APR Tuning Products for the Audi B6 - A4

APR is proud to release our newest addition to the APR Motorsport lineup, APR Compressor Inlet Hoses for the 1.8T. We designed these hoses to fill a gap in the market where other silicone hoses simply don’t perform.

After extensive testing our engineers have found that the OEM compressor inlet hose is not rigid enough to prevent collapse during high boost situations where airflow to the turbo is most important. A collapsed hose creates a huge airflow restriction that robs your motor of potential power!

Our engineers designed a replacement hose of high quality silicone with wire wrapping throughout to ensure no collapse at even the highest boost pressures. We found that simply recreating the hoses in silicone, no matter the density of the silicone, still allowed a collapse to occur. The wire wrapping ensures that not even the slightest collapse will be experienced providing more air to the turbo via the larger diameter of the hose and smoother transitions unleashing hidden power!

APR Motorsport Compressor Inlet Hoses are available in three colors; blue, black, and red. All APR Motorsport Hoses include everything you need for complete installation, including fittings and clamps.

APR's Snub Mount Upgrade replaces the front engine mount on the car. This mount enhances upshifting and downshifting, reduces driveline shock, and helps power transfer by taking up excess drivetrain slack.

APR's B6 A4 Exhaust is a complete stainless steel, mandrel bent, cat-back exhaust. On an A4, the catalytic converter is bolted to the turbocharger and then the exhaust begins with the downpipe. Unlike most other aftermarket exhausts, the APR exhaust includes a 2.5" downpipe. APR has two different exhaust systems available for the B6 A4, the Stealth and the Sport. These systems are a complete package replacing all of the tubing from the OEM catalyst to the polished stainless tips that are acid etched with the APR logo.

The original, quieter APR Stealth exhaust starts with the downpipe, and then the exhaust continues back to the innovative center muffler, where it splits into dual 2.25" pipes. Each of these mandrel bent pipes goes to its own muffler with a 3.5" rolled, round tip. This exhaust is very quiet and simply changes the tone to a deep, unobtrusive sound.

The APR Sport exhaust is for the no-compromise enthusiast that wants maximum gains and doesn't mind a little extra exhaust note. This system is similar in construction to the Stealth exhaust, but deletes the center muffler

With TIG welding, fully stainless construction, and CNC'ed hangers, you will not find a higher quality system on the market. APR is so confident in the construction of the B6 A4 exhaust it comes with a full lifetime warranty.

APR’s B6 A4 exhaust systems have been designed to have flow rates more then sufficient for even the highest levels of performance. Whether for street or track use we will have the right application for you.

APR is please to present our front mounted intercooler for the A4 1.8T. The construction and advanced design techniques used in the APR intercooler sets ours apart from all the others on the market. Utilizing such technologies as a top-bottom feed core, custom mandrel bent plumbing, and innovative cast endtanks with internal vaning, our intercooler has produced excellent results in testing.

The conditions of one test that was performed is as follows: at 20 psi of pressure with a vehicle speed of 70 mph, and an elevation of approximately 500 feet above sea level. Under these conditions the internal flow was measured at 720cfm. Also at those conditions, with an input temp of 240º F, the intercooler was quite effective; cooling the output air to 126º F. While doing this, the intercooler measured a pressure drop of only .58 psi.

Equally as impressive with the APR intercooler was the external pressure drop (the amount of air pressure behind the intercooler) of only 1.01 psi. This helps to allow airflow to other critical parts of the car such as the radiator and A/C condenser. While the internal pressure drop is important, the external pressure drop is often overlooked. Most other intercoolers commonly cause 1.5 to 2.0 pounds of pressure drop, hindering the radiator from effectively doing its job of cooling the engine.

The highlights of the APR Intercooler kits include the following:

* APR Cast End Tanks with Internal Vaning
* Top-Bottom Feed Bar and Plate Aluminum Core
* Mandrel-Bent, Powdercoated Stainless Steel Plumbing
* APR Custom Silicone Intake Hoses
* All Associated Bracketry and Hardware

APR’s Front Mounted Intercooler Kits were developed specifically with the 1.8T engine in mind. Extensive research went into to choosing the proper sized heat exchanger and what the optimal flow direction would be. A top-bottom, bar and plate heat exchanger with proprietary internal heat sink fins was chosen. This style heat exchanger offered very competitive performance when compared to the more an extruded tube design. Along with a low internal pressure drop, this style heat exchanger excels by presenting a lower external pressure drop then an extruded tube design. This allows for more air to penetrate through it for cooling of the radiator and other essential components.

Once the ideal heat exchanger was chosen, the task of using it to its fullest potential began. Unique cast aluminum end tanks were designed to ensure that the hot air entering the system would travel the full length of the core. A precise fin structure within the end tank helps to distribute hot air evenly across the core for the most effective cooling possible. Each fin is positioned at a specific angle to direct the correct amount of air down into that section of the heat exchanger. This allows the whole core to work at dissipating the heat.

When moving this air to and from the intercooler, you want to do so with the least amount of resistance as possible. With this in mind an effective series of tubing was designed. A combination of stainless steel and silicon tubing was used to create seamless internal geometry for the air to flow through. The stainless sections are used for the longer spans of tubing. The silicon is used to seamlessly and smoothly transition between diameters and to navigate through existing hardware.

The FMIC kit would not be complete without quality mounting hardware. Careful attention was paid to this area. We found that custom sheet metal designed brackets offered a healthy balance of a strength and aesthetics. All sheet metal parts are powder-coated to withstand rust so that they will remain strong throughout the life of the product.

Overall APR’s FMIC kit is the absolute best kit you will find on the market today. We work hard to design and engineer products that will last long and perform well for years to come and this product is no exception.

Our all aluminum end-tanks are factory like cast pieces. A cast piece ensures consistency in the production process, which in turn guarantees proper fitment to the core. Once mated and welded to the core, all assemblies are pressure tested to 60psi before even arriving at APR’s facility. The fins cast inside the tank help distribute the incoming air evenly across the core. The number of fins and the angle of each were changed many times until the optimum results were achieved. This design is an APR exclusive in this market. You won’t find this attention to detail in any other offering.

There are two primary core designs commonly used for cooling: the bar and plate design and the extruded tube. While both offer similar performance, a bar and plate intercooler is more efficent for cooling the intake charge temparature.

The size of the core is also very important. APR started with the optimum size core that can handle applications common on the 1.8T. From a standard chipped car to a Stage III, this core is extremely efficient and does an outstanding job in reducing intake temps.

The plumbing on an intercooler system is very important. Getting the air to and from the heat exchanger is simply a necessary part of the kit. Doing this job as smoothly as possible requires a little more attention to detail. The piping included in the kit is mandrel bent, powder coated stainless steel. The beaded ends (as seen in Pro-E drawing) help keep the silicon hoses in place under pressure.

The tooling for the silicon hoses is drawn up on Pro-Engineer and manufactured in house for precise fitment. Incorporated into the design is a recessed end, which allows the pipe to lie flush inside the hose, eliminating protruding edges that inhibit airflow.

All brackets included in the kit are powder coated and shaped from 16-gauge sheet metal for excellent strength and long lasting reliability. The spacers used to level the core are machined aluminum and fit perfectly on the machined mounting points of the end tanks.
To reinforce the modified bumper support, we have added a 14 gauge steel plate across the top of the support. This essentially replaces the portion removed from the lower half of the support, retaining the function of the assembly as a whole.

Many said it would never happen, but APR is now proud to release our K04 upgrade kit for the B6 Audi A4 1.8T. Our kit includes the K04 turbo, the compressor inlet O-ring, three turbo to downpipe studs, one manifold to turbo gasket, four Bosch fuel injectors, and one turbo to cat gasket. This kit is a straightfoward turbo swap that makes a big difference in the power output of the car.

This kit makes solid gains in both horsepower and torque. With no other mods than an APR Exhaust, the kit made 247hp/286lb-ft on 93 octane gas. Although the exhaust is not required, it is highly recommended.

If you are currently an APR Stage I/I+ or II/II+ customer and purchase a K04 upgrade, you will receive all EMCS options for free.

The software for this kit is also available separately for current APR Stage I/I+ or II/II+ customers for $199 or $699 for new customers.

Highlights of the APR R1 Diverter Valve Include:

* Diaphragm-Based Valve
o High-Temperature, Nomex-Reinforced Material for Extreme Durability
o Zero-Friction
o No Sticky O-Rings to Maintain and Grease
o No Pistons to get Stuck
o Consistent Performance Year Round
* Flow-Optimized, Investment-Cast Main Housing
* Stainless Steel Vacuum Fitting
* Zero-Maintenance Design
* Built with Finest Materials and Surface Treatments
* Fully Machined and Assembled at APR Headquarters in the United States for Optimal Quality Control

The APR R1 diverter valve was designed to be the ultimate solution to the problem of unreliable factory and aftermarket diverter valves and to be the leader in performance. Although most are of good design, factory diverter valves are built in a very conscious manner and the materials and overall life and reliability suffer. For the performance enthusiast, the diverter valve is an important component whose proper operation is paramount to optimal engine operation.

Enter the R1: APR�s R1 diverter valve addresses all of the reliability problems of the factory-supplied diverter valves and aftermarket replacements and takes performance to the next level. The R1 is a diaphragm-based valve. A diaphragm is the best option for a diverter valve for several reasons. First off, a diaphragm has negligible friction. Piston-based valves have considerable friction from the piston, o-ring, and bore assembly. The lower friction R1 diaphragm equates to faster response and better overall performance. Secondly, diaphragms do not require the periodic greasing that piston-based valves do. Piston-based valves must be qreased periodically (usually every year or sooner), requiring removing the valve from the car, disassembling and reassembling the valve. The APR R1 was designed to be maintenance free for the life of the product. Thirdly, a diaphragm based valve will never have a stuck piston. Piston-based valves periodically incur stuck pistons (especially if the required maintenance schedules are not followed.) Due to the lack of a piston, the APR R1 solves this problem.

The R1 is designed for optimal performance. The main body of the valve is investment cast in an aluminum alloy. By utilizing this casting process in lieu of a more conventional machining process, APR was able to optimize the internal geometry of the valve to provide the ultimate in flow performance. This geometry cannot be created utilizing conventional machining. As such, the APR R1 has much better flow characteristics than other diverter valves. Combined with the low friction diaphragm assembly, this equates to a valve that is truly a performance leader.

The materials used in the R1 are standard setting. The diaphragm is created out of high temperature material and incorporates a Nomex fabric reinforcement layer for enhanced durability and a diaphragm that will never tear. The alloy main body is finish machined at APR and receives a multilayer corrosion resistant and cosmetic enhancing finish. All machining and final assembly takes place at APR headquarters in the United States for optimal quality control and consistency.

APR announces the Stage III+ kit, the ultimate turbo system upgrade for the 2002-2005 A4 1.8T. This kit is capable of 340 horsepower and 332 foot-pounds of torque at the flywheel on 93 octane gas, while retaining stock-like drivability. The highlights of the kit include the following:

* APR Investment Cast Inconel Exhaust Manifold
* Honeywell/Garrett Ballistic Series Ball-Bearing Turbocharger
* Larger APR designed Mass Airflow Sensor Housing
* APR Custom Cast Silicone Intake Hoses
* APR High Flow Fuel Injectors
* All Associate Plumbing and Hardware

Stage III+ for the B6 A4 is being released initially with only stock, 91, and 93 octane programs. Race gas programs will be available soon.

The power increase with the APR Stage III+ kit for the A4 1.8T is substantial. It is highly recommended that brake and suspension upgrades are done to safely use the potential of this upgrade. It is also recommended that the stock engine internals be upgraded for power levels above 93 octane, as APR is not responsible for this type of damage to the engine.

The VAG 1.8T has quickly proven itself as one of the most technological power plants available. While the engineers who developed the kit made fantastic gains in both efficiency and reliability, they left much to be desired with regard to power. The B6 A4 Stage III+ Turbo kit bridges this gap with uncompromising quality and extreme power. Stage III+ is the newest addition to APR's quality line of products for the A4.

While other companies use the terms "tuner" and "R&D" loosely, we at APR feel that quality products start with quality planning. We begin with an idea and study the feasibility of the product. As designers we put a strong emphasis on safety and reliability. APR engineers developed the Stage III+ kit using Pro Engineer Wildfire 3-D CAD software and a Faro Platinum CMM machine. Prototypes are then processed using the 3-D Systems SLA machine. This rapid prototyping procedure allows for quick cast prototypes to ensure a perfect fitting final component. After the component has been verified correct, the final material cast can be run.

The Stage III+ utilizes one of the newest and most efficient turbos available. The Honeywell/Garrett turbos utilize the latest ball bearing design coupled with an integral wastegate and Inconel wheel. Make no mistake, these are not standard turbos retrofitted to ball bearing specs; they are the same type used in countless forms of motor racing such as the Audi R8 in the 24 Hours of Le Mans Series. APR is one of a few Garrett Engineering Houses in the US. We work closely with their engineers to design turbos that produce our desired performance level for each kit.

The APR Exhaust manifold is investment cast Inconel 625. Such material was chosen for its excellent thermal properties. Inconel can withstand temperatures of up to 2500 degrees Fahrenheit without structural degradation. The manifold runners are paired so that the exhaust pulses do not interfere with each other. This design maximizes low-end spool-up and boost-response. The manifold runners were also sized according to the power levels desired and with the size of the exhaust ports in mind. In order to prove the design, the drawing, as it existed in Pro-E, was run through a computational fluid dynamics program. This APR exhaust manifold is arguably the best 1.8T manifold available anywhere in the world due to its superior design and construction. No other company in North America has come close to reproducing a manifold at this level.

Other components quickly reached their operational limits and were also fabricated. The increased flow necessitated a larger MAF Housing. The diameter of the intake tubing was also increased to accommodate the increased airflow. A new larger air horn was placed on the MAF to further increase velocity. A flow straightener was then added to keep turbulence to a minimum. A flow straightener seems like a small detail and is easily over looked by most companies. However, this "small detail" is an integral component of this system allowing the larger MAF housing to be properly utilized. Larger injectors are added to the kit to keep the fuel system within acceptable parameters.

APR engineers write their own proprietary data logging software and analysis programs. This tuning software, combined with APR's Dynapack chassis dynamometer, allows a degree of precision never before seen in the aftermarket industry. Our dyno tuning allows us to tune to any RPM at any load level. This equates into the smoothest, most powerful tuning available. Our software, as with our hardware, is equally ahead of the competition. It's a rare combination to find a tuning company that engineers both the software AND the hardware for their systems. The advantage of designing hardware that is built to utilize our specific software, is obvious. OUR hardware working with OUR software is what comprises a truly engineered "system" and not just a conglomeration of parts.

No other company has the switching capabilities or the programming capabilities that we have. From home programming to industry leading EMCS, our products set the bar in which all others are measured.

The Stage III+ exhaust manifold is investment cast out of Inconel, a high-temperature nickel alloy. The manifold was designed in CAD and optimized using computational fluid dynamics (CFD) software. What this means to the end user is the ultimate in performance and reliability.

These CAD designed hoses are designed to replace the factory hoses between the airbox and turbocharger, and the turbocharger to the factory cross-over pipe. APR both designs and makes the tooling for these items in house, using a combination of our CMM tool, SLA machine, and CNC machine.

The mass air flow sensor (or MAF sensor) measures the amount of incoming air and sends an analog signal to the engine computer representing the amount of air flowing into the engine. The MAF sensor is mounted in a cylindrical housing that is sized according to engine displacement and maximum power output. We replace the stock MAF housing with a cast aluminum unit to allow the proper metering of the additional airflow and to minimize pressure losses. The cast aluminum housing is CNC machined to exacting tolerances and powder-coated to inhibit corrosion.

Representing the latest in turbocharger technology, a Garrett Ballistic series turbocharger is the only choice for a premium turbocharger system. APR is unique in that we deal directly with Garrett turbochargers rather than buying turbochargers through turbocharger supply houses. Our engineering-house distributor status with Garrett turbochargers means that we receive assistance from the manufacturer on technical issues and work with Garrett engineers on specifying the optimal turbocharger for each application.

The correct flow straightener was sourced to ensure laminar air flow through the mass air flow sensor. This is important for proper air flow metering at all flow levels. The flow straightener is sandwiched between the MAF meter and the air horn and is held in place by a retaining clip.

APR sent many hard hours with a major OEM manufacturer to develop a fuel injector that has the same spray pattern as a stock injector, but with a very high flow output.

APR is proud to release our newest addition to the APR Motorsport lineup, APR Throttle Body Hoses for the 1.8T. We designed these hoses to fill a gap in the market where other silicone hoses simply don’t perform.

After extensive testing our engineers have found that the OEM throttle body hose is not rigid enough to prevent flex during high boost situations where getting airflow to the motor is most important. A flexed hose like the factory one creates delayed throttle response and pressure drop.

Our engineers designed a replacement hose made of high quality silicone to minimize flex and get the pressurized air to the motor faster. APR Motorsport Hoses also have smoother transitions to help increase air velocity.

APR Motorsport Throttle Body Hoses are available in three colors; blue, black, and red. All APR Motorsport Hoses include everything you need for complete installation, including fittings and clamps.

Show your APR pride with our APR Tuned badges. Our badges have a polished chrome finish to keep a factory-like look over the years. The badge is approximately 2 3/4" long and 1 1/2" tall, and nicely replaces the stock engine designation badge on the back of the car.

APR now offers a complete coolant line kit for your 1.8T with a Garrett or KKK turbocharger. These lines look great and include all the necessary hardware.

APR now offers a complete oil line kit for your 1.8T with a Garrett GT turbocharger. These lines have the correct fittings crimped directly to the stainless line, minmizing the chance for leaks on these critical parts.

The oil feed line is a -6 line that comes with all the necessary banjo fittings and hardware for the 1.8T. It also comes with the correct oil inlet restrictor for the GT series turbos.

The oil drain line is a -10 line and includes the CNC'ed flanges for both the drain of the turbocharger and the oil pan itself. This line also includes all the necessary hardware for a tight seal.

APR is proud to be the Authorized Distributor for Carbonio Cold Air Intake (CAI) systems. Manufactured from aerospace grade carbon fiber, Carbonio further improves this material by incorporating a proprietary thermal barrier layer in its construction. The result is an exceptionally light and strong part that minimizes intake temperatures. This ensures that the engine optimizes power by receiving the coldest and most oxygen rich air possible.

Carbonio’s line of intakes for Audi automobiles represent the pinnacle of induction design. Extensive testing has resulted in an intake that maximizes performance in all driving conditions. Power will come on sooner and the engine will pull for longer and stronger.

Benefits of the Carbonio CAI System include:

* Increases Horsepower and Torque
* Improves Throttle Response
* Decreases Turbo 'Lag'
* Flattens Torque Curve (engine is less 'peaky')
* Improves Fuel Economy
* Enhances Engine's Volumetric Efficiency
* Enhances Sound of Turbo Diverter Valve
* Works with All Aftermarket Diverter Valves
* Installs in an Hour (does not require bumper or headlight removal)
* Maintains All Factory Emissions Components
* Fits Both Manual and Automatic Transmissions
* Unique Thermal Barrier Composite Construction Ensures Low Inlet Temperatures
* Fully Compatible and Complimentary with APR Software and Exhaust systems

Each Carbonio A4 Kit Includes:

* Aerospace Grade Carbon Fiber Main Section Ensures Inlet Temparatures Stay Low
* Carbon Fiber Main Section has Show Quality Finish
* Complete Photographic Instructions
* Filter Design Eliminates Need for Secondary Air Pump
* All Necessary Hardware Included for Easy Install without Cutting Or Modifying
* Works on APR Stage III+ Cars with Larger MAF