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Mikse

Mikse´s TiAL S605 Build ..€urostyle..

Delays after delays, after change of plans and a few setbacks it´s time to start my TiAL 605 build.

If I sould describe shortly this I would say two words: Snowball effect. The plan was to do a basic Turbo swap with necessary mods but ended up upgrading a few extra parts .
.
Here´s the part list:
.
Engine size: 2.7L
Rods: Rosten
Pistons: Stock
Heads: 2.4 (Slightly ported)
Cams: 2.4/ RS4
Valvetrain: Stock
Intake Valves: Stock
Exhaust Valves: Rosten stainless
Head Gaskets: MTM Compression Dropping ~8.8
Intake Manifold: Ported RS4
Intake: X-0.5 fiberglass
Y-Pipe: Stock
Throttle Body: RS4
Pressure pipes: 63,5mm custom
Diverter Valves: Forge
Turbo kit: TiAL S605 /w Divorced exhaust flanges
MAF: EPL GT MAF
Fuel Rails: RS4
Injectors: Bosch ev14 72 lb
Fuel Pump: Bosch 044 In-Tank
Tune: Remotely By EPL
Water/Meth Injection: Aquamist HFS-3
Clutch: Southbends Stage 5 DXD-B
Flywheel: TTV Racing steel ~8kg
Intercooler(s): ERs w/ Modified stock shrouds
Mounts: 034 track density Motor and 034 street Tranny
Exhaust Manifolds: KKD Motorsport carbon steel tubular
Downpipes: 3" custom for DSM Flange
Exhaust: Custom 3,5" with two silencer. 3,5" Apple racing in the middle and Vibrant 3,5" in the back
Coilovers: H&R
Wheels: 17x8 O.Z Ultraleggera
Miscellaneous: VEMS Wideband with EGT, 25 row oil cooler.[/b]

...and a couple of pics  


Jonmurgie

Re: Mikse´s TiAL S605 Build ..€urostyle..

WOW - sounds like it's going to be epic Look forward to seeing the progress...

Mikse wrote:
Injectors: Bosch ev14 72 lb


Would you happen to have the Part Number of these injectors? Trying to sort a set from my supplier but he's after the right P/N and no where lists it!!
jimbo

SMOKIN.
Mikse

Jonmurgie wrote:

Would you happen to have the Part Number of these injectors? Trying to sort a set from my supplier but he's after the right P/N and no where lists it!!

These came with the fueling kit: 0280158117. Weird part is the 550/650/750cc all have the same part.nro. I can´t tell 100% sure what size the are because injector doesn´t say it.
jimbo wrote:
SMOKIN.

Hopefully not, smoke is never a good thing  
Jonmurgie

Many thanks indeed - that's supremely helpful
Mikse

The engine has been pulled of. This timing belt was only 30tkm/3,5years old so it was a good time for engine pull.


Pistons and cylinders looked OK.


And the rods does look even better
MarkB

Mikse wrote:

And the rods does look even better


Wow! Seeing them side by side is really something else!
Mikse

I thought to shed some light about the port size between RS4 vs 2.4 heads as aemkej@LOBA showed the difference between the two of them.
This thread

I have to say aemkej is right and wrong (at least in my part). My head is ARJ and there was ~2mm difference between the ports, smallest vs largest were 54,5mm vs 56,58mm.!? Don´t know is there some reason for this or is it just poor manufacturing?


Smallest 2.4



And for a comparison 2.8 head intake port


We ended up porting all intake ports and intake manifold ports so they match perfectly.

Ported RS4 intake


And the porting didn´t stop here.. but I´ll get back to it later.
Matt_D

Awesome spec list, more pics!
lucky

Nice work

They are good collectors KKD?

I would go with it
S4mi

Good to have someone in Finland building an S4 with something else than K04 AND sharing it with others. You're not going to make a thread on ACF..? Worried about MOT officers, are we?   Anywho, good luck with the build, spec looks great! You working with the wizard from J-Town?
Mikse

I think this is public enough. I like to keep low profile and I thought should I make this build thread but the "Wizard" said I should definitely make one   We´ll try to document all the essentials things and hopefully this will be helpfull to others who´s thinking of doing something similar. I´m sure the Wizard will chime in at some point.
Haven´t worried MOT yet and don´t think there is anything worry about (hopefully)..
Externally not much different than basic S4
mattyb

[quote="jimbo:311691"]SMOKIN. [/quote]

I have only just seen that Jimbo, you could be right!!!!
jimbo

Thought some might get it. others wouldnt.          
grizz

Lol .. I hope not ..
Mikse

mattyb wrote:
I have only just seen that Jimbo, you could be right!!!!
Are you implying you are experiencing same as peter?

More porting on the exhaust side:

I think the exhaust manifold flange has RS4 specs so it had a little smaller ports than my 2.4 heads. Now the exhaust ports and manifold inlet ports are port matched.

2.4 head exhaust side ported



KKD exhaust manifold



TiAL´s turbine housing inlet was much larger than K04 so outlet port is now port matched also. This looks like this now.
lucky

Hi,
you will install brackets for the Turbo?
Mikse

Turbos installed



And 034 engine mounts.
Jonmurgie

Looking good - what do you make of those KKD Manifolds so far?
arotished

Cant wait until I get so far that I can actually put the turbos on!

Good luck mate! Looking forward to see your results!
s4rmm

Re: Mikse´s TiAL S605 Build ..€urostyle..

Mikse wrote:
Tune: Remotely By EPL

Why did you pick EPL?
There should be some good tuners in Finland too?
Mikse

Unfortunately there is no good tuner around here...
Picked up EPL because they are the most experienced tuner with TiAL´s and they offer multiple revisions to the tune until the car runs perfectly. And their GT MAF is something new in audiworld, No bad idle (with too big MAF housing) or saturation in MAF readings.. but more on that later
Mikse

Updates. The TTV flywheel is installed with the 4mm washer from auto tranny so we could use stock bolts and tq. Pressure plate was very tight fit so everything is ok and I didn´t get the monday version. The flywheel that´s been barked around here is one of the cheapest part and almost the only part I have zero complaints. Hopefully works well.


And the pressure plate
marc1

Awesome
GDS968

Mikse wrote:
Updates. The TTV flywheel is installed with the 4mm washer from auto tranny so we could use stock bolts and tq. Pressure plate was very tight fit so everything is ok and I didn´t get the monday version. The flywheel that´s been barked around here is one of the cheapest part and almost the only part I have zero complaints. Hopefully works well.


And the pressure plate


NICE ONE
Mikse

marc1 wrote:
Awesome

GDS968 wrote:

NICE ONE


Thanks. Wait till you see the downpipes. They look so good I´m not sure I even want to put them on.. Made with sweat and love    ...but not by me
Mikse

3" with divorced exhaust flanges and v-banded cats.
okkim

Quote:
Thanks. Wait till you see the downpipes. They look so good I´m not sure I even want to put them on.. Made with sweat and love    ...but not by me


 
Mikse

While waiting for a few parts both inlet pipes are ready.
We did same as MRC and cutted the inlet pipes in half for a future maintenance.





Also a custom made pressure pipes have been installed. Just need to buy a few silicone hoses for attach them to ER´s.



MathiasS

going great there!
Mikse

MathiasS wrote:
going great there!

Partly thanks to you and your parts  btw do you know the history of the rs4 fuel lines I got? There was a big dent in the FPR housing. All should be good now and the dend has been fixed but was wondering what could have caused it. Someone had an argument with it and there was a fight??
Here´s a picture of it.

MathiasS

I bought it from someone a couple days before I sold it to you. I only took it out of the box to make the pictures so I'm sorry I can't help you with any history. They are supposed to come from a car with around 100k km but who knows  
Mikse

build is progressing
S4mi

Sooou?? What's the latest Mikse? Is the engine back in and all? Have you started tuning with EPL?
Mikse

Not yet. There are a few things to do and IF everything goes well (so far nothing has gone as planned...) I should be able to flash base tune soon.

The word "Bolt-On" should be erased from the dictionary  
supersi

What problems you had ?
MarkB

Mikse wrote:
The word "Bolt-On" should be erased from the dictionary  


LOL I hear that.
Mikse

MarkB wrote:
Mikse wrote:
The word "Bolt-On" should be erased from the dictionary  


LOL I hear that.

Heh I Feel That.
supersi wrote:
What problems you had ?

The whole build should have been completely bolt-on, quick and easy but few issues and setbacks we´ve had with it doesn´t qualify as "bolt-on". Here´s a list of those few unexpected issues.
I´ll try to keep this short

1. Faulty timing belt, 30tkm old pic
2. leaky water pump, 30tkm old
3. RS4 fuel lines, dend in FPR 8see above)
4. 2.4 head ports were NOT matched to RS4 intake manifold, EVERYTHING was portmached, see pic
5. 2.4 exhaust port was much bigger than KKD exhaust manifold, portmached (this is not KKD´s fault by any means) Manifolds are excellent.
6. TiAL turbo inlet was bigger than KKD outlet, port mached.
7. TiAL S605 was almost bolt-on. small wastegate actuator bar clearence.
8. 25 row oil cooler came with wrong length oil feed lines and sandwhich plate oil filter adapter (seller did send new parts), Had to go to hydraulic shop to shorten them. The cooler is so big there is 1mm clearence between hood...after a small modification.
9. X-1 intake shield and TiAL inlet pipe
10. Took a fiberglass mold of the X-1 intake and something went from and the shield broke
andream88

Mikse wrote:

1. Faulty timing belt, 30tkm old pic
2. leaky water pump, 30tkm old
3. RS4 fuel lines, dend in FPR


LOL
and you call these problems????

I had a damaged piston during shipping, rust on a piston pin, cast defect on a 2,4L head, brand new cams full of small holes (cast defects), wrongly clocked turbo which didn't fit, ported manifolds nearly impossible to get properly rewelded, passenger side manifold fouling the head, defective rear sealing flange (had to buy a new one waiting for AUDI's replacement...so ended up buying 2).....etc etc.

You have been lucky, mate. VERY lucky!

Mikse

andream88 wrote:


LOL
and you call these problems????

You have been lucky, mate. VERY lucky!


Damn you were quick. I was editing the post while you quoted.
andream88

Mikse wrote:
andream88 wrote:


LOL
and you call these problems????

You have been lucky, mate. VERY lucky!


Damn you were quick. I was editing the post while you quoted.


ahahah, lol.

now that sounds about right!!!
Mikse

Part 2:

11. After a few start everything looked OK but when we were about have a first test drive we had a big oil leak. One of hte driver side head cam chain tensioner bolt was broken.

12. In HFS-3 install we used Bentley manual for wiring diagram but had a problem with the pump working correctly. After looking all possibities what was wrong, downloaded ELSA and it showed quite a few difference in wirings compared to bentley manual.

Andrea: I wouldn´t say these a huge problems, just a things that wasn´t planned So far I´m happy that nothing have been broken..yet.

Hopefully there won´t be part 3  
Mikse

Chain tensioner bolt, or what was left of it.

Mikse

Mikse wrote:
Hopefully there won´t be part 3  

...part 3 in progress..

In the meanwhile here´s a couple of pictures of my new GT MAF...if anyone is interrested.
Custom calibrated Hitachi sensor.



S4mi

Any progress here? Have you figured out why all Tial 605 builds seem to disappear before finishing..?
Mikse

Heh no one here cares about TiALs so lack of interest for updates makes these builds to vanish ;D

Mikse wrote:
Mikse wrote:
Hopefully there won´t be part 3  

...part 3 in progress..

part 3 solved...
arotished

Mikse wrote:
Heh no one here cares about TiALs so lack of interest for updates makes these builds to vanish ;D.


I wonder why
Mikse

arotished wrote:
Mikse wrote:
Heh no one here cares about TiALs so lack of interest for updates makes these builds to vanish ;D.


I wonder why

heh exaclty! They are dirty cheap and make shitload of power    I think its a smokey deal

One bad apple shouldn´t ruin the whole basket. But I think the biggest issue is these are non-BW products and made by someone else than ..
mattyb

I am in love with mine.... power for pennies. would you believe you can make 600 on stock coolers !!!
Mikse

mattyb wrote:
I am in love with mine.... power for pennies. would you believe you can make 600 on stock coolers !!!

Exaclty. And I´m waiting the divorced turbine housing to bring something extra to the table.. to both ends.
mattyb

I am looking forward to your results!!!!
Keep us posted..
arotished

Mikse wrote:
arotished wrote:
Mikse wrote:
Heh no one here cares about TiALs so lack of interest for updates makes these builds to vanish ;D.


I wonder why

heh exaclty! They are dirty cheap and make shitload of power    I think its a smokey deal

One bad apple shouldn´t ruin the whole basket. But I think the biggest issue is these are non-BW products and made by someone else than ..


Nothing about the one bad apple, just the interested on this board.

Looking forward to see the results Mikes! When do you think it's ready?
Mikse

Well IF nothing breaks on the hardware side and I don´t have any issues (which is very doubtful) I might get it tuned before winter. I had problem with flashing the base tune and the ECU went crazy! The immo activated and we didn´t have the tools to fix it at the time. I sent ecu to tuner via 5 days express mail and the package was lost in the mail!! Took over 3 weeks to find it and get it to receiver. This whole prosess has taken almost 2 months so its been quiet around here   Now the ecu is back and the car is running again  

I do have to thank the tuner at this point. The customer support/service is something beyond excellent and fast. Just have to wait and see what is the outcome after the car is tuned.
ScottR

Keep going mate, you'll get there.

I've hit a bit of a low point with my build, but know it will turn around eventually.

Looking forwards to seeing your results.
okkim

Is this already running?
Mikse

hmm.. how I missed this reply? Well I guess I could give a short update since quite a lot has happened since last update. I've been busy, lazy, filled with bad luck and the winter isn't helping me either...

When I got the car back home my alternator failed 2 days later. At the same time I was solving the charging issue I accidentally left the cars tranny on neutral and my front bumber took a small hit.
This was the outcome

OEM achat gray colour with matte finish. More pics here


Then it was time to take logs for the tune (finally!). Took two pulls on 3rd gear and it started to whine guite a loud... I've had some noise from 3rd and 5th gear for years and last winter the 2nd gear made noise when it -25C degrees so rebuild was no option since it would have been most likely more expensive. Found new gearbox from -04 A6 and it only had 70tkm on it.

Aquamist HFS-3 has been so big PITA I don't even know where to start... I still have failsafe issues with it but I'm working on it when the weather allow me to take test pulls on the road..

Car is running with base map currently but atleast it's running  

Custom 3,5" catback is the quietest 3,5" I've heard and I love it. Might take a few clips if I have a chance to do it.
arotished

NICE!
MathiasS

How did the turbokit fit ? was everything bolt on ?
Mikse

Almost bolt-on. Inlet pipes had to be modified a little as mentioned in the install manual but otherwise no big issues. Some clearence issues with hotside housing and drive shaft shield because I have same unmodified TD05 hotside as the 770's have.
okkim

I heard that also the wastegate actuators were pain in the ass to adjust. The rods were touching the compressor housing, and could open only 2 mm! The parts had to be grinded to make more room.
monkeyrs6

Progess

Come on there must be some progress.. Tim
Stertman

okkim wrote:
I heard that also the wastegate actuators were pain in the ass to adjust. The rods were touching the compressor housing, and could open only 2 mm! The parts had to be grinded to make more room.


Thats Tial quality! Same on al the 3 kits I have sold... And one kit broke after 1000km and NO help from Tial.
arotished

Dont seem to be a problem over on the state, there they love the Tial series, even if they tend to fail every now and then...
Mikse

Stertman wrote:
okkim wrote:
I heard that also the wastegate actuators were pain in the ass to adjust. The rods were touching the compressor housing, and could open only 2 mm! The parts had to be grinded to make more room.


Thats Tial quality! Same on al the 3 kits I have sold... And one kit broke after 1000km and NO help from Tial.

Do you mean TiAL claim its not covered by warranty or they refuse to rebuild the turbos at all?
arotished

Mikse wrote:
Stertman wrote:
okkim wrote:
I heard that also the wastegate actuators were pain in the ass to adjust. The rods were touching the compressor housing, and could open only 2 mm! The parts had to be grinded to make more room.


Thats Tial quality! Same on al the 3 kits I have sold... And one kit broke after 1000km and NO help from Tial.

Do you mean TiAL claim its not covered by warranty or they refuse to rebuild the turbos at all?


No no, they just stopped replying to their emails
Stertman

Mikse wrote:
Stertman wrote:
okkim wrote:
I heard that also the wastegate actuators were pain in the ass to adjust. The rods were touching the compressor housing, and could open only 2 mm! The parts had to be grinded to make more room.


Thats Tial quality! Same on al the 3 kits I have sold... And one kit broke after 1000km and NO help from Tial.

Do you mean TiAL claim its not covered by warranty or they refuse to rebuild the turbos at all?


We wanted a new turbo right hand side as the housings is damage to, But after 18 month trying to pay for a new turbo my faith is gone! And trust me we have sent pics, talking with Johnatan on the phone, sending emails and so on... My customer is now running on LO700 for 2 summers and are happy and car is making 550whp. The other 2 kits I sold is still running but I cant work with companies with zero customer support.
Mikse

Wow, what was the reason they refused to sell you new right hand turbo? Did they want you to send the damaged turbo to TiAL for a rebuild or what? Hard to believe they just refused to help!?
monkeyrs6

So what was the outcome of this build thread
arotished

monkeyrs6 wrote:
So what was the outcome of this build thread


WIP
monkeyrs6

What does that mean
jimbo

work in progress
monkeyrs6

Was the engine not pulled in June 2011
Mikse

Tune was finished last year just haven't bothered update for a long time. No dyno sheep but what Virtual dyno tells mid 500's at the wheels with 26psi.

Sterman bumped this up after a year but would like to know waht I asked before why TiAL didn't sell/rebuild failed turbo..?
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