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XS - Power Relentless X - Pro 4 Fitting and test

MIGGZ Jan 7, 2015

  1. MIGGZ

    MIGGZ nanananananananan BATMAN

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    Hi guys

    So a customer of mine has a S3 and his stock Manifold decided to crack, looked at all the options and the Relentless V4 seemed like the best option. Got hold of XS power and they were more then helpful to answer my millions of questions so i decided to order myself one as well and also being the first in South Africa I was extremely keen to get cracking.

    I ordered the manifolds through Sam on the relentless facebook page it took like a week to get to me which is amazingly fast.

    So here is my experience and fitting guide for the manifold on a 2003 Audi A3 FWD K04.
    I have only done a before dyno and ill be doing a after dyno once the car has adapted and iv gone through everything again to make sure im happy.

    [​IMG]

    [​IMG]

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    1st up is new gaskets, nuts, washes, bolts and studs

    [​IMG]

    Turbo to DP studs (figured I would replace while its open)

    [​IMG]

    Mani to turbo bolts and stud (essential to have these)

    [​IMG]

    Mani to head washes and nuts
    [​IMG]

    to be continued......
     
    Last edited by a moderator: Jan 18, 2018
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  3. MIGGZ

    MIGGZ nanananananananan BATMAN

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    and all together

    [​IMG]

    [​IMG]

    [​IMG]


    Now the work begins.....

    Dyno before (3rd gear run)

    [​IMG]

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    i started off by removing the charge (boost) pipe, the tip and induction for some space.

    [​IMG]

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    i loosened the downpipe

    [​IMG]

    [​IMG]

    loosen and remove the bracket that bolts turbo to block

    [​IMG]

    now loosen the 3 bolts on top holding the turbo and the turbo should move down



    now you can loosen the bolts holding the manifold to the head and just pull it off and out the bay
    [​IMG]

    [​IMG]
     
    Last edited by a moderator: Jan 18, 2018
  4. MIGGZ

    MIGGZ nanananananananan BATMAN

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    here is the stock mani to the V4

    [​IMG]

    [​IMG]

    i used some high heat lock tight to the stud

    [​IMG]

    and fitted it to the hole closest to the firewall or furthest from head

    [​IMG]
     
    Last edited by a moderator: Jan 18, 2018
  5. MIGGZ

    MIGGZ nanananananananan BATMAN

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    now here comes the fun part!!!!!

    what you want to do is put the manifold onto the studs on the head but dont make it flush yet... on the pic below these are the most difficult ones to get to so put the nut on the manifold and move it closer to the head while turning the nut till it just bites and do the same procedure to the rest of the nuts till all is on and start tightening away

    [​IMG]

    now once that is all done you can offer the turbo up to the mani.

    push the stud through the hole like in the picture and tighten just enough to bite, now add the bolt in number 2 slot and tighten till it bites

    [​IMG]

    [​IMG]

    now put the 3rd and last one on and wiggle it around until you get the threads and tighten away rationing between 1 and 2 and 3 being the final one

    [​IMG]

    [​IMG]

    tighten the dp back up

    [​IMG]

    [​IMG]

    the bracket for the turbo to block brace i bent it a little and it fitted well back to position closed up and bolted all the parts back up

    [​IMG]

    [​IMG]

    overall im very impressed with this product and highly recommend it.

    The bum dyno tells me there is a huge gain in low end grunt, top rpm feel. the car just feels alive again and extremely responsive and the engine tone has changed as well giving a more aggressive sound.......


    stay tuned for figures and dyno results
     
    Last edited by a moderator: Jan 18, 2018
    rhubarb4 likes this.
  6. badger5

    badger5 www.badger5.co.uk Site Sponsor

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    you used a std gasket from turbo to manifold?
     
  7. MIGGZ

    MIGGZ nanananananananan BATMAN

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    yes sir i did, few people that has the manifold said they used the stock gaskets
     
  8. Prawn

    Prawn My other car is a MINI!!!!

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    Great work miggles! Nice to see you moving out the the dark ages with a manifold that'll really let it flow properly :)

    How long would you say it took you start to finish?
     
  9. MIGGZ

    MIGGZ nanananananananan BATMAN

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    hahahahah its all your fault

    from start to finish it was like 5 to 6 hours but also had some issues with a bolt that broke so that killed time and to figure out how to tighten the manifold so all the nuts are on as once its flush to the head i could not get 2 nuts on so had to loosen everything and re tighten
     
  10. antwan64og

    antwan64og Registered User

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    I thought the Pro 4 flange was bigger than stock and thats why people hogged out the ko4 hotside and ran gasketless (as there's none that match) to make it flow better?
     
  11. MIGGZ

    MIGGZ nanananananananan BATMAN

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    as i could see the port on the flange was bigger but match porting the turbo to mani could work, was not going to do that as next up is BBT hybrid
     
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  13. S3 Hilife

    S3 Hilife It's an addiction Gold Supporter VCDS Map User

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    Good write up Miggz, this is something i've been wanting to have a go at for a while but thought it was a much harder job than you made it look.

    I think i'll give it a go myself now, thanks

    Steve
     
  14. MIGGZ

    MIGGZ nanananananananan BATMAN

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    thanks dude biggest tip i have for you is get different shaped spanners and lots of patience, the mani to head i used spanner size 12 nuts i used a total of 3 different 12 spanners
     
    S3 Hilife likes this.
  15. flying oyster

    flying oyster flying oyster

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    Good write up wish that was around when my m8 did mine nice work
     
  16. MIGGZ

    MIGGZ nanananananananan BATMAN

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    thanks dude, reason i did it is i could not find a write up anywhere so hope this will help fellow V4 guys
     
  17. flying oyster

    flying oyster flying oyster

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    We had to move my engine mounts a bit to fit mine in end then found out they were shot all lined up ok in the end had it on for a fair few months
     
  18. MIGGZ

    MIGGZ nanananananananan BATMAN

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    im going to be doing a S3 end of this month thats going to be fun
     
  19. Broken Byzan

    Broken Byzan Photographic Moderator Staff Member Moderator VCDS Map User

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    So another one moving the turbo about grrr I wish they were consistent. Bending the lower bracket by how much made it fit?
     
  20. superkarl

    superkarl MAN OF STEEL

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    brilliant thread miggz

    do you have logs of egts before?
    because even if the power gains aren't all that great, if you log a significant reduction in egts that will prove there's potential for more tuning. Timing too
     
    Last edited: Jan 7, 2015
  21. MIGGZ

    MIGGZ nanananananananan BATMAN

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    i moved the bracket about 11mm and it was perfect
     
  22. MIGGZ

    MIGGZ nanananananananan BATMAN

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    thank you karly!!!!
     
  23. badger5

    badger5 www.badger5.co.uk Site Sponsor

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    there will be a step down to the gasket, flange portion is slightly bigger than gasket ID, although pipe which is welded into it is smaller ID..
     
  24. badger5

    badger5 www.badger5.co.uk Site Sponsor

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    a mk2 has arrived today with v4
    its previous fitting on std k04 manifold downpipe now hits something apparently on v4
     
  25. Nathan Barnes

    Nathan Barnes Registered User

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    Hey Miggz

    Are the turbo to mani bolts you used OEM? Just wondering because the ones I picked up this week from the local Audi dealer looked different to yours??
     
  26. MIGGZ

    MIGGZ nanananananananan BATMAN

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    Hey bud

    Nope got other bolts as to tighten the bolts with a socket won't work due to space and the stock heads are shyt lol
     
  27. badger5

    badger5 www.badger5.co.uk Site Sponsor

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    those E headed factory bolts are not great to hold onto or undo are they..
    strong bolts but horrible E socket fitting
     
  28. Nathan Barnes

    Nathan Barnes Registered User

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    Oh....Do I need a special socket then Bill?
     
  29. badger5

    badger5 www.badger5.co.uk Site Sponsor

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    for factory OE k04 bolts yea. Its an E (something) socket.. cant remember which one it is off hand
     
  30. MIGGZ

    MIGGZ nanananananananan BATMAN

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    They are a ball ache I stripped one on the S3 and i was like one step short of taking a grinder to the whole motor hahahahhaha
     
  31. MIGGZ

    MIGGZ nanananananananan BATMAN

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    [​IMG]

    Those the sockets for it
     
  32. Nathan Barnes

    Nathan Barnes Registered User

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    Hmmm. Looks like they might be a tight fit on a Pro4 using OEM bolts.
    I'm beginning to regret buying genuine ones now! Drat, drat and double drat.....
     
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  34. Nathan Barnes

    Nathan Barnes Registered User

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    You got the part number for the turbo/DP studs handy Miggz?
     
  35. MIGGZ

    MIGGZ nanananananananan BATMAN

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    Hahahahahahha chill dude you can sell those ones off quick
     
  36. MIGGZ

    MIGGZ nanananananananan BATMAN

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    No bud I don't sorry I just took a sample to a nut and bolt place
     
  37. antwan64og

    antwan64og Registered User

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    Do nordlock washers work with locking nuts?
    I thought they were just for bolts and 8.8 bolts at that, as using anything harder is too tough for them to bite into?
     
  38. MIGGZ

    MIGGZ nanananananananan BATMAN

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    No idea hey? But the nuts I used were copper nuts they soft?
     
  39. Broken Byzan

    Broken Byzan Photographic Moderator Staff Member Moderator VCDS Map User

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    Gosh i am surprised :angel:
     
  40. Broken Byzan

    Broken Byzan Photographic Moderator Staff Member Moderator VCDS Map User

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    11mm, good job it was a 2wd, a quattro car would have been stuffed. Is the car EGT equipped upon its K04 conversion ? You will need to monitor them very closely now
     
    <tuffty/> likes this.
  41. Nathan Barnes

    Nathan Barnes Registered User

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    Cool, will do the same. Thanks bud
     
  42. MIGGZ

    MIGGZ nanananananananan BATMAN

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    I have a egt probe in the K04 for when I did ebc just need to put a gauge on now as I removed ebc. Any reason to the sudden monitor?
     
  43. nonamed

    nonamed Registered User

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    Are You still satisfied with v4 rentless manifold? no problems?
    Also please let me know:
    1. Do You still have some spare cooper gasket mani to turbo?
    2. As I read OE bolts for manifold to turbo are pretty hard to use with v4 . Where may I get these bolts You used? Do You remeber the size?
     

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