Tuning project: Audi 2.5 TFSI RS3 8Y with over 1000 hp!

With the newer 2.5 TFSI EA855 evo, which is also used in our green car, Audi then brought a completely new benchmark into play. The current five-cylinder engine is lighter, more compact, more powerful and at the same time more economical than its predecessor. These attributes make it the holy grail among compact sports cars for performance enthusiasts. Audi achieved this in particular thanks to better and lighter materials: the cylinder block, screws and vibration damper are made of aluminium, while part of the oil pan is made of magnesium. The stainless steel crankshaft has been reduced in size and thus optimised in terms of weight. Pistons and conrods have also been revised.

It comes with 400 hp ex works and can reach speeds of up to 290 km/h depending on the configuration. It has been made more compact by switching to a single-track belt drive, which also has a positive effect on fuel consumption. The shorter installation length of the engine gives us a little more room for customisation, which has already elicited a few prayers.

You can follow our tuning guide and install the individual tuning levels or aim for a higher level directly. The first few hp can be achieved with small things such as ignition coils and spark plugs, an enlarged pressure pipe, upgrade- suction etc.. From tuning level 3, things get serious and the larger turbocharger is used.

For us, not everything, but really a lot, revolves around the turbocharger. We want to constantly improve our turbos, as performance stands or falls with the turbocharger. We therefore plan our tuning projects with a larger turbocharger and align the other components accordingly. For our RS3 8Y, we started with the Turbo-Total upgrade turbocharger Thor 666. This is suitable up to 690 hp and gives us some breathing space on our way to the 1000 hp. Its response behaviour is mega, as is its durability, and boost and pressure are a good combination for the start of our tuning project! It can also be swapped via plug & play, as it is based on the original.

For the medium power range, i.e. up to 850 hp and 900 Nm, we have installed the 2.5 TFSI EA855 evo Thor G30-900 upgrade Bolt On turbocharger from Turbo-Total. Here, too, the response behaviour and torque are outstanding. The materials and workmanship are high-end and here, too, most intake systems etc. can be fitted via plug & play.

For extreme performance, the 2.5 TFSI EA855 evo Thor G35-1050 Extreme upgrade Turbo Gen.2 from Turbo-Total was then used. It is designed for an incredible 1000 hp and 1000 Nm and is therefore perfect for those who are serious about their performance. This high-end turbocharger not only contains the finest materials, but also the latest technology in terms of charging: everything here is optimised for flow and performance. This turbocharger really does require a comprehensive conversion, but it is definitely worth it.

Even if we go up to just under 700 hp, we simply won't get far with some standard parts. From a torque of 650 Nm you need upgrade- conrods, otherwise you will very quickly have a hole in the block. The piston also need to be changed. We use our High Boost Ulti Kit for 2.5 TFSI EA855 evo engines directly in our RS3 8Y, as this is already designed for an output of 1000 hp . In addition to forged pistons and steel connecting rods, it also contains the connecting rod bolts, connecting rod bearings, head gasket and ARP- stud bolt. It is therefore an all-round carefree kit that contains the most important parts perfectly matched to each other and can accompany us on the way to the 1000 hp, so the parts do not have to be replaced with each higher tuning level.

For the same reason, our Audi RS3 8Y is also equipped with our 2.5 TFSI EA855 cylinder head High Boost ULTI kit. The valves, springs and all other components it contains not only work together like Swiss clockwork, but are also suitable for over 1000 hp power and extreme torques.

To overcome these challenges, we rely on our CNC milled billet intake manifold for 2.5 TFSI EA855. Thanks to the high-strength aluminium and the workmanship, this intake manifold is suitable for outputs of more than 1000 hp. The highlight is that we can install 10 additional injection nozzles in front of the intake port. We therefore use two injectors per cylinder: a smaller one for idling and a larger one for the high power range. This ensures that sufficient fuel is injected and the pressure remains even.

The extreme performance we are aiming for also requires an improved suction. Our upgrade carbon suction delivers almost 1000 cm³ more volume than the series counterpart and thus feeds the engine the ideal amount to significantly increase its efficiency. In particular, we enlarge the intake bend to the air filter box from four to five inches to bring the flow rate up to this level. This allows our RS3 to realise its full performance, and no more power is lost due to insufficient air intake.

Other parts installed in our green RS3 8Y:

• Competition intercooler
• Injection valve kit
• NGK Competition spark plugs
• Reinforced DSG clutch
• Reinforced dual-mass flywheel
• Oil cooler kit V2
• Transmission oil cooler kit
• Race camshafts
• 4“ Downpipe
• Catch tank kit for the engine
• Catch tank kit for the transmission

Of course, that's not all. Be sure to check out our tuning guide, where you'll find a list of the tuning parts you need for each tuning stage, along with helpful tips!