800HP Audi Build-Up - Part 2

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).

The downpipe outlet where it changes from 4" to 3.5"

The Aeromotive fuel filter with -10 feed and -6 return lines

034's dual fuel-pump setup and its accumulator

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 034 gets 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.

Upgraded fuel pressure regulator with fuel and boost pressure sensors

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-like 1250cc 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 GT42RS turbo 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 measures 19x17x3", yet fits behind a stock bumper.

The massive front-mount intercooler measures 19x17x3"

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.

With the exhaust as a potential bottleneck, 034 took no chances and fabricated a 4" downpipe. They then merged it into the 3.5" exhaust piping that remains sans muffler. We're glad there are no decibel limitations on this contest.

With air and fuel taken care of, 034 chose its own 034EFI stage IIc engine management system to control the sparks. The programmable unit offers degree-based timing calculations that give 0.25 accuracy. The unit also has built-in, 20 amp ignition drivers that directly fire the 034EFI ignition coils, allowing over 8 milliseconds of dwell at 40psi boost levels for optimum spark ionization in the highly pressurized cylinders.

034 is also proud of the fact its EMS system features sequential valve-timed injection, sequential ignition, and boost control with compensation for all environmental variables.

High-current 20 amp ignition coils

Taken from under the car; notice the larger oil cooler, oil pan, header runners and aluminum turbo outlet

Custom breather reservoir built by 034 with a 1.5" inlet helps relieve crankcase pressure. Below is the 550w Audi RS2 radiator fan