One of the slickest features of this modification is the ease with which in can be accomplished.  The procedure involves removing the engine computer and shipping it to us for modification and installing the modified computer and a wastegate spring when the modification is returned

 It is in the right front passenger footwell behind a cloth covered plastic panel that is held to the side of the car by one screw near the floor.  The computer itself is held in place by one screw at the top left of the computer. That screw goes thru a plastic bag that covers the wiring connector and the upper part of the computer.

Disconnect the wiring harness by pressing the catch toward the connector and simultaneously lifting on the catch end of the connector.  The connector will pivot upward. Caution: Both the wiring harness plug and receptacle are plastic and can be broken if excessive force is used.

 Loosen the hose clamp on the manifold pressure hose and slide it up the hose.  The hose can be slipped up the smooth brass tube on the computer by prying with a flat blade screw driver.

Intended Acceleration

2524 Pacific Avenue SE

Olympia, WA 98501

Insure it for the replacement cost of the computer which with taxes is about $1300.00.  Call (360) 754-1411 prior to shipping for scheduling the modification.  At present we can do two modification a day.  Your modified computer will be returned with the same expediting as it was received. However, if you send a personal or company check your computer will be held for 10 days.  I suggest sending a bank check or money order for $795.00.

Reconnect the wiring harness.  Slip the pivoting end of the connector under the pivot and press down on the catch end of the connector until it clicks into place.  Reattach the manifold pressure hose and tighten the hose clamp. Replace the plastic bag over the computer and attach the computer to the side of the car with the screw and washer. Reinstall the cover over the computer using the screw previously removed.

The following is done when the motor is cool to the touch. Locate the wastegate at the right side of the motor toward the rear.  Remove the six nuts and spring washers (newer cars use self-locking nuts only) that hold on the wastegate cap.  One of the nuts and spring washers also holds a soft aluminum plate with an Audi part number. Remove it if it has not already been broken off. Pull back the cap. You do not need to remove it entirely.*

Install the new spring, and replace the cap. It is easier to install a couple nuts without the washers at first to hold the cap in place.  Install the four other nuts and spring washers, then remove those nuts and install the remaining two washers and the two nuts again.

You may want to disconnect the three connectors behind the wastegate.  It is possible to remove the cap without disconnecting them! It is also difficult to reattach the connectors. Try to do it without disconnecting them first. If you wish to disconnect them, note the order and color of the connectors (draw a picture if you have to).

This completes the removal and installation instructions.  If you have a question please give me a call at (360) 754-1411.

Note:

When modified the 200/5000 TURBO/QUATTRO, when should display about 1.7 BAR on a cool day with a warm engine.  A stock Audi should display 1.4 and definitely 1.3

Don't push any engine hard until it is warmed up.  Especially on engines with Knock Sensors. The knock sensor is deactivated when the engine coolant is below 122 degrees or when the boost is below 0.7 BAR.

If 1.1 or 1.2 is displayed on a stock Audi or 1.5 on a modified one. Check our tech tips web site pages or:

Check the full throttle switch

Check the multi-purpose water temp sender

Check the wastegate frequency/solenoid valve

Check your hoses especially between the turbo and the intake manifold.

Check the hoses to the wastegate frequency valve.  Some have been found installed incorrectly.

EARLY 5000 Turbocharged Cars Only --Those without the Allen Cap Screw visible inside the underside of the wastegate cover. 1984 & some 1985 (Does not apply to 1983 & earlier)

Remove the metal plug from the top of the wastegate... Drill a small hole in it...  screw in a sheetmetal screw...Grab it with pliers and wiggle the plug out.

Vary the boost for different grades of gas by turning the 6mm socketed set screw (don't let the engine detonate).  I recommend a aftermarket boost gauge for setting.  13 PSI is safe with 92 octane. Exceed 13 PSI at your own risk.

First you have to break it free. Put the cap back on the wastegate studs without the spring...a built in vise to hold it. Now stick in the 6mm allen wrench. Rap it smartly with a hammer to break the threads free. Spray in some WD-40 or equal.  Smack it back and forth a little more each time until you can turn it.  If you simply start to turn it you can break the wrench.  The impact method works best

INTENDED ACCELERATION

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