My Build Thread (or How A Wideband Install Turned Into Built Motor Install)

[skeeball]

Honestly, all I meant to do was install a wideband sensor but things got a little out of hand. I got the Innovate LC-1 installed in place of the stock pre-cat sensor and wired everything up. Only the ECU was not happy with the narrowband emulation coming from the LC-1. Well, it turns out the AVK comes stock with wideband sensors (this was my fault for not researching further, but everything I had read said that the stock sensors were narrowband). So I booked an appointment with RAI to weld in a separate bung for the wideband.

I figured this was the perfect opportunity to install an x-pipe and some center resonators. The current exhaust is just straight pipes from the cat back to Supersprint mufflers. It concerned me that there was very little room with the stock cats to install another sensor and on the day I was to drop the car off at RAI I get a call from Steve (3.0 King) offering a good price on some used headers and cat-less downpipes. I took him up on the offer and dropped those off with Ray.

While installing the headers several of the exhaust manifold studs snapped off (a common problem on the AVK). So the heads had to come off. And since Steve also had a built AVK block for sale...





Assuming everything checks out ok, here is the built block that is going in:



Mike Z at Unitronic has the current file and is creating a new tune.

[AudiA4_20T]

Monster

[Ill 3.0]

Awesome, was just going to see what you decided. Should be huge improvement over stock G3 setup.

[skeeball]

A couple more pics.

Heads in the hot tank.

[dougyfresh]

Mike Z at Unitronic has the current file and is creating a new tune.

Nice.

How are you doing updates? Logging the car and sending him info to tweak the file? You'll have to send him your ECU then so he can reflash it?

[skeeball]

Nice.

How are you doing updates? Logging the car and sending him info to tweak the file? You'll have to send him your ECU then so he can reflash it?

He is doing an initial tune, then logging and tweaking from there. It's my understanding that Ray can plug the ECU into his bench unit and Mike can actually manipulate it over the interwebs.

[Ill 3.0]

He is doing an initial tune, then logging and tweaking from there. It's my understanding that Ray can plug the ECU into his bench unit and Mike can actually manipulate it over the interwebs.

Did he already write a file for the stock compression motor?

[skeeball]

I don't know how far he has gotten. He has looked at the existing file but I'm not sure what has happened beyond that. Engine is still apart, we are waiting on parts (gaskets, bolts, brackets, and stuff).

[shoppingcart111]

Did they seriously put the heads with the cam position sensors(electrical) in the hot tank, or was that just for the pics, something tells me their going to fail down the road if that's the case. Looks good other wise.

[Mr.Audi]

rai ftw!!!

[skeeball]

I fairly sure they are sealed hall sensors so no damage. If they do fail down the road, Ray warranties his work.

[dougyfresh]

He is doing an initial tune, then logging and tweaking from there. It's my understanding that Ray can plug the ECU into his bench unit and Mike can actually manipulate it over the interwebs.

Might want to check up on that before you venture further down this road...

It'll save downtime and headaches in the future.

[skeeball]

The tuning is getting done no matter how long it takes. My suspicions about how the car had been running have been confirmed. Despite the fact that it was still running after 2.5 years, I'm not going back down that road.

Unitronic FTW

[dpatel]

And exactly what suspicions would those be??

[AudiA4_20T]

16:1 AFR at full throttle and 25+ degrees of timing

[dirtybrd]

The leaner the meaner!

[skeeball]

27.75 degrees actually, and 16:1. Those were requested values at WOT. Mike Z thinks the car was running on the default safety maps most of the time. That obviously doesn't apply to the GIAC tuned cars.

But I don't want this thread to be a discussion about that. Onwards and upwards.

[skeeball]

Update:

Engine is back in the car.



Front clip with my oil cooler hanging out waiting to be installed.



Blower is going back to Stiegemeier because of rotor to case contact. Hopefully they warranty their work since it started right after they rebuilt it. So now we wait.

[dougyfresh]

Blower is going back to Stiegemeier because of rotor to case contact. Hopefully they warranty their work since it started right after they rebuilt it. So now we wait.

Huh? How did that happen? Blown bearing causing the rotor assembly to 'walk'?

[Ill 3.0]

Update:

Engine is back in the car, minus the heads.

original block or built 9:1 block? with headers I assume?

[skeeball]

Huh? How did that happen? Blown bearing causing the rotor assembly to 'walk'?

I wish I knew. It started making a nasty noise right after the rebuild. When we opened it up, you could see where the rotors were scraping against the case.

[3.0 King]

is a smaller pulley in the plan?...

[A4ringedONE8T]

Recommendation while its apart. Ill show a flow chart

Supercharger --> dumpster --> shopping --> turbo's --> install turbo's --> done wasting time, money, and effort

[A4ringedONE8T]

But seriously, stop it with this supercharger bullshit, they dont make any power for the money. Someone step up and do some turbo's, the million 2.8l - 3.2l BMW turbo builds are making us look bad!!!!

[skeeball]

is a smaller pulley in the plan?...

Baby steps. Let's just get the car running again.

Recommendation while its apart. Ill show a flow chart

Supercharger --> dumpster --> shopping --> turbo's --> install turbo's --> done wasting time, money, and effort

lol, if I went turbo now the car wouldn't be running again for 6-12 months. This is my DD. And I don't want to even think about the fabrication costs that would run me.

[AudiA4_20T]

But seriously, stop it with this supercharger bullshit, they dont make any power for the money. Someone step up and do some turbo's, the million 2.8l - 3.2l BMW turbo builds are making us look bad!!!!

make some manifolds

[Ill 3.0]

original block or built 9:1 block? with headers I assume?

??

[skeeball]

Sorry. Yes, built block, 9:1 compression, headers and downpipes.

[Ill 3.0]

Sorry. Yes, built block, 9:1 compression, headers and downpipes.

Nice, looks like its moving along then.

[Craigo]

Sounds like you purchased all my parts from Steve - how are they treating you?

[skeeball]

Yeah, your car lives on! Not sure how well they are going to perform yet. The motor makes me a little nervous but I guess we will find out.

[skeeball]

No new pics but the blower will be back on Friday. Steigemeier fixed it for free which is what I hoped but didn't actually expect to happen. Big to them for backing their work.

All the steel for the exhaust is in, so if all goes well the tuning should start next week.

[Don Supreme]

12 sec pass coming soon?

[dougyfresh]

Awesome, Dave!

I'm making some progress this week too. Got the cams in and engine timed last night. Lots of little things to finish....

[skeeball]

Engine is back in the car and sounds great. Not going to win a beauty contests though.



Here are some pictures of the exhaust. Headers:



Driver's side downpipe.



Downpipes to x-pipe.



Vibrant resonators.



Everything is v-band clamped together.





Hopefully we have the first version of the new file loaded today. RAI is packing up to head down to Dubs at the Beach and I need the car to get to work this weekend.

[AudiA4_20T]

YES DAVE.... did Ray do that exhaust for you?

[Ill 3.0]

wow, quick progress considering the holiday on Monday. any chance of a sound clip? I'd love to hear that exhaust.

[pondside36]

Sweet, glad to hear it all came together for you.

[AudiA4_20T]

I'm next lol

[dougyfresh]

I'm next lol

In theory.



We're doing V-Band on my exhaust too. I can't wait. Looks good Dave!