Full STG III BW K04 Build

[A62TURBO]

OK guys, I put my full blown 2.8 770 build on the back burner for a future project, and decided to go full stage III on the A6. I was able to pick up the turbos and fueling kit from EPL at a good price. Now I gotta piece together a few more RS4 components and I should be ready for engine removal. Here are a few pics of what I have to date.

http://i330.photobucket.com/albums/l439/a62turbo/fa83bbed.jpg
OEM RS4 inlets

http://i330.photobucket.com/albums/l439/a62turbo/2d7fa251.jpg
STG III fueling kit

http://i330.photobucket.com/albums/l439/a62turbo/15ddb27e.jpg
EPL 85mm MAF

http://i330.photobucket.com/albums/l439/a62turbo/cd03fc3e.jpg
NGK BKR7E Spark Plugs

http://i330.photobucket.com/albums/l439/a62turbo/38687630.jpg
Bosch EV14 52lb Injectors

http://i330.photobucket.com/albums/l439/a62turbo/08645b6c.jpg
and most important, the BW K04's


I would love to hear comments/suggestions for this build, keep in mind it is my DD and I want to keep it as comfortable and reliable as possible.

[SALES@RS WORX]

Greg, Good luck with the build bud. It was nice meeting you the other day. Let me know if there is anything else i can help you out with. I would recommend aquamist! We have them in stock and on sale with 10% off.
Have a Happy Thanksgiving.

Cheers

[A62TURBO]

Thanks Ryan, it was nice meeting you too. I'll let you know when I'm ready to pick up the Meth kit. Happy Thanksgiving to you too!

[A62TURBO]

Got a few parts in today.

Some RS4 love
http://i330.photobucket.com/albums/l439/a62turbo/bcfe265d.jpg

One of the ER shrouds
http://i330.photobucket.com/albums/l439/a62turbo/e70fc349.jpg

http://i330.photobucket.com/albums/l439/a62turbo/4cfbf58c.jpg

http://i330.photobucket.com/albums/l439/a62turbo/36ab0587.jpg

[A62TURBO]

I got a lot of work done today. Removing the lock carrier was not as hard as I thought, here are some pics of my progress. I'm also currently waiting for my 034 DP's with test pipes, Spec stg3+, OEM DM flywheel, and some other misc. hardware. I should have the engine out within the next week.

This is how I started out today:
http://i330.photobucket.com/albums/l439/a62turbo/DSC_0015-2.jpg
http://i330.photobucket.com/albums/l439/a62turbo/DSC_0016-2.jpg

Fan removed and put to the side:
http://i330.photobucket.com/albums/l439/a62turbo/DSC_0020-4.jpg

Draining the coolant was also really easy:
http://i330.photobucket.com/albums/l439/a62turbo/DSC_0022-3.jpg

Lock Carrier off:
http://i330.photobucket.com/albums/l439/a62turbo/DSC_0028-1.jpg

Intercoolers and piping out of the way:
http://i330.photobucket.com/albums/l439/a62turbo/DSC_0045.jpg
http://i330.photobucket.com/albums/l439/a62turbo/DSC_0029-1.jpg
http://i330.photobucket.com/albums/l439/a62turbo/DSC_0047.jpg

Very interesting, I didn't know the trans cooler was behind the DS intercooler. No need for that anymore:
http://i330.photobucket.com/albums/l439/a62turbo/DSC_0052.jpg

[A62TURBO]

So I got a nice package from UPS yesterday. Finally got my 034 DP's, poly snub mount and cage, 034 track motor mounts, turbo mounting hardware, and SAI delete plates. All I have to say is that these DP's are of amazing quality and construction, I will definitely continue doing business with 034 on future builds. Now I'm waiting for the clutch and flywheel from EPL, and the I have to order a timing belt kit and bunch of seals so I can do everything with the motor and trans out. Here are some pics of what I got from 034.

I also decided to remove my spare block from the engine stand so I can get it ready for my engine:
http://i330.photobucket.com/albums/l439/a62turbo/6de6d592.jpg

This made block removal from the engine stand a breeze, I'll also be using this hoist for transmission separation when the motor is out:
http://i330.photobucket.com/albums/l439/a62turbo/b2c49311.jpg
http://i330.photobucket.com/albums/l439/a62turbo/cfe40d89.jpg
http://i330.photobucket.com/albums/l439/a62turbo/5ec9ee6b.jpg

034 goodies:
http://i330.photobucket.com/albums/l439/a62turbo/a9ed7c6b.jpg
http://i330.photobucket.com/albums/l439/a62turbo/87944b03.jpg
http://i330.photobucket.com/albums/l439/a62turbo/a13f112f.jpg
http://i330.photobucket.com/albums/l439/a62turbo/5430323d.jpg

Bye Bye SAI:
http://i330.photobucket.com/albums/l439/a62turbo/85914c8d.jpg

[Danza]

looks like good stuff

[A62TURBO]

Getting closer, drained the oil today so I can get the AC compressor and lines out of the way but I ran into a snag when I didn't have a big enough socket to remove the oil cooler (does anyone know the size?). Since I couldn't do anything about the compressor I just decided to start clearing the top of the motor, SAI pump and hoses are now gone and for sale. I'm surprised how much space the SAI takes up in the back of the motor, good riddens.

http://i330.photobucket.com/albums/l439/a62turbo/afcf8fe8.jpg


http://i330.photobucket.com/albums/l439/a62turbo/08ff5fe0.jpg

http://i330.photobucket.com/albums/l439/a62turbo/0d44fc06.jpg

http://i330.photobucket.com/albums/l439/a62turbo/15d388ac.jpg

http://i330.photobucket.com/albums/l439/a62turbo/b0848bef.jpg

http://i330.photobucket.com/albums/l439/a62turbo/9bd2a2a2.jpg

http://i330.photobucket.com/albums/l439/a62turbo/1f9e7467.jpg

[Austonwerner4]

What are you doing for a clutch?

[A62TURBO]

Spec stg3+ and stock DM flywheel, should be in by the end of the week from EPL.

[A62TURBO]

Got some work work done yesterday and today.

Got the AC compressor detached, just held up with a zip tie until the motor comes ou:

http://i330.photobucket.com/albums/l439/a62turbo/1a2367de.jpg


Disconnected the engine ground and peeled back the positive battery wire as well:

http://i330.photobucket.com/albums/l439/a62turbo/38483869.jpg


Removed the ECU and accompanying wires, was easier than I expected:

http://i330.photobucket.com/albums/l439/a62turbo/351af79d.jpg

http://i330.photobucket.com/albums/l439/a62turbo/13108670.jpg

http://i330.photobucket.com/albums/l439/a62turbo/f4d4bafe.jpg

http://i330.photobucket.com/albums/l439/a62turbo/17272a98.jpg

[A62TURBO]

Finally pulled the motor/trans on Saturday all by my damn self, I started around 2:30 and motor was out by about 6:00. Other than having to remove the PS axle and down pipes it was pretty straight forward. It did wear me out though, which is why I'm posting this a few days later. Here are some pictures, didn't take too many as I was by myself .

http://i330.photobucket.com/albums/l439/a62turbo/187cb11b.jpg

http://i330.photobucket.com/albums/l439/a62turbo/265cc619.jpg

http://i330.photobucket.com/albums/l439/a62turbo/32dcdb4d.jpg

http://i330.photobucket.com/albums/l439/a62turbo/4c198b19.jpg

http://i330.photobucket.com/albums/l439/a62turbo/468a182d.jpg

http://i330.photobucket.com/albums/l439/a62turbo/6d8b473d.jpg

http://i330.photobucket.com/albums/l439/a62turbo/c6d2c15d.jpg

http://i330.photobucket.com/albums/l439/a62turbo/a0678103.jpg

Trans bolts in order from top to bottom.
http://i330.photobucket.com/albums/l439/a62turbo/80803655.jpg

This is how she sits until I remove the clutch and flywheel so it can fit on the engine stand.
http://i330.photobucket.com/albums/l439/a62turbo/98976f06.jpg

[A62TURBO]

Finally got the engine on the stand after a week of trying to remove the last three flywheel bolts, I had to resort to cutting them off. I can finally get to swapping out parts, cleaning the engine bay, and going stg 3 already.

http://i330.photobucket.com/albums/l439/a62turbo/bfdf24c2.jpg

http://i330.photobucket.com/albums/l439/a62turbo/c5b64382.jpg

http://i330.photobucket.com/albums/l439/a62turbo/e05b1d07.jpg

http://i330.photobucket.com/albums/l439/a62turbo/70396d34.jpg

http://i330.photobucket.com/albums/l439/a62turbo/7b6f91d8.jpg

http://i330.photobucket.com/albums/l439/a62turbo/256161e0.jpg

http://i330.photobucket.com/albums/l439/a62turbo/3e563c97.jpg

[A62TURBO]

Started doing some tear down work today, removed and broke the Spyder hose, all of the SAI system, and some other lines connected to the fuel rail. I also got a package from ECS today with a lot of good stuff. Next is removing the turbos and associated lines, gonna try and start that tomorrow. Here are some pics for your enjoyment.

ECS goodies
http://i330.photobucket.com/albums/l439/a62turbo/6958678b.jpg

Removing SAI
http://i330.photobucket.com/albums/l439/a62turbo/5bb6947b.jpg

A lot of lines
http://i330.photobucket.com/albums/l439/a62turbo/d45c610b.jpg

Peace!!!
http://i330.photobucket.com/albums/l439/a62turbo/775577ab.jpg

I need more space!
http://i330.photobucket.com/albums/l439/a62turbo/030a418a.jpg

I'm surprised at the amount of dirt all over the engine, I gotta get cleaning!
http://i330.photobucket.com/albums/l439/a62turbo/f9687c27.jpg

[A62TURBO]

Turbos are pretty much in:

http://i330.photobucket.com/albums/l439/a62turbo/89fbd8c7.jpg

Started getting to work on the top end, fuel rail is off. I gotta make sure I blow all the crap off the top of the engine before removing the injectors, don't want anything falling in those holes.

http://i330.photobucket.com/albums/l439/a62turbo/fb44f43b.jpg

http://i330.photobucket.com/albums/l439/a62turbo/227bbb34.jpg

[A62TURBO]

Started doing the timing service today. Swapped out the water pump and thermostat. Next I have to pull the cams and do the rest of the seals. Here are some update pics.

http://i330.photobucket.com/albums/l439/a62turbo/700f941e.jpg

http://i330.photobucket.com/albums/l439/a62turbo/be99dcaa.jpg

http://i330.photobucket.com/albums/l439/a62turbo/c9291f26.jpg

http://i330.photobucket.com/albums/l439/a62turbo/e3664461.jpg

http://i330.photobucket.com/albums/l439/a62turbo/baeff5f5.jpg

http://i330.photobucket.com/albums/l439/a62turbo/1f8751da.jpg

http://i330.photobucket.com/albums/l439/a62turbo/f842a58f.jpg

http://i330.photobucket.com/albums/l439/a62turbo/c1578568.jpg

[A62TURBO]

Progress, progress, progress, finally looking like a finished engine again. I finished all the seals up top and painted the valve covers flat red. Turbos and lines are completely installed, here are some update (iPhone) pics.

http://i330.photobucket.com/albums/l439/a62turbo/281401cb.jpg

http://i330.photobucket.com/albums/l439/a62turbo/5c8a31ff.jpg

http://i330.photobucket.com/albums/l439/a62turbo/54f68711.jpg

http://i330.photobucket.com/albums/l439/a62turbo/78bae3a0.jpg

[A62TURBO]

Some updated pics I took today:

http://i330.photobucket.com/albums/l439/a62turbo/6821b5b0.jpg

http://i330.photobucket.com/albums/l439/a62turbo/c45f0b1d.jpg

http://i330.photobucket.com/albums/l439/a62turbo/b5a66c6b.jpg

http://i330.photobucket.com/albums/l439/a62turbo/93058fcc.jpg

http://i330.photobucket.com/albums/l439/a62turbo/0e6523c1.jpg

http://i330.photobucket.com/albums/l439/a62turbo/8de09244.jpg

[Yesmar]

looks good man

[A62TURBO]

Thanks yesmar, Wrapped the Dp's with some DEI titanium wrap, and got the er's ready.

http://i330.photobucket.com/albums/l439/a62turbo/5ca4242f.jpg

http://i330.photobucket.com/albums/l439/a62turbo/b73809c0.jpg