Horsepower is like a drug. It provides a nice high for while, but the cravings for more soon ensue. This is the case with the Audi A3 equipped with AWE's K04 turbo upgrade. It wasn't the lack of power that prompted the quest for greater thrills, but brief exposure to the vehicle's potential. It just so happens that AWE has recently finished development on a fuel system upgrade to accompany the K04. Time to get a fix.
Vehicle data
2006 Audi A3
Engine: 2.0T
Transmission: Six-speed S tronic
Mileage: 32,941
Testing octane: 91
Dyno Data
Dyno type: Mustang dynamometer
Outside temperature (F): 76 degrees (baseline), 78 degrees(91- and 100-octane)
Test gear: Third
Modifications currently installed
*AWE transverse K04 turbo kit
*AWE turbo-back exhaust with 200-cell metallic catalytic convertor
*OEM Audi S3 intercooler
Baseline
*AWE K04/AWE turbo-back exhaust/S3 intercooler/91-octanePeak wheel-hp: 233 @ 6300 rpmPeak wheel-torque (lb-ft): 244 @ 4500 rpm
AWE K04 kit/AWE fueling kit/VF Engineering intake/91-octanePeak wheel-hp: 255 @ 5300 rpm
Peak wheel-torque (lb-ft): 270 @ 4600 rpm
AWE fueling kit (high-pressure fuel pump/OEM S3 Injectors)
Facts
*S3 injectors are a direct bolt-on and offer a 13-percent increase in fuel flow when compared to the stock unit
*Use of OEM S3 injectors ensures 100-percent compatibility with the ECU
*High-pressure pumps use new internals in a factory housing
*A PVD (plasma vapor deposition) application of a DLC (diamond-like coating) reduces friction, enhances strength and durability
Pros
*Use of OEM injectors and fuel pump housing make the upgrades virtually undetectable
*At cruising speed, the larger injectors consume the same amount of fuel as the stock units, so freeway mpg is unaffected
*Keeps the factory pump retain spring to prevent excessive cam lobe wear
Cons
*Larger injectors increase fuel consumption under full throttle; spirited driving will cause a slight reduction in overall mpg
*Injectors are difficult and time-consuming to install
Price
$999.95 for current AWE K04 owners
Parts
Four injectors, injector install kit, special install tool to assemble the pump, piston shaft, GIAC software (current AWE K04 owners only)
Installation time
2 to 4 hours
Notes: Unlike conventional injectors that can be installed by simply removing a fuel rail, the FSI system requires removal of the intake manifold. Special tools are also needed to properly remove and install the cylinder head-mounted injectors. The fuel system operates at pressures of 110 to 130 bar (1,617 to 1,911 psi) and one small mistake in the installation process can be dangerous.
Recommendations
After removing the fuel pump, it's important to inspect the cam lobe that operates the pump to make sure that it hasn't flattened out or is showing signs of excess wear. Standard fuel additives will not remove carbon/sludge build-up from the intake ports or valve stems, because fuel does not flow across these surfaces. So a good time to remove any excess carbon/sludge build-up from the intake ports and valves is when the intake manifold has been removed.
VF Engineering IntakeFeatures
*Single-piece, mandrel-bent, 2.75-inch, 18g steel piping incorporates an integrated billet MAF sensor flange
*Laser-cut MAF/exhaust and air filter heat shield, K&N washable and re-usable air filter
Pros
*Mandrel bending process offers precision fit and optimal flow
*Intake pipe is sized properly to work in conjunction with the ECUMAF/exhaust shield blocks radiant heat from the turbocharger, protecting the MAF sensor from heat damage while reducing heat transfer into the intake pipe
*Air filter heat shield channels air from the front scoop directly into the air filter and blocks radiant heat from the radiator hose
Cons
*Air filter rubs on the heat shield; can be adjusted away from the shield, but then it comes close to the brake master cylinder reservoir