Archive for AudiSRS.com The place for Performance Audi
 


       AudiSRS.com Forum Index -> Projects and Builds
mikey-s

K04 Project finally started..

Well I finally got around to starting my K04 upgrade. I managed to borrow a two poster ramp in a friends workshop for a while, so that should make the job much easier. Attempting an engine pull on a four poster would have been a complete pain..

I do have plans for a Garrett kit, but this is a long way off, so for now it will have to be plain K04s. Here's the spec I'm going for at the moment..

Standard S4 bottom end, (not fitting my pistons & rods this time around)
Compression lowering gaskets,
RS heads, with complete RS intake system, RS injectors, ex manifolds,
RS intercoolers,
K04's
710Ns,
Wallbro fuel pump,
Custom Mocal oil cooler
XS 2.5" dual stainless turbo back system
BMC panel filter  

I also have H&R coilovers, Hotchkis ARB, Complete B5 RS brake setup with EBC redstuff rears and poss Ferodo DS 2500 fronts, and an ESP DTS.

I know there's lots of areas where I could improve the spec of this project, but this is being done on a rather tight budget, so I will have to make do for now.

This was taken on my phone so excuse the poor quality. Another hour on Monday morning and it'll be out..


Ash25

Looking GOOD!

congrats on starting this mate....very similar to what my car is undergoing at the moment! you doing this all ourself.....good man...i havent a clue on the details...would put it back with loadsa bits left over    

keep us informed on the progress, and of course with pics!

what sort of power you heading for, or is it put all the bits in and see what comes out (again like mine!)

Good luck!

Ash
mikey-s

I'd like to say that I'm aiming for specific/BHP Torque figures, but it will just be a case of seeing what Doug can squeeze out of it. It'll be practically RS spec with the addition of the dual exhaust, BMC filter, and Wallbro fuel pump, so maybe 440 ish sounds like a good number?

Just need to contact MRC regarding a safe map (to prevent overfuelling) and head gaskets.

More pics will follow..
Ash25

sounds good.....what made you choose the walbro pump rather than say the bosch one thats talked about? or am i talking rubbish?

Ash
mikey-s

Price..  the wallbro (in tank) is a lot cheaper and there are some guys using them with good results.
H8CAK

Nothing wrong with Walbro
tdiquattro

rs ex manis are the same as s4, so you could get away without the change, save on gaskets and nuts etc, and the panel filter shouldnt make any difference, so you could save there as well. good luck with the project, i run a walbro with no problems.
mikey-s

tdiquattro wrote:
rs ex manis are the same as s4, so you could get away without the change, save on gaskets and nuts etc, and the panel filter shouldnt make any difference, so you could save there as well. good luck with the project, i run a walbro with no problems.


I was under the impression that it's only the very late S4 ex manifolds were the same as the RS, but I'm changing to RS heads anyway, and they have manifolds with them.

Already bought the panel filter because I was initially aiming for more power.
tdiquattro

ok cool, as i understand it there are several versions of the manis, but nothing special about the rs4, the changes were for relaibilty not the internal diameter, so not a power mod. Good to hear you are going K04 ! wait for the first drive     ,  just meant for others looking that those bits could be a saving.
tdiquattro

oh just to add,

rs4 clutch pressure plate
new gear linkage end ball cup (orange thing)
heat sleeve for oil feed lines
retain but cut short the heat sheilds over the turbo/dps
prime the turbos with oil
double/double check ex mani and turbo bolts/nut torque
let the engine/gearbox centre on the mounts
new 034 emgine/gearbox mounts
part fill the rear diff mount with silicone
heat wrap first section of DPs
cut dps and install 2.5 inch V band clamps
poly snub mount
check waste gate opening pressures
DavidT

h8cak wrote:
Nothing wrong with Walbro


Does it depend on what power you want to run though ?
mikey-s

tdiquattro wrote:
oh just to add,

rs4 clutch pressure plate
new gear linkage end ball cup (orange thing)
heat sleeve for oil feed lines
retain but cut short the heat sheilds over the turbo/dps
prime the turbos with oil
double/double check ex mani and turbo bolts/nut torque
let the engine/gearbox centre on the mounts
new 034 emgine/gearbox mounts
part fill the rear diff mount with silicone
heat wrap first section of DPs
cut dps and install 2.5 inch V band clamps
poly snub mount
check waste gate opening pressures


Already got the RS clutch.
Car only done 50k so gear linkage still ok.
Heat sleeve.. good idea.
Prime turbos.. already planned thet.
Diff mount mod.. good idea.
Heat wrap dp's.. not so sure.
I'm adding Ilok flexis to the dp's.
Checking opening pressures too..
Chris M

Be interesting to see what figures you achive, i'm going to be on with a simular project with mine. No RS top end, just ported heads and intake manifold on stock K04's and a front mount and a few other bits.
grizz

Chris M wrote:
Be interesting to see what figures you achive, i'm going to be on with a simular project with mine. No RS top end, just ported heads and intake manifold on stock K04's and a front mount and a few other bits.


Come on Chris , Whats the "few other bits" ... You must be able to get some goodies from Doug..
Chris M

Not too much at the moment. Spec should be: Ported heads and inlet,  Thick headgaskets, custom intake pipes, fuel pump, injectors, ported manifolds, 3" downpipes + custom linkpipes and centre section, front mount and water injection.
frazered

good stuff Mikey

what sort of timeframe are you aiming to complete this by ?
mikey-s

I'll only have a few days on it before I have to go back to work, so it'll be finished next time I'm home. Within 6 weeks I'd say. If I had more time I reckon it would
be finished (apart from a remap) by the end of the week..

I've booked the Nurburgring for the 30th May - 1st June so it will have to be finished and have had a good few miles on it by then..

This is the other reason it's taken me so long..  the cars new home..

tdiquattro

my 2.5 dps/wrap/short heat shields/oil line heat sleeves/v bands....
- keep part heat sheilds to cover the turbos but make O2 sensors easy
- v bands to make the next engine work easier
- fill the rear diff mount, if i did it again i wold part fill it, say 4 corners











DavidT

Moved to project & builds forum. Keep the photos coming Mikey
Chris M

Chris M wrote:
Not too much at the moment. Spec should be: Ported heads and inlet,  Thick headgaskets, custom intake pipes, fuel pump, injectors, ported manifolds, 3" downpipes + custom linkpipes and centre section, front mount and water injection.


That said, I'm trying to persuade Doug to let me fit one of the spare RS4 Engines he has here    Would be an easier less hassle option.

Good luck with the project Mikey.
mikey-s

Today was quite productive, and everything seemed to go well, until my journey home..  I was in slow moving traffic and looked over at the other carraigeway at a crash that had just happened.. then yes, you guessed it, I looked around and the traffic in front of me had stopped.. and I didn't. My first crash ever. 20 years of incident free driving then this. What a bloody numpty!  



All went well.. until I done this on the way home!  


James

Any excuse to buy an RS4 front bumper.
Ghost

Oh bugger at least you are okay - no consolation I know...
ScottR

Hope your no claims were protected, otherwise insuring yours is going to be very painful!
mikey-s

James wrote:
Any excuse to buy an RS4 front bumper.


Lol  

I don't have no claims protection..  
mikey-s

Building the heads yesterday I found the drivers side exhaust cam worn, and this had started to wear the follower. Luckily Grizz sorted me out with the necessary parts.    I'll be keeping an eye on them, with an inspection every 5000 miles or so! I also spent some time making a couple of blanking plates for the air injection holes, and I'll be ordering a couple of gaskets for them tomorrow.

I've received the compression dropping gaskets from MRC so the heads should be back on tomorrow. I believe these are a 0.9 drop which should take it to 8.4:1.  I was going to get the ECU off to MRC for a safe map so I could confidently drive it down to them for a custom jobbie, but apparently it should be ok as long as it has RS injectors & MAF plus the N75 has to be disconnected.

Forgot the camera today, so my next lot of pics will be taken tomorrow...

Oh, and I couldn't find a second hand bumper for my avant runaround, so I've had to fit my S4 bumper for now, just to get it roadworthy!  That'll teach me!  
buzzard

keep your pecker up mikey.

It will be all worth it in the end.

will be good to see what figures you get.
Are you making it to the rolling road weekend???
mikey-s

I'm always a happy bunny.. especially at the moment with a project like this. 'Like a pig in sh*t' some would say!

I won't make it to the rolling road because I'll be working away soon so the car will have to wait.
mikey-s

The motor is almost ready to go in! After getting the cam off Grizz, it didn't take long to build the heads and get them on. Sorted out the pipework around the inlet manifold, ie N249 delete, new spider hose, etc.  I had to fit both the EGT sensors on the same locating studs, but I then found out the pass side loom isn't long enough so I can't plug it in! I did think of moving the sensor but that would mean making up a bracket to mount it, and I really like the current location so I have decided to extend the loom by around 3 inches.. job for Monday.




After spending a couple of hours making blanking plates for the air injection holes I then found out the two heads had different bolt setups..    so I ended up threading both of the holes with a M10 tap and fitting blanking plugs & alloy washers (the holes are the perfect size for a M10 tap).

I very nearly cocked up..  I manage fit the L/H turbo oil drain tube, then I remembered I hadn't taken out the blanking plug! Oops! I would have been soo p*ssed off if hadn't realised my mistake..  

Had to wait for the stealers to get me a waterpump & thermostat, but that's all done with new cambelt & idlers. Happy days..

I managed to forget my RS clutch AGAIN.. so mating the box up will have to be a job for Monday.

I decided to cut off the rather naff band type exhaust couplings and fit a pair of flexis. I went with the 2.5 inch Ilok type for more reliability. Not sure if I'm allowed to say this but a BIG thanks goes to Ian Birch at PIPEWERX.COM for his help with supplying and welding the flexis onto the downpipes. I went to see him at 4.30 today, when most people are thinking of going home, and he got cracking on them straight away. Cheers for that!  I've seen this guys work in the past.. and I'd highly recommend him.







So all in all it's going really well. If it wasn't for having to run around sourcing parts etc I may have already had it running. I'm itching to get it back in, but the workshop where I'm doing it doesn't open weekends!    Roll on Monday!
ScottR

Your making some great progress there.
mikey-s

Yeah, though it could have gone a bit quicker. In saying that, I'd rather be thorough and know it's going to be good first time.

Anyone got a pic of an RS4 N75 rubber locating bracket? The inlet manifold I got didn't have one fitted so a couple of cable ties will have to do until I can get hold of one.
mikey-s

Managed to get the engine back in today! But I had flat batteries in my camera so no pics I'm afraid..  

Fitted the complete RS clutch and got the box on, then extended the loom to connect the r/h EGT sensor because it's in a different position on the RS inlet manifold. Then finished the loom off with cloth tape to make it look original. Had to then hunt around for turbo inlet pipe o-rings.. the K03's don't use them! Good job I spotted that one because they would have been a complete b*tch to do in situ!

Had the engine almost ready to go in then realised I didn't have turbo/downpipe gaskets or studs, plus I forgot to buy some heat wrap. A quick trip over to see Grizz and he sorted me out again.. cheers fella.    

Anyway, the whole process has up to now been relatively hassle free, and I've enjoyed every minute, well almost.. after getting the lump back in today I found the gearbox oil cooler pipes that I'd forgotten to refit, so off again with the r/h engine mount..  

Should get some pics tomorrow..

I
jimbo

good work mike
spen

excellent work Mike.  You'll beat me by several months at this rate!
mikey-s

Spen, our projects don't compare.. I'm just bolting a few things together while you're doing a complete rebuild!

Another productive few hours spent on it this morning.. Got the gearbox oil cooler pipes back on after forgetting to fit them yesterday!  

Managed to get tightened up on it's mounts and the subframe all torqued back into place. While I was there I fitted the ESP DTS. It didn't want to line up no matter what I done, so in the end I had to elongate the holes in the rubber mount, even now it's under a little bit of tension which I'm not 100% happy about. Also, there doesn't seem to be much room for movement of the subframe if needed when the geometry is adjusted, ie the 6mm allen bolts going up into the chassis are a snug fit inside the alloy DTS bracket, while the original bracket has room for movement. Whether this is going to be a problem I don't know..

Managed to get it 90% wired up, fitted the modified airbox with BMC filter. I'm itching to get it running, and it's only about an hour or two away, but I'm off to work for a while so the car has to come to a standstill. How annoying!!  

Sorry for the bad pics.. I really must buy a new camera.. or learn how to use this one!





Stigter

Nice flexi's sure seen them before somewhere? lol
are these the 3" downpipes from the XS system from ebay just with proper flexi's fitted and heat wrapped?
mikey-s

They are 3" tapered down to 2.5", with flexi's welded in place of the naff band type joint, wrapped then painted with high temp paint to seal the wrap.
frazered

did you manage to finish her off Mikey?
mikey-s

Still out of the country. Will be working on the car again on the 2nd April, and hopefully it'll be ready for a remap by the middle of the next week, though I don't want to book it in for the remap until I know it's problem free.

I have to finish off the exhaust, fit the intercoolers, then put the front panel back on with a custom oil cooler and that should be it. While it's on the ramp I may as well fit the coilovers, ARB's and RS brakes.

I'll keep you posted, and should be able to take some better pics because I treated myself to a proper camera!

Mike
tdiquattro

Looking good, just about the engine line up, did you line up the subframe guide holes to get it central?, and it is worth loosening the engine and gearbox mounts and using a hoist to wiggle the engine and drop it central.

Good luck with the rest of the build!
mikey-s

The subframe has gone back in exactly the same position it was in, and the engine & box mounts are stress free. The only thing I'm not happy with is the ESP DTS mount, I had to elongate the holes in the mount to get it to line up, and even now it's not 100%. Whether it's going to transmit vibes to the body has yet to be seen.
Doug

the newer version of the esp dts has holes are already elongated - is this sideways not lining up or front to back? If it is front to back - turn the mount around.
mikey-s

It's sideways. I did try the mount all possible ways, but the best I could do is have the holes maybe 8mm or so out of line. I did elongate the holes in the rubber mount, but ran out of space so I had to force the mount into line by about 4mm, so it's still under a slight bit of tension.
mikey-s

Well finally got it running today.. and I'm well pleased. It sounds really sweet.

But today didn't go without it's problems.. firstly I spun the engine over to get some oil pressure, then carried out a boost leak test, all was fine. I then sent the car up on the ramp to have one last look over it before I started it up, and I noticed a drip or two of oil from both turbos. It's not coming from the oil feed or drain, it's coming out of the turbine housing (exhaust side). Any ideas??

Secondly, I fitted a new Walbro fuel pump, but it wouldn't bring fuel up to the engine. I had an RS4 fuel pump so I fitted that instead, even that wouldn't pump fuel..  Anyway, after a few hours of faffing around I found out the polarity was wrong! WTF? I followed the correct colour code and checked the polarity when I crimped new connections for the Walbro pump, so feck knows why it runs backwards with the correct polarity..

Looking good for the MRC remap. Booked in for the 15th April, and should make it as I don't have to pull the engine for leaking turbos!
ScottR

Nice one Mike!  Can't wait to see it running.
mikey-s

Right, finally managed to drive it under it's own steam, and I've done around 50 miles so far and I have to say it's going great and I will definately be at MRC on wednesday for the remap.

Just a few things I've noted.. the DTS transmits only a very little amount of vibes to the body, and the vibes will hopefully disappear altogether when the rubber mount gets a little tired.

The exhaust doesn't fit anywhere near as good as the last one, so it's basically thrown on just for the remap, and I'll get it sorted out when I get back. It's only a fitment issue so shouldn't affect the remap.

I'm surprised how well it's running on the standard S4 map. I did speak to MRC regarding a safe map but was advised I didn't need one. I have the N75 disconnected and it drives and idles 100% spot on.

The H&R coilovers are a fair bit harder than I would like, so I will probably change them out in the very near future. May even go for a set of lowering springs to fit to the standard shockers..


Anyway, I'll post up some FATS times & logs after the remap. Fingers crossed it all goes well..

Mike
       AudiSRS.com Forum Index -> Projects and Builds
Page 1 of 1