AT REVO, WE TRY OUR UTMOST TO DELIVER THE BEST PERFORMANCE TUNING SOLUTIONS FOR THE VW AUDI GROUP AND FORD PLATFORMS. WITH OUR STAGE 2 DEVELOPMENT ON THE RS3 8V2 (DAZA & DNWA) PLATFORM COMPLETE, WE WANTED TO FURTHER OUR PRODUCT LINEUP ACROSS TO THE RSQ3 – THIS IS OUR JOURNEY.
Let’s start with what we know already; the RS3 8V2. We purchased two of our cars for the extensive development work we wanted to carry out throughout the platform. The first was a 2018 Audi RS3 Saloon housing the DAZA engine (Non-GPF). The second was a 2019 Audi RS3 Saloon which had the DNWA engine with a GPF.
At Revo we’re not keen on removing any GPF (or DPF for the matter). So, to keep all of our tuning and hardware legal we developed our software which met the performance gains we wanted whilst NOT removing the GPF (DNWA engine only).
Over an extensive calibration period, we produced Stage 1 & Stage 2 software for both variants of engines PLUS a choice of overrun style depending on your preference (DAZA engine only). We also designed, prototyped and developed all of our hardware for the platform including; the intercooler, intake, turbo inlet pipe, flow formed RF0 wheels and a track-focused 6-pot brake kit along with 2-piece brake discs. The entire Stage 2 package can be purchased as a Performance Pack, offering all the hardware and software you require for a complete Stage 2 RS3 8V2.
Now that that’s out of the way, let’s see the car.
Where shall we start? I know, software.
From the get-go, we wanted to meet the power and torque from the DWNA found in the RS3. We wanted to match our Stage 1 & 2 performance and carry it across to the RSQ3 however, this time we could add in new features and updates which we have developed since the original release of software on the RS3 8V2. With our in-house calibration engineers plus an unlimited amount of cars to test & verify amongst our dealer network, we had this!
One of our Calibration Engineers, Dan, was the original creator of the Revo RS3 8V2 software so it only made sense for him to carry out the calibration on the RSQ3. He began with many data logging sessions then swiftly moved on to testing our Stage 1 software from the RS3 8V2.
Yeah, it’s easy to think that with the same engine in both the RS3 and the RSQ3 our software would transfer straight over. Unfortunately, it isn’t that simple. One of those reasons was the overrun option we featured in the RS3 software. The RSQ3 didn’t give one hint of overrun or burbles even when stock, so a straight swap of software wouldn’t fix that instantly.
it has a gpf, remember
I’d like to jump in here to point out the elephant in the room; the GPF. At Revo our position couldn’t be clearer when it comes to removing GPFs (and DPFs for that matter), we DON’T. All of our software has been designed to work alongside any factory GPF without the need to remove or alter it in any way, allowing you to modify your pride and joy, legally.
our software in a nutshell
In conclusion, we found the calibration of our software for the Audi RSQ3 to be very similar to the RS3 (as you would expect). However, it wasn’t all beer and skittles. We had a few hurdles to overcome including the exhaust overrun predicament and a few unexpected cross-over issues.
That being said our RSQ3 Stage 1 software is refined, reliable and more importantly, makes a difference. We’ve been able to learn from our initial Stage 1 & 2 software for the RS3 and create an incredible harmony between our software and the 5-cylinder powerhouse.
Hardware, hardware and more hardware
As with our software, our hopes were that the majority of parts from the RS3 would carry over onto the RSQ3 platform. We began by stripping down the front end, comparing parts, numbers, and samples. Let’s take a dive into each individual hardware part.
The limitations of the stock intercooler were apparent throughout testing. The stock part consistently struggled to manage charge air temperatures, especially on a fruitful drive.
Luckily, we have the perfect solution. Designed with a bar and plate core to maximise the efficiency of heat transfer, the pressure drop is also controlled as the air meets less resistance compared to that of a tube and fin alternative. The Revo Intercooler also features carefully specified fin geometry to maximise cooling properties while minimising flow restriction. Not to mention it fits perfectly.
The Revo Intercooler has been designed to improve on every restrictive element of the stock cooler, enhancing cooling efficiency by lowering intake air temperatures by up to 38ºC vs. the Stock intercooler, allowing you to drive harder, for longer.
With peak gains of +17 HP (hubs) & +43NM Torque, along with increased performance throughout the entire rev range. The stock intercooler struggles to effectively function in comparison to the Revo Intercooler which remained consistent throughout.
Straight off the bat, we knew we would have one hurdle from looking at the RSQ3 vs the RS3. The intake itself sat higher than the engine in comparison to the RS3. The good news is it would only affect one hardware item; the intake system.
We began by testing the fitment of our Carbon Series intake lid, success. We then tested our Carbon Series back intake hose (the one that’s 20% larger than stock), success. The tricky part in the operation was attaching the Revo larger back intake hose with the Carbon intake. Due to the fact that the standard airbox is substantially higher than the engine, attaching them together caused kinks in our silicone. Let’s fix that below…
NEW SILICONE JOINER
We began with a scan of the stock part using our state-of-the-art 3D scanning equipment. This immensely reduces the time to measure, test and develop new products vs completing the same by hand. Additionally, the accuracy is second to none which makes our products superior with a faster turnaround. Couple this with our 3D printer, the journey from concept to reality is minute.
At this moment in time, that’s all we have regarding the new silicone joiner which is needed to join our intake system together. Keep an eye out on this blog and our socials for more information on the release. alternatively, keep an eye on our website www.onlyrevo.com.
2.5L turbo inlet pipe
The 2.5L TFSI engine is capable of incredible power gains even with the stock turbocharger. Whilst the stock inlet is fine for stock power, once you start increasing performance the stock inlet pipe becomes a restriction to airflow and holds back the potential gains.
The main design focus of the Revo inlet pipe was to increase the internal volume and increase the airflow directly into the turbo. The data gained from our testing of the stock part showed that increasing the inlet size to 4” and maintaining that internal cross-sectional area throughout as much of the pipe as possible produced significant airflow increases and subsequent performance gains.
The Zircotec © coating applied to the inlet is a ceramic/metal hybrid mixture. With superior thermal resistance properties reducing heat absorption and preventing loss of performance. Insulating the Revo inlet on all sides with this coating aids the thermal management from both direct exhaust manifold radiative heat as well as general engine bay heat reflected onto the pipe.
The Revo turbocharger inlet kit offered an average gain of +15WHP and +23NM torque over the stock inlet system. The increased airflow and improved thermal management of the Revo kit also delivers an impressive peak performance gain of +23.5WHP@4400rpm and +38NM @4400RPM over the stock inlet system.
that’s a wrap…
After years of continued development across the 2.5L TFSI platform, we’re delighted to include the RSQ3 software and hardware into our product lineup. Across the 2.5L platform, we’ve completed thousands of development miles, multiple updates and a ludicrous amount of manpower to create an all-in-one solution in terms of performance and reliability.
If you’ve got an RSQ3 yourself and would like to purchase any of the software or hardware above, please find your nearest local Authorised Revo Dealer here.
To stay tuned for more information on the entire RS3, TTRS and RSQ3 lineup click here.