XS - Power Relentless X - Pro 4 Fitting and test

MIGGZ

nanananananananan BATMAN
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.

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

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

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

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Mani to head washes and nuts
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to be continued......
 
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MIGGZ

nanananananananan BATMAN
and all together

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Now the work begins.....

Dyno before (3rd gear run)

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

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i loosened the downpipe

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loosen and remove the bracket that bolts turbo to block

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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
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MIGGZ

nanananananananan BATMAN
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

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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



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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

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tighten the dp back up

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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

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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
 
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Prawn

My other car is a MINI!!!!
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?
 

MIGGZ

nanananananananan BATMAN
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?


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
 

antwan64og

Registered User
yes sir i did, few people that has the manifold said they used the stock gaskets

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?
 

MIGGZ

nanananananananan BATMAN
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?

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
 

MIGGZ

nanananananananan BATMAN
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

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
 

flying oyster

flying oyster
Good write up wish that was around when my m8 did mine nice work
 

flying oyster

flying oyster
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
 

Broken Byzan

Photographic Moderator
Staff member
Moderator
VCDS Map User
So another one moving the turbo about grrr I wish they were consistent. Bending the lower bracket by how much made it fit?
 

superkarl

MAN OF STEEL
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
 
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badger5

www.badger5.co.uk
Site Sponsor
yes sir i did, few people that has the manifold said they used the stock gaskets

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..
 

badger5

www.badger5.co.uk
Site Sponsor
So another one moving the turbo about grrr I wish they were consistent. Bending the lower bracket by how much made it fit?
a mk2 has arrived today with v4
its previous fitting on std k04 manifold downpipe now hits something apparently on v4
 

Nathan Barnes

Registered User
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??
 

MIGGZ

nanananananananan BATMAN
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??
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
 

badger5

www.badger5.co.uk
Site Sponsor
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
those E headed factory bolts are not great to hold onto or undo are they..
strong bolts but horrible E socket fitting
 

Nathan Barnes

Registered User
Oh....Do I need a special socket then Bill?
 

MIGGZ

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

Nathan Barnes

Registered User
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.....
 

Nathan Barnes

Registered User
You got the part number for the turbo/DP studs handy Miggz?
 

antwan64og

Registered User
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?
 

Nathan Barnes

Registered User

MIGGZ

nanananananananan BATMAN
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
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?
 

nonamed

Registered User
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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