Such a simple job for more power

S3 Hilife

S3 Hilife

It's an addiction
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Today I decided to get a couple of jobs done that i'd been putting off for a while. I bought a phenolic inlet gasket and injector service kit and also a throttle body spacer ready for my wmi kit. I also wanted to clean and paint the Inlet manifold at this point.

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Looking closer around the injectors you can see how manky it is from leaky injectors
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So off it came and it got a good scrub and degrease and then prepped for paint
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Whilst the paint dried the injectors went in the ultrasonic cleaner along with the FPR
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And O rings replaced along with the pintel washers but I had trouble removing the little filter baskets hence the 'help' request earlier today so I only replaced one for fear of damaging the injectors. They cleaned up really well though
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Once the paint had dried on the IM it was time to put it all back together including the phenolic gasket with new bolts and the throttle body spacer just in case I decide to mount the wmi nozzle after the throttle body.
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Definatly not the best paint job i've ever done due to the cold damp weather but its a big improvement, please excuse the poor quality pics as it had got dark by this point
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Ok so I'll be honest I wasn't expecting any noticable difference but the car instantly felt much more powerful and pulls so much harder, boost pressure is the same but seems stronger, I can only assume this is a combination of injectors now being clear but the AITs were way down due to the phenolic gasket which has to be one of the most effective mods (AWESOME lol)

Taken on a 2 mile test run after some "thorough testing" haha. The weather was quite cold and damp but still i've never seen or felt results like that in this car before. Normally AITs are at least in high 30s but on this run it never went above 15*c
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I just thought I'd write this for anyone who hasn't thought about fitting the phenolic gasket and cleaning their injectors, it is a fairly easy job to do, took me most of the day but that included thoroughly cleaning and painting the inlet manifold but you should see some really good results and well worth putting on the "to do" list

Steve
 
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Good post…and thank god you removed the S3 badge :thumbs up:
 
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A good example of exactly how effective the phenolic gasket is... I had considered it but didn't think it'd effect AIT's this much, just always thought it was a bit over kill!

May reconsider now though.......
 
VAG-Slag said:
A good example of exactly how effective the phenolic gasket is... I had considered it but didn't think it'd effect AIT's this much, just always thought it was a bit over kill!

May reconsider now though.......
Click to expand...

It supprised me too, I wasn't expecting that either but really glad I did it
 
I'm planning to do all this next weekend, just waiting on delivery of the ultrasonic cleaner.

The only other thing you could of done is put the throttle body in the cleaner too.

I also went one step further and gasket matched the inlet manifold just because I could.
 
antwan64og said:
I'm planning to do all this next weekend, just waiting on delivery of the ultrasonic cleaner.

The only other thing you could of done is put the throttle body in the cleaner too.

I also went one step further and gasket matched the inlet manifold just because I could.
Click to expand...

The throttle body was really bad aswell, would have put it in the cleaner but its only a 0.75ltr and wouldn't fit, cleaned it manually in the end
 
Hmmm. So, lower intake temps = more power? Am I understanding this correctly?

Could be encouraged to try one of those kits, Bill. Love the improvement the v3 tip has given.

I take it this would be another incremental gain?
 
jaykay8L said:
Hmmm. So, lower intake temps = more power? Am I understanding this correctly?

Could be encouraged to try one of those kits, Bill. Love the improvement the v3 tip has given.

I take it this would be another incremental gain?
Click to expand...
To a degree yes this is why we all fit big FMICs, i'm sure Bill or Tuffty could explain this better than me but if you imagine your inlet manifold as a heat exchanger, why would you want that nice cool air passing through a hot IM. The phenolic gasket just brings the temps down to reduce heat transfere.
I cant say my result of the extra power was solely the result of fitting the gasket but I was amazed at how the AITs dropped and the car felt so much better

Steve
 
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badger5 said:
http://badger5.biz/epages/3927bc2c-...en_GB/?ObjectID=207475&ViewAction=ViewProduct
Click to expand...
when are the largeport in stock bill?

jaykay8L said:
Hmmm. So, lower intake temps = more power? Am I understanding this correctly?

Could be encouraged to try one of those kits, Bill. Love the improvement the v3 tip has given.

I take it this would be another incremental gain?
Click to expand...
stops heat transfer, so makes the IATs on multiple runs more consistent. In a way it gives lower intake temps.

i question whether it does actually lead to cooler iats, or whether it just insulates, or isolates the sensor itself so that it READS lower. I suppose either way = good things. And we like good things. Bad things are, bad
 
[QUOTE="superkarl, post: 2310900, member: 46175"
i question whether it does actually lead to cooler iats, or whether it just insulates, or isolates the sensor itself so that it READS lower. I suppose either way = good things. And we like good things. Bad things are, bad[/QUOTE]

Totally agree but even if that is the case but I believe the ECU starts pulling timing when AIT's go above 30 degrees (perhaps someone can confirm?), so if it can prelong that from happening then it's always gonna be a good thing!
 
VAG-Slag said:
[QUOTE="superkarl, post: 2310900, member: 46175"
i question whether it does actually lead to cooler iats, or whether it just insulates, or isolates the sensor itself so that it READS lower. I suppose either way = good things. And we like good things. Bad things are, bad
Click to expand...

Totally agree but even if that is the case but I believe the ECU starts pulling timing when AIT's go above 30 degrees (perhaps someone can confirm?), so if it can prelong that from happening then it's always gonna be a good thing![/QUOTE]
Mid 30s according to one of Tufftys recent posts
 
jaykay8L said:
Hmmm. So, lower intake temps = more power? Am I understanding this correctly?
Click to expand...

Perhaps a better way of explaining: colder air is denser air (i.e more oxygen for it's volume) and there for needs more fuel to burn properly, the ECU sees this, is able to chuck a bit more fuel in and the end result is essentially a bigger bang and more power... Happy days!
 
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superkarl said:
when are the largeport in stock bill?


stops heat transfer, so makes the IATs on multiple runs more consistent. In a way it gives lower intake temps.

i question whether it does actually lead to cooler iats, or whether it just insulates, or isolates the sensor itself so that it READS lower. I suppose either way = good things. And we like good things. Bad things are, bad
Click to expand...

they are in stock
 
Hi guys, just wondering if the spacer is supposed to come with gaskets? In the picture I can see two gaskets but I didn't receive any
 
ordering mine today along with badger5 V2.2 TIP. happy days
 
Great write up crazyhilife.

Quick question, is it easy to remove the intake? and throttle body?

Also once it has been cleaned and reassembled do you need to reset anything with VCOM? or can you unplug battery and wait a period of time for it to reset itself?

Any help would be appreciated

S3_DAVE
 
Hi Dave, thanks, yes its fairly straight forward tbh, just make sure you clean thoroughly around the head and intake flange so not to let any debris fall in, once clean disconnect all vacuum hoses, air temp & EGT sensors and remove throttle body. Then undo the large hex bolt under the IM, remove injector rail (two hex screws) and unplug injectors (remove for cleaning) I took fuel pressure out of fuel pressure regulator first by removing it with a rag to soak up any fuel spill.
Then just undo the seven hex screws and two nuts on IM fange and remove.
Clean and replace old gasket with the phenolic kit and refit in reverse order.
If you are going to remove the IM completely to clean or paint it then you will need to remove the EGT sensor black box on bottom of IM and the sensor plug which goes through the IM from the injector loom.
The large hex bolt under the IM wont line up afterwards as everthing sits a little higher so I left this off as do many other people.
Cant think of anything else to note off top of my head but im sure someone will point out if i've missed something.

I didn't reset anything or do a TB allignment afterwards and havent scanned with VCDS yet but everything seems good

Have fun, hope it helps

Steve
 
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crazyhilife said:
Hi Dave, thanks, yes its fairly straight forward tbh, just make sure you clean thoroughly around the head and intake flange so not to let any debris fall in, once clean disconnect all vacuum hoses, air temp & EGT sensors and remove throttle body. Then undo the large hex bolt under the IM, remove injector rail (two hex screws) and unplug injectors (remove for cleaning) I took fuel pressure out of fuel pressure regulator first by removing it with a rag to soak up any fuel spill.
Then just undo the seven hex screws and two nuts on IM fange and remove.
Clean and replace old gasket with the phenolic kit and refit in reverse order.
If you are going to remove the IM completely to clean or paint it then you will need to remove the EGT sensor black box on bottom of IM and the sensor plug which goes through the IM from the injector loom.
The large hex bolt under the IM wont line up afterwards as everthing sits a little higher so I left this off as do many other people.
Cant think of anything else to note off top of my head but im sure someone will point out if i've missed something.

I didn't reset anything or do a TB allignment afterwards and havent scanned with VCDS yet but everything seems good

Have fun, hope it helps

Steve
Click to expand...

Thanks for this Steve,

I have another question (Im sorry) if I have a standard AMK engine setup is it just the small port Phenolic Intake Manifold Spacer I need?

Also where did you buy yours from Bill?
 
S3_DAVE said:
Thanks for this Steve,

I have another question (Im sorry) if I have a standard AMK engine setup is it just the small port Phenolic Intake Manifold Spacer I need?

Also where did you buy yours from Bill?
Click to expand...
Yep small port kit should be the same, bill at Badger 5 should be able to sort you out mate, just check when ordering that you get the right one

Steve
 
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Spur of the moment thing, I decided to just do a quick video showing my result, just uploaded to youtube.
Sorry about the image quality and background music

Steve

 
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audi upgrades
Can't wait to get mine fitted! I would love to see intake temps under 30 degrees! (Australia doesn't get down to 8.5 degrees too often)
 
Jenno007 said:
Can't wait to get mine fitted! I would love to see intake temps under 30 degrees! (Australia doesn't get down to 8.5 degrees too often)
Click to expand...
Lol, I think I'd prefere the warm weather to cold intake temps imho, my bro lives in Perth and he said it was over 30•c the other week.
I wouldn't mind some of that this time of year
 
What states he in? I'm in WA and the weather has been weird lately.. Still nice and warm though.

Just a little bit warmer and I'll be able to use our pool!
 
audi upgrades
I'm 20 minutes away from there haha. Scarbs is a great beach
 
Jenno007 said:
I'm 20 minutes away from there haha. Scarbs is a great beach
Click to expand...
Haha Small world, when I finally get chance to come over I'll fill the plane up with parts for the Oz crew, lol
You've probably seen him around driving a modified silver commodore, he works in a garage there, I was planning on doing the same but couldn't get a visa, they dont let any old rif raf into Oz
 
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crazyhilife said:
Haha Small world, when I finally get chance to come over I'll fill the plane up with parts for the Oz crew, lol
You've probably seen him around driving a modified silver commodore, he works in a garage there, I was planning on doing the same but couldn't get a visa, they dont let any old rif raf into Oz
Click to expand...
I'll be honest mate, everyone has a modified commodore haha.

Shame you couldn't get over
 
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