Complete ZO6 exhaust A4
Thread Starter
Racer
Joined: Sep 2003
Posts: 256
Likes: 0
From: Boulder City NV
Complete ZO6 exhaust A4
Just finished installing a complete ZO6 exhaust into my 05 A4 car and I can tell you, its not a job for the faint hearted. I had to cut each muffler pipe in two places and modified the h pipe to mate up with them. The 3" over axle pipes have no more than a eigth inch between the trans and fuel tank pan on the curb side. I'm sure using the stock 21/2" pipe would have been a lot easier and probably the smarter way to go. But, the 3" will work-just take your time if you're so inclined. Hal
Thread Starter
Racer
Joined: Sep 2003
Posts: 256
Likes: 0
From: Boulder City NV
I ran some 3/8 air brake hose back and t'd it into the PB vacuum line up front. Right now I just have it t'd in at the mufflers so its quiet all the time. I'm looking for a vacuum solenoid now and will switch it from a switch I'll mount in the counsel. I brought a wire along with the 3/8 hose while I was at it to feed the solenoid. I guess I'm just too cheap, er thrifty, to buy one of the systems out there. Hal
Melting Slicks
Joined: Dec 2006
Posts: 2,887
Likes: 2
From: Exhaust Commander Wireless Bi-Mode Exhaust Controllers, Innovative and advanced technology! --- Check out our website @ www.sunsetorangecreations.com
St. Jude Donor '13
Congrats on getting the 3" system in the A4 car!
Its a pain but it can be done.
Youll find that since you t'd into the brake boooster line that when you go WOT for extended the periods the butterflies will open when the vacuum goes away. It makes it a somewhat throttle position based system.
A few people out there run this way with just a vacuum line from the manifold to the butterlfies, no solenoids and switches. And when they go WOT a few seconds later the butterflies open and when they close throttle they close again.
Adding the vacuum solenoid will be easy for you at this point and then would give you full control over the valves to do with them as you wish.
Good Job on the install, and enjoy your new Bi-mode exhaust!
Ben
Its a pain but it can be done.
Youll find that since you t'd into the brake boooster line that when you go WOT for extended the periods the butterflies will open when the vacuum goes away. It makes it a somewhat throttle position based system.
A few people out there run this way with just a vacuum line from the manifold to the butterlfies, no solenoids and switches. And when they go WOT a few seconds later the butterflies open and when they close throttle they close again.
Adding the vacuum solenoid will be easy for you at this point and then would give you full control over the valves to do with them as you wish.
Good Job on the install, and enjoy your new Bi-mode exhaust!
Ben
Thread Starter
Racer
Joined: Sep 2003
Posts: 256
Likes: 0
From: Boulder City NV
Thanks for the advice on the vacuum setup. I know you sell a fine system and appreciate you taking the time to give me tips-especially since I'm somewhat cutting into a potenial sale for you. I have to give you 
for being a class act. Thanks, you're a credit to the Forum. Hal
for being a class act. Thanks, you're a credit to the Forum. Hal
Racer
Joined: Jan 2008
Posts: 392
Likes: 0
From: Tall Oaks NY
I also added the Z06 mufflers to my car but didn't keep the 3" pipe. I did though mod my cans by cutting them open and having the perforated pipe inside replaced with a solid pipe. Sounds awesome, what the car should have had from the beginning. Here is a short video clip, only rev'd to 4k rpms. I have to say it sounds so much better in person and when really opened up it makes me proud 
I still need to connect a vacuum so I can close the flaps for early morning start ups. It has effected my gas mileage in a negative way, I find myself getting on it more often to hear the music to my 
but so worth the huge 
it gives me.
http://s293.photobucket.com/albums/m...t=CIMG1808.flv
I still need to connect a vacuum so I can close the flaps for early morning start ups. It has effected my gas mileage in a negative way, I find myself getting on it more often to hear the music to my but so worth the huge it gives me.http://s293.photobucket.com/albums/m...t=CIMG1808.flv
Le Mans Master
Joined: Aug 2004
Posts: 5,259
Likes: 16
From: Monroe Township New Jersey
St. Jude Donor '05-'06-'07-'08-'09-'10-'11-'12-'13-'14-'15-'16
St. Jude donor in memory of jpee '14
Just finished installing a complete ZO6 exhaust into my 05 A4 car and I can tell you, its not a job for the faint hearted. I had to cut each muffler pipe in two places and modified the h pipe to mate up with them. The 3" over axle pipes have no more than a eigth inch between the trans and fuel tank pan on the curb side. I'm sure using the stock 21/2" pipe would have been a lot easier and probably the smarter way to go. But, the 3" will work-just take your time if you're so inclined. Hal
If I can make a suggestion you should wrap the electrical connection to the trans with heat reflective silver tape to protect it as the Z06 pipe is much closer than the original pipe, after 4000 miles mine is fine with a slight rattle from time to time. I cheated and utilized clear tubing from home depot and ran it through the inside of the car and hooked it up to the Z06 vacuum pump & tank I used add a circuit to power the pump and installed it in the heated seat fuse location. I have yet to get the car tuned but it was several hundreds faster the last time at the track. It really needs to be tuned in order to get any material amount of HP gains from the installation.
The CF member who did the first conversion can be found by doing a search for "my christmas project". He actually modified a F55 switch to work, good luck
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Thread Starter
Racer
Joined: Sep 2003
Posts: 256
Likes: 0
From: Boulder City NV
Thanks for the tip, I was planing on doing that (insulation) before I drove it. It looks like it can use it on both sides to be safe, its REALLY tight back there. I sent the Ecm out to COW today so will be anxious to feel the differance.
The install was a little 'FUN' alright but I think there is an easier way around it. If you were to cut the over axle pipe at the two straight locations, horizontal and forward angled straight area, and put a couple of couplings at the cuts, you could rotate the pipes around to get your clearences. All that would be left is adjusting the H pipe by taking a couple pie cuts out of it to align with the rear pipe. Sounds simple enough but...... Glad its behind me for sure.
The install was a little 'FUN' alright but I think there is an easier way around it. If you were to cut the over axle pipe at the two straight locations, horizontal and forward angled straight area, and put a couple of couplings at the cuts, you could rotate the pipes around to get your clearences. All that would be left is adjusting the H pipe by taking a couple pie cuts out of it to align with the rear pipe. Sounds simple enough but...... Glad its behind me for sure.
