In case you've missed it, Eurotuner is part of the Castrol Syntec Top Shop Challenge (www.SyntecTopShop.com), in which several magazines have teamed up with a reputable engine builder to produce the best all-around engine. The contest has been bringing out the best and worst of everybody involved. From our perspective, rivalries have been blown out of proportion and we're lucky the cops haven't shown up to settle these disputes. However, let it be said: we won't be beaten by the imports!
On the tuning side, the entrusted engine shops have had no time to respond to our shin-kicking, hair-pulling tactics. These guys are pushing the limits in power and reliability, and are further challenged by having to create the best possible power curve. Suffice it to say, building the most impressive all-round motor isn't easy, and we're glad 034 Motorsport has taken charge of our fate in this competition. And don't forget, you could win this engine at the end of it all, so check out the website (www.SyntecTopShop.com).
In the first part of our Audi 80 2.3-liter engine build (et 5/08) we focused on 034's assembly of the stout bottom end, followed by various tricks of the trade performed on the head to flow more air and because the area under the curve is also important getting it in the combustion chambers faster. This month, we'll show how 034gets copious amounts of air and fuel into the combustion chambers, and with a massive spark causing a cylindrically confined fireball powerful enough to interest the military.
Starting with the fuel system, 034 installed its dual 044 fuel pump kit with an accumulator tank. The pump pushes fuel into a -10 feed line and through a -10 Aeromotive fuel filter. Pressure to the 034EFI 20v fuel rail is controlled by a Fuel Lab pressure regulator before feeding the hose-like1250cc injectors. The unsquirted fuel returns through a -6 line to the stock fuel tank.
A fuel system of this magnitude commands a psychotic amount of air in order to ignite. And while we won't reveal our turbocharger of choice for fear of tipping off the competitors too soon, the engine's fared well with its temporary GT42RSturbo during initial testing. The massive snail is fitted to an 034 Audi i-5 header featuring 1.5" runners made from 321 stainless steel to handle the heat. Boost is controlled with a 44mm Tial external wastegate.
Before intercooling, the heavily compressed air from the turbo travels through a 3" outlet that splits into dual 2.5" piping. With both pipes feeding the intercooler, 034 reports better distribution of flow across the intercooler core, which measures19x17x3" , yet fits behind a stock bumper.
Passing through 3" piping, the chilled air meets 034's big-bore throttle body and cast intake manifold, which reportedly flows 30% more than stock, with only a 2-3% variance between runners (as opposed to the factory manifold's fluctuations of around 25%). To save the turbo, a 50mm Tial blow-off valve relieves boost when the 70mm throttle closes.