S4 one?)?

The gear Box is OK for 600 BHP and as far as the internal damage, it could happen to anyone, you just dont know unless you strip the entire engine down
Cheers
jr

[kiwi_mtm]

So all parts were ordered along with the new H&R PSC Coil over suspension again the first on the RS4 in the UK, adapted from the DTN cars in Germany a fully ajustable system with dampening dialers.

I Got a quote on these yesterday. Nice, but almost twice ! the price of ths std coilovers.. I'm lookin seriously at the std coilovers v's the GmbH.

TBA....

[Edward]

Sounds fantastic John, hope you have great fun! [img]images/graemlins/thumbs.gif[/img]

And 181 mph @6750rpm, whats the absolute limit, do you think the potential is there for 190/5?

Cheers, Ed

[TarmacTerrorist]

[img]images/graemlins/quote.gif[/img]

got up to 185 on the clock and 181 on the Sat Nav, and was only revving to 6750 rpm.

Have the footage here on tape. Wasn't just a short burst either, we ran close to that speed for a good few miles [img]images/graemlins/clap.gif[/img] [img]images/graemlins/FIREdevil.gif[/img]

[Joshie]

[quote

So expect turbo failures they are looked upon as an expendable item in the car.
Cheers
jr [/quote]

hee hee - that's the way I used to look at it.

Once the car is mapped it should be truly awesome John. Bet you can't wait [img]images/graemlins/1syellow1.gif[/img]

[Riz_RS4]

Come to think of it, where's Riz

I`m still here chaps..... and their being no RS3 doesnt worry me the slightest..... [img]images/graemlins/wink.gif[/img]

Jr hope you have many miles of fun [img]images/graemlins/thumbs.gif[/img]

Riz [img]images/graemlins/s3addict.gif[/img]

p.s. my trainer`s are here and accounted for [img]images/graemlins/roflmao.gif[/img]

[Golich]

Sorry to hear about your troubles [img]images/graemlins/pftroest.gif[/img]

I'm amazed a solid could get it's way up through all the turbo pipework through an intercooler up though the intake pipe through the throtal body and into the cylinder.

I think you were extremely unlucky - But on the otherhand what an animal you have now! [img]images/graemlins/thumb.gif[/img]

[johneroberts]

Should see about 7200 rpm tops and with the boost running at 1.4 bar and peaking at 1.8 bar i reckon 195 real time.
That will do [img]images/graemlins/grin.gif[/img]
Cheers
jr

[DuncS3]

nice one John, glad its sorted and look forward to Oulton Park for a look

Dunc [img]images/graemlins/s3addict.gif[/img]

[rs4steve]

[img]images/graemlins/thumbs.gif[/img]

[Edward]

That's impressive to say the least and 1.8 bar too, that's not silly amounts so things shouldn't, touch wood, be too stressed. Sounds like a trip to Brunters to find out! [img]images/graemlins/smile.gif[/img]

[Nikolaos]

Hi John,

H&R Power Control System suspension! [img]images/graemlins/thumbs.gif[/img]
I had this suspension installed a couple of months ago. H&R in Germany made a pecial setup of this suspension exactly for my car. They got all the datas they needed from me like Power/torque, wheels, tyres, spacers, weight front/rear, brakes front/rear etc, plus info like where I drive the car and what exactly I expect from the car.

The result was awaysome! [img]images/graemlins/thumbs.gif[/img] It took very long time for the setup and I was prepared to cancel my order but at the end I'm happy. [img]images/graemlins/boots.gif[/img]

John you said that you have installed the MTM stage 6 520PS.
You mention turbo's and exhaust manifolds but it should be plus cylinder head proccesing, right? This is always the last step of all the engine modifications.
Also, when you replace turbo's it should be replaced together with different injectors, fuel pump and fuel pump regulator. Is that right? or only your turbo's were replaced?

I'm planing to install the MTM exhaust manifolds within a few months and they are extremely expensive. [img]images/graemlins/033102bad_1_prv.gif[/img] What do you think od them?

[toasty]

So have you had the final remap and RR session done yet?

Be interesting to hear just how much power you get.

....you'll have to get your sig changed too! [img]images/graemlins/grin.gif[/img]

[Golich]

John someone asked why you didn't go for the 600bhp MTM mod.

I thought the same until I re-read the Audi driver article on the MTM mod.

I'll quote the Audi driver article on the MTM 602bhp mod.

The Cosworth Engine in the RS4 produces 142 bhp/litre the highest specific output of any production car. The MTM version pushes this into orbit with 223bhp/litre more than double the 100bhp/litre benchmark for high-performance engines.

While Cosworth retained the 2671cc (81.0x86.4mm bore and stroke) capcity of the basic Audi block, the rest of the engine around it was totaly redesigned. The block was strengthened the crank beefed up and lightened, lighter stronger pistons and cons rods along with sodium-cooled valves. The cyclinder heads were redesigned to optimise gas flow. With larger intake and exauhst ports than the S4, these heads are manufactured by a specially developed casting technique. (Cosworth developed)Special manifolds were cast for the twi KKK KO4 turbos which which work with the Bosch Motronic ME7 sequential fuel injection system and 9.0:1 compressio ratio. The engine benifits from a pair of larger more efficient intercoolers and the turbos are said to be capible of producing 2.2bar absolute on overboost.

To get 602 reliable horses from this already tuned engine MTM goes back to 1st principles. The engine is stripped and every component that will be re-used is checked for dimensional accuracy, weight and balance. Then new forged and machined connecting rods are used with the original pistons. The standard valves are paired of with uprated valve springs allowing higher sustained revs. The original oil coooler is retained, but the sump is given internal baffles to keep the vital lubricant in the right places when the car is being driven hard. The cylinder head is ported and polished and the compression ratio reduced from 9.0:1 to 5.8:1 by some subtle machining work and a thicker head gasket.

The inlet system is modified to admit more air and the exhaust manifolds are also new. "The standard KKK K04 turbos are only good for 458bhp with just two metal catalysts sports exhaust and ECU conversion." Roland Mayer explained "You can get up to 470 with modified KKK KO4 turbos. But to get over 600bhp we need to go up to the next turbo 'group' so we put a pair of K16's on the manifolds. These are internally modified to our own requirements and flow a lot more air at high revs." Bigger fuel injectors and a second fuel pump cope with the maximum boost pressure of 1.6bar rising to 2.0bar on over boost.

The complete exhaust system is replaced with MTM's own crome nickel cast-iron manifolds, four free-flowing metal catalysts and larger bore 70mm diameter twin pipe stainless steel system. "There is some movement because of the torque reaction, so we use expansion joins on the manifolds to prevent cracking." Rolan explained.

Interesting that MTM haven't gone for larger intercoolers or one large center intercooler is this possible/practical for the twin turbo?

Is this being done for the B5 S4?

What has Andiroo fitted to his?