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TurboTy
Knows a Bit


Car: Audi S4 B5
Power: 330
Torque: 517 nm

Joined: 05 Jan 2016
Posts: 212

Location: Dorset

PostPosted: Fri Dec 23, 2016 10:16 am  Reply with quoteBack to top

A quick picture of the engine out, I'm sure you've all seen it before



Will provide a proper update as the new bits get bolted on
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TurboTy
Knows a Bit


Car: Audi S4 B5
Power: 330
Torque: 517 nm

Joined: 05 Jan 2016
Posts: 212

Location: Dorset

PostPosted: Fri Dec 23, 2016 10:33 pm Reply with quoteBack to top

Managed to do some cleaning today to get rid of the worst of the oil and got the new turbos in place, still need to be torqued up but getting there.

Also taken a look at the hall sensor on the cam shaft as the seal was leaking

Swapping over some bits from old to new


One of the new turbos in place


Hall Sensor Oil seal, can see at the bottom where the oil was getting through


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TurboTy
Knows a Bit


Car: Audi S4 B5
Power: 330
Torque: 517 nm

Joined: 05 Jan 2016
Posts: 212

Location: Dorset

PostPosted: Tue Jan 03, 2017 8:58 pm Reply with quoteBack to top

Another mini update, nearly done now... planning to get her to the exhaust shop first thing Saturday morning so on the final push.

Engine and box is in, clutch slave cylinder back in (eventually -_-) all plumbed up, most of the electrics are connected, front support on... still haven't started her yet, got fluids to fill up and intercoolers to go yet.

Some pictures:

3" downpipes now on


Also fitted 034 snub mount and xs bi-pipes, was a bit dark when I took the picture:


Two of the CV boots were perished and one was split... it got extra split when the gearbox mounts got jammed against the driveshafts whilst trying to get the engine out. Ended up replacing all cv boots in the name of preventative maintenance:


To do list:
Bonnet release cable before I forget!!
Tighten gearbox mounts
Torque drive shaft and prop shaft bolts
Fit intercoolers
Boost leak test
Coolant and engine oil
Gear linkage
Fit retrimed steering wheel
ECU
Start her up!
Rest of the front end, bumper, lights etc

The end is nigh
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Noggymike
Veteran


Car: 2002 B5 RS4
Power: 430 bhp
Torque: Whatever
Engine code: BHP

Joined: 07 Oct 2012
Posts: 11942

Location: In front of you, lol'ing

PostPosted: Tue Jan 03, 2017 8:59 pm Reply with quoteBack to top

   

_________________
2002 B5 RS4 Noggy
1998 B5 S4 Noggy Avant, FS mid Feb 2017, PM me.
2008 BMW 118d Daily slaaaag
2000 TT 225 Roadster (on going project)
1982 UR Quattro gem in the making
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TurboTy
Knows a Bit


Car: Audi S4 B5
Power: 330
Torque: 517 nm

Joined: 05 Jan 2016
Posts: 212

Location: Dorset

PostPosted: Sun Jan 22, 2017 9:13 pm Reply with quoteBack to top

The end wasn't as nigh as I thought...

Got it mostly back together, went to start her, turned the key and nothing, not click, no turning over not a sausage. All the dials and gauges worked but nothing mechanical.

After checking the voltage to the starter motor it turned out the starter was faulty. Bloody frustrating as it would have taken me 5 mins to change with the engine out but more like 4 hours after I'd put it all back together -_-

New starter in and she fired up right away

Idled quite happily, I let her warm up fully to set the new turbos in, checking all the fluids

As it stands she is now home on the driveway, with downpipes but no exhaust. Plan was to get a custom exhaust however I've snapped up a miltek system so will get that bolted on. Now has 3" decat downpipes however I need to make up some temporary cats from the old dps to get her through the MOT.

Thought I'd do a boost leak test today to make sure I'd put everything back together properly. Only managed 5psi of pressure and could hear air hissing out, after a lot of soapy water I've traced it to an injector of all things! So will need to replace all the injector seals at some point

To do list:
Fog light bulb to replace
Drive shaft gaurd to bolt back onto gearbox
Fit exhaust
Make up replacement cats
Take to MOT
MOT will fail, ask garage to find out why I cannot get comms with the k line, then clear airbag light and fix leveling headlights, then re-MOT!
Fix injector seals
Replace centre bearing on propshaft
Give her a good clean inside and out!!!
Add fuel and enjoy!

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Noggymike
Veteran


Car: 2002 B5 RS4
Power: 430 bhp
Torque: Whatever
Engine code: BHP

Joined: 07 Oct 2012
Posts: 11942

Location: In front of you, lol'ing

PostPosted: Sun Jan 22, 2017 9:36 pm Reply with quoteBack to top

TurboTy wrote:
The end wasn't as nigh as I thought...

Got it mostly back together, went to start her, turned the key and nothing, not click, no turning over not a sausage. All the dials and gauges worked but nothing mechanical.

After checking the voltage to the starter motor it turned out the starter was faulty. Bloody frustrating as it would have taken me 5 mins to change with the engine out but more like 4 hours after I'd put it all back together -_-

New starter in and she fired up right away

Idled quite happily, I let her warm up fully to set the new turbos in, checking all the fluids

As it stands she is now home on the driveway, with downpipes but no exhaust. Plan was to get a custom exhaust however I've snapped up a miltek system so will get that bolted on. Now has 3" decat downpipes however I need to make up some temporary cats from the old dps to get her through the MOT.

Thought I'd do a boost leak test today to make sure I'd put everything back together properly. Only managed 5psi of pressure and could hear air hissing out, after a lot of soapy water I've traced it to an injector of all things! So will need to replace all the injector seals at some point

To do list:
Fog light bulb to replace
Drive shaft gaurd to bolt back onto gearbox
Fit exhaust
Make up replacement cats
Take to MOT
MOT will fail, ask garage to find out why I cannot get comms with the k line, then clear airbag light and fix leveling headlights, then re-MOT!
Fix injector seals
Replace centre bearing on propshaft
Give her a good clean inside and out!!!
Add fuel and enjoy!




During sorting all the above PITA to do list




Just focus on the last line!

_________________
2002 B5 RS4 Noggy
1998 B5 S4 Noggy Avant, FS mid Feb 2017, PM me.
2008 BMW 118d Daily slaaaag
2000 TT 225 Roadster (on going project)
1982 UR Quattro gem in the making
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TurboTy
Knows a Bit


Car: Audi S4 B5
Power: 330
Torque: 517 nm

Joined: 05 Jan 2016
Posts: 212

Location: Dorset

PostPosted: Thu Feb 02, 2017 6:12 pm Reply with quoteBack to top

Mini update

Doing my list a bit backwards, but I know if I don't I'll start driving her and not want to carry on fixing!

Injector seals replaced this afternoon:



Looks like they were damaged when they got put in so no idea how long they've been like this! Boost leak tester back on and still finding many leaks. The bi-pipes have bosses welded in for meth injection, turns out the grub screws weren't sealing so put some ptfe tape round them. Another leak from a hose on the breather system. Still can't get much past 5 psi but it slowly chasing down all the leaks.

Jobs for this weekend:
- Fit new down pipes
- Eye up temporary cat fitment and get tube/parts on order
- Measure up centre prop bearing and get one ordered
- Fit drive shaft guards back on gearbox
- Continue boost leak testing
- Clean and leather condition seats if I get time

Next weekend I think I'll crack it!
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Noggymike
Veteran


Car: 2002 B5 RS4
Power: 430 bhp
Torque: Whatever
Engine code: BHP

Joined: 07 Oct 2012
Posts: 11942

Location: In front of you, lol'ing

PostPosted: Thu Feb 02, 2017 7:24 pm Reply with quoteBack to top

Did you get the newer style blue injector o rings?

_________________
2002 B5 RS4 Noggy
1998 B5 S4 Noggy Avant, FS mid Feb 2017, PM me.
2008 BMW 118d Daily slaaaag
2000 TT 225 Roadster (on going project)
1982 UR Quattro gem in the making
View user's profileSend private message
TurboTy
Knows a Bit


Car: Audi S4 B5
Power: 330
Torque: 517 nm

Joined: 05 Jan 2016
Posts: 212

Location: Dorset

PostPosted: Thu Feb 02, 2017 7:34 pm Reply with quoteBack to top

Noggymike wrote:
Did you get the newer style blue injector o rings?


No they were a purpleish colour, whatever TPS said I needed
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TurboTy
Knows a Bit


Car: Audi S4 B5
Power: 330
Torque: 517 nm

Joined: 05 Jan 2016
Posts: 212

Location: Dorset

PostPosted: Sun Feb 05, 2017 8:11 pm Reply with quoteBack to top

Changed the downpipes over, now on Miltek 3" which taper to 2.5". The job was actually much easier than I anticipated as I didn't have any heat shields and the drive shaft guards to deal with.

Got a new centre bearing for the prop on order
Also have some exhaust tube reducers and v band flanges to make my standard cats fit in place for the MOT.

These are the last two jobs before MOT, so close now!
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Noggymike
Veteran


Car: 2002 B5 RS4
Power: 430 bhp
Torque: Whatever
Engine code: BHP

Joined: 07 Oct 2012
Posts: 11942

Location: In front of you, lol'ing

PostPosted: Mon Feb 06, 2017 9:51 pm Reply with quoteBack to top

TurboTy wrote:
Changed the downpipes over, now on Miltek 3" which taper to 2.5". The job was actually much easier than I anticipated as I didn't have any heat shields and the drive shaft guards to deal with.

Got a new centre bearing for the prop on order
Also have some exhaust tube reducers and v band flanges to make my standard cats fit in place for the MOT.

These are the last two jobs before MOT, so close now!



Good work

_________________
2002 B5 RS4 Noggy
1998 B5 S4 Noggy Avant, FS mid Feb 2017, PM me.
2008 BMW 118d Daily slaaaag
2000 TT 225 Roadster (on going project)
1982 UR Quattro gem in the making
View user's profileSend private message
TurboTy
Knows a Bit


Car: Audi S4 B5
Power: 330
Torque: 517 nm

Joined: 05 Jan 2016
Posts: 212

Location: Dorset

PostPosted: Thu Feb 23, 2017 8:16 pm Reply with quoteBack to top

Been a while since my last update, and actually the second time i'm writing this as the last post declined to post

Recap of the to do list:
Fog light bulb to replace - to be done
Drive shaft gaurd to bolt back onto gearbox - done
Fit exhaust - done
Make up replacement cats - done
Take to MOT - done
MOT will fail, ask garage to find out why I cannot get comms with the k line, then clear airbag light and fix leveling headlights, then re-MOT! - to be re-MOT'd
Fix injector seals - done
Replace centre bearing on propshaft - done
Give her a good clean inside and out!!! - done
Add fuel and enjoy! - so dam close!!!

Replaced the centre bearing on the propshaft, I can confirm it is doable but I did have to get imaginative to get the prop apart:





Once that was sorted, new (to me) Miltek exhaust fitted with the temporary cats. Downpipes are now 3" to 2.5" so bought some 2.5" V bands and cut the old downpipes down to fit them into the new exhaust, haven't got a photo of them yet but will get one once they are replaced after the MOT

Took her for an MOT, failed on the airbag light and a front bulb. Specifically took it to a VAG specialist so they could find out why various computers could not get comms with the car but they gave up. Stripped out as much of the interior as I could be bothered and called out an auto-electrician to see what he could do, 2 hours later he tracked it down to the old NAV unit, as some of it had been removed, it was throwing a wobbly and jamming the k-line. Unplugged this and now finally have comms back!! Time to work out what is wrong with the aircon and self-levelling lights now!



As I finished uni early today, I had the afternoon to give her a quick clean and polish. Also gave the inside a vacuum and cleaned/conditioned the seats.









Waiting for the 1st of the month to come around before MOT otherwise I'll lose a months worth of tax, roll on Wednesday!!!

Then I can get rid of the Honda, been using it as my run around whilst the Audi has been off the road. Safe to say I cannot wait for turbo power to be back in my life. With the VTec I feel like a boy racer, you have to either drive it flat out of not bother at all. Having said that, it'll beat the Audi hands down on the corners, I will miss the twisty stuff



Thanks for reading
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