Max@034's B5 A4 V6 Build Thread - 6 speed swap, turbo soon, etc

[Max@034]

I've modified this first page for folks just checking it out; a lot has happened since i posted this 6 months ago. The car is about to be on full standalone engine management via a 034EFI Stage IIc, along with a single turbo conversion on the stock AHA motor, running 10+ psi and going for 400whp. Theres been a lot of technical discoveries about the potential robustness of the AHA/ATQ, granted some things are addressed, so check it out:

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A few folks suggested I started a build thread for my B5. So this is a build thread for my '99.5 B5 A4 2.8L V6 Quattro. You don't see many of these with a lot of mods on them, but I got the car for dirt cheap, I like being different, and I've fallen in love with it. Despite my 100+ mile a day commute, and my absolute constant abuse of this car, it has held through besides a marred input shaft on the 5 speed V6 transmission. However, after 8k miles of even more abuse under the hands of me, it finally got to the point where something had to be done about the noise the tranny was making. Not wanting to just throw in another long ratio V6 tranny, I decided to do a 6 speed swap to an 01E transmission from a B5 S4.

The transmission is just the first part of this cars journey; the next thing on the list is a Precision 5857 single turbo. I wanted to catalog the modifications the car undergoes, along with dyno runs, etc. Having owned a 2.8L before, I wanted to see what the potential of this engine is. Everyone is always so quick to jump into to say "go buy a 1.8T or an S4". But some of us like our little underrated 2.8's and selling/buying a car is a lot of annoyance.

The new transmission is great. I really like the shorter ratios, and it revs about 250-300rpm lower in 6th on the highway. I had an RS4 clutch in there previously, but for some reason this new S4 clutch feels a lot better. Car feels a lot faster with the shorter ratios too.

So here is a mod list, then a list of the necessary parts for the 6 speed swap, and then some pictures.

Current EDITED Mod List:
- 01E 6 speed transmission and associated drivetrain (more below)
- B&M short shifter
- 034Motorsport custom 2.8L tune
- 034Motorsport Street Density transmission mounts
- 034Motorsport poly snub mount and cage
- 034Motorsport Street Density rear diff carrier bushings
- 034Motorsport X34 Cold Air Intake
- 034Motorsport Adjustable Upper Control Arms
- 034Motorsport Adjustable Rear Swaybar endlinks
- 2.5" custom catback exhaust w/ resonator and Vibrant Stealthpower dual 3" outlet muffler
- 034Motorsport High Flow Cats
- Stasis Ohlins Mototsport Coilover suspension
- Porsche Boxter 4 piston front brakes with A8 312mm rotors
- B5 S4 rear brakes with vented 252mm rotors
- 17x8" Rota Torque rims w/ 255/40R17 Conti tires
- Full exterior S4 conversion (nearly complete)

6 Speed Swap Parts:
- 01E transmission from a B5 S4
- 01E bellhousing spacer (DON'T FORGET)
- 01E shifter linkage, stabilizer bar, and crossorod (there is an early/late version)
- 01E clutch and flywheel and pressure plate
- 01E throwout bearing release arm
- 01E transmission mount brackets (bracket from tranny mounts to tranny housing)
- 01E shifter box and shifter (you can use 5 speed, but you'll have to push down to get into 6th)
- 01E driveshaft heatshield
- B5 S4 rear diff from 6 speed
- B5 S4 driveshaft from 6 speed
- B5 S4 front axles from 6 speed
- B5 S4 or B5 A4 V6 uprights (to fit the S4 axles)

About to be Installed:
- Precision 5857 turbo with .82AR
- 034Motorsport 034EFI Stage IIc standalone engine management
- 034Motorsport Plug In Engine Harness, motorsport spec coated/sealed
- Large FMIC w/ custom piping
- B5 S4 intake manifold w/ 30v DBC throttle body
- 034Motorsport Phenolic transistion intake manifold spacers
- 034Motorsport 2.8L exhaust manifold flanges for single turbo conversion
- AEM methanol injection kit

Notes: B5 A4 rear axles fit if you swap flanges on the rear diff. Reverse light is a 5 pin Bosch female on the V6 tranny; it is a 2 pin Bosch female on the S4 transmission. Heatshields for axles can swap over; driveshaft heat shield does not. Everything else swaps right in.

[Max@034]

Also, while I know its more "feasible" to buy a 1.8T or an S4... I already own those cars. I wanted to do something different and fun with the V6, that will give me about 250whp with 8 or so psi. Kit is all planned, just need to get the S4 working before I tackle any other projects.

[Ldiaz12]

I'm glad you chose to be different, another reason to visit the forum. That intake ....will it work fine with the 2.8 12v? I really like it.

[somebody5788]

Sweet project =D, looks to me like an early 99 not a 99.5 though. How can I get a job at 034 so I can just do a project like that??? lol.

Just be sure your oil system is in top shape (I recommend sea foaming it or something) Also I'd recommend meth injection as well as a quality front mount. 250AWHP is about the limit for this engine before the pistons fry but I think with some precautions it's possible to get on a daily driver and not have any long term side effects.

Might check out scaudi.com even though you are looking into a turbo they have more information then anyone about boosted 2.8's. And there are several with built engines (usually from blowing them up at 10 psi...)

[brettj20]

its about time someone wants to do something with a v6

[geeky]

Nic, is the the actual pressure thats causing the piston issues or the volume of air being moved? on that note, how much air does a G1 or G2 move, anyone have a graph I can look at?

[coolgraymemo]

i like that sound...

[LightSwitch]

that exhaust sounds great man, i look forward to the rest of the build.

[v3n0m]

Yeah nice project, and i think, so far that is the BEST exhaust I've heard on a b5 a4. Thats my opinion, not even close to ricy. Thats the exact exhaust i want, to sound like a v12, and not a rocket.

[Silverstreak98]

Looking forward to following this thread Max!

Also curious what modifications, if any, you had to make to the intake to get it to work for you 30V? It looks great, I'd probably buy one in a second if it wasn't a hassle to make it work.

[shokwav09]

when you said everything else swaps right in, does that include all fasteners and bolts?

[Dan[FN]6262]

are you going to make a custom manifold for the single turbo, or just pick up the OEM V6 single turbo exhaust mani that audi produces?

[somebody5788]

Nic, is the the actual pressure thats causing the piston issues or the volume of air being moved? on that note, how much air does a G1 or G2 move, anyone have a graph I can look at?

Supposedly it's the pressure. I'm not entirely sure. I would think it's the heat myself as they actually melt lol. But supposedly its because the ring seizes.

[.Mad Hatter.]

looks to me like an early 99 not a 99.5 though.

This, awesome either way though Max!

[somebody5788]

How much would an exhaust like that run for my supercharger?? lol

[Max@034]

I'm glad you chose to be different, another reason to visit the forum. That intake ....will it work fine with the 2.8 12v? I really like it.

Its the passenger head that causes a bit of a fitment problem. I just jammed the heatshield in there and it stays in place nicely, lol.

i like that sound...

that exhaust sounds great man, i look forward to the rest of the build.

Yeah nice project, and i think, so far that is the BEST exhaust I've heard on a b5 a4. Thats my opinion, not even close to ricy. Thats the exact exhaust i want, to sound like a v12, and not a rocket.

I'm quite fond of the sound myself. I'm excited to get some turbo noise in there. My S4 is hands down one of the best sounding cars I've heard, and thats not just to stroke my ego lol.

Looking forward to following this thread Max!

Also curious what modifications, if any, you had to make to the intake to get it to work for you 30V? It looks great, I'd probably buy one in a second if it wasn't a hassle to make it work.

The heatshield itself fits in there pretty good; it won't bolt up, and its a bit of a squeeze at the front end, but as you can see, it looks great. Its not a factory fit like it is in the S4, but nice. However, there is a problem; the MAF. The 2.8L MAF uses a MAF with a 4 bolt flange, so you need an adapter plate. You can see my adapter plate in the photo.

when you said everything else swaps right in, does that include all fasteners and bolts?

Pretty much. Swap the axle flanges on the rear diff, all the bolts can be reused, the driveshaft support bolts up, etc etc. You'll need the shorter hardware for the transmission brackets, and the hardware for the throwout release arm, and hardware for the linkages, etc. But the major stuff bolts right up.

[Max@034]

are you going to make a custom manifold for the single turbo, or just pick up the OEM V6 single turbo exhaust mani that audi produces?

I was thinking about trying to grab one of the OEM pieces, but it is going to be so easy to fab up some flanges for the stock manifolds and run the pipes up from the collector/downpipe flanges. I'm going for a used turbo, and as many used components as possible to keep cost down since this is just the initial setup.

This, awesome either way though Max!

Oops! I am teh sux

How much would an exhaust like that run for my supercharger?? lol

Depends on the shop you use. I have high flow cats, an AWE 2.5" bullet resonator, and the Vibrant Strealthpower 2.5"**>dual 3" muffler.

I used that specific muffler because it is the same one I use on my S4 (albeit the one on my S4 is 4" instead of 2.5");

[Trisha90]

that video is of your S4??! nice, my boyfriend found this video a couple weeks ago and really wants to do this, 4" sounds really good

[Dan[FN]6262]

I was thinking about trying to grab one of the OEM pieces, but it is going to be so easy to fab up some flanges for the stock manifolds and run the pipes up from the collector/downpipe flanges. I'm going for a used turbo, and as many used components as possible to keep cost down since this is just the initial setup.

that was my thoughts also.

[Max@034]

that video is of your S4??! nice, my boyfriend found this video a couple weeks ago and really wants to do this, 4" sounds really good

Yep my baby. That was on K03's. The car is now on GT28R. Should be interesting to hear what it sounds like when its done.

that was my thoughts also.

I am itching to do the turbo! I almost wish my S4 was working more so I could do the A4 project, then to be able to drive the S4 finally after months of it being down. It is looking more and more simple to me. Plus, I am having turbo withdrawal.

[Coopa]

The car is now on GT28R.


This!^ Gt's in s4s are just insane.

[Max@034]

The car is now on GT28R.


This!^ Gt's in s4s are just insane.

Should be a lot of fun. Originally, it was going to be my track car, but now I've decided to keep the S4 as the daily driver, the A4 V6 as the beater, and my A4 1.8T as my racecar. I've still got 1 more A4 chassis I dunno what to do with. Shooting for about 500whp as the starting point.

Classic: owning 4 Audi's and only 1 works.

[bandit]

I really like the fact that you're trying to do somthing new but I don't see the point of having a GT'd s4 and a turbo V6 A4 as a daily driver or beater so to speak. I'd just keep the A4 clean and maintained and not have to dump cash into both cars when they break.

[NeedingAnAudi]

I really like the fact that you're trying to do somthing new but I don't see the point of having a GT'd s4 and a turbo V6 A4 as a daily driver or beater so to speak. I'd just keep the A4 clean and maintained and not have to dump cash into both cars when they break.

Your logic doesn't make sense since Max works at 034. They can't keep their hands off anything

[bandit]

Your logic doesn't make sense since Max works at 034. They can't keep their hands off anything

Seems dumb to slap a turbo on a N/A V6 just to run 6psi

[.Mad Hatter.]

Seems dumb to slap a turbo on a N/A V6 just to run 6psi

Seems dumb to slap a K04 on a 1.8t just to gain 30hp, but guys do it.

Edit: noticed your sig. after I typed that...even more applicable now.

[Euromike]

Seems dumb to slap a turbo on a N/A V6 just to run 6psi

a RELIABLE 6psi

not all of us can afford 2.7TT's blowing shit up all the time lol

[Coopa]

I see this evolving into something more than 6psi & smallish turbo at some point.

[Turbo Nerd]

Seems dumb to slap a K04 on a 1.8t just to gain 30hp, but guys do it.

Edit: noticed your sig. after I typed that...even more applicable now.

I swear I laughed so fu*king hard I spit mt. dew on the computer lmaoooo

[Dan[FN]6262]

I am itching to do the turbo! I almost wish my S4 was working more so I could do the A4 project, then to be able to drive the S4 finally after months of it being down. It is looking more and more simple to me. Plus, I am having turbo withdrawal.

Im loving having boost. I just threw a PTE6262 on my 1.8

[bandit]

Seems dumb to slap a K04 on a 1.8t just to gain 30hp, but guys do it.

Edit: noticed your sig. after I typed that...even more applicable now.

PC-16 is a little more than 30hp bud, and its called "budget" for a reason.

[.Mad Hatter.]

It's actually not much more than 30 (over a chip)...and you can do an elim. turbo for just about the same price.

AAAAAAAAAAAAAAAAnyway.

[bandit]

It's actually not much more than 30 (over a chip)...and you can do an elim. turbo for just about the same price.

AAAAAAAAAAAAAAAAnyway.

uhh no. Chipped hp on a 150hp 1.8t is 197ish, PC16 is 265 and almost 300 ftlbs. Apparently canadians can't do math.

[.Mad Hatter.]

uhh no. Chipped hp on a 150hp 1.8t is 197ish, PC16 is 265 and almost 300 ftlbs. Apparently canadians can't do math.

Don't get upset. After exhaust and all the stuff you need for a K04 anyway, you are about 30hp more with a k04. Hell, even 50hp more, you're in pretty deep for a minimal return... :)

Sorry Max...back on topic. This build is unique, and at the VERY LEAST, some of the 2.8 guys will have a good resource for their options.

[bandit]

Don't get upset. After exhaust and all the stuff you need for a K04 anyway, you are about 30hp more with a k04. Hell, even 50hp more, you're in pretty deep for a minimal return... :)

Sorry Max...back on topic. This build is unique, and at the VERY LEAST, some of the 2.8 guys will have a good resource for their options.

It's ok Hatter I'm not upset, I know math is tough and everything.

[$teady$upreme]

I like the way you still have those rear badges on hahahaha. (so stealthy, sleeper look until they hear your exhaust)

SUBSCRIBED to this awesome build.

[Dan[FN]6262]

PC-16 is a little more than 30hp bud, and its called "budget" for a reason.

It's actually not much more than 30 (over a chip)...and you can do an elim. turbo for just about the same price.

AAAAAAAAAAAAAAAAnyway.

uhh no. Chipped hp on a 150hp 1.8t is 197ish, PC16 is 265 and almost 300 ftlbs. Apparently canadians can't do math.

Don't get upset. After exhaust and all the stuff you need for a K04 anyway, you are about 30hp more with a k04. Hell, even 50hp more, you're in pretty deep for a minimal return... :)

Sorry Max...back on topic. This build is unique, and at the VERY LEAST, some of the 2.8 guys will have a good resource for their options.

It's ok Hatter I'm not upset, I know math is tough and everything.

this conversation is/was hilarious.

[anmagro]

wow! this is great! i cant wait till you get this figured out with the tune and everything!

please please if there is a single request for us 2.8 guys in this build, it is to try and have the turbo run on the stock internals and see what kind of power numbers you can get from there! and if all is well, show us your dam tune! tuning has always been the biggest problem for the 2.8 weather it be in a supercharger or even turbo.

lookin good with the exhaust keep it up!

[viceprp]

It's ok Hatter I'm not upset, I know math is tough and everything.

I once thought doing a k04 would be a great mod but then I noticed the little gain that you get out of that snail. The only benefit that you get is the low end torque and the additional 30whp with a loss in mpg. The difference in your build costs is probably $300 and Mad will get an additional 80miles on his tank than you. So in ~32 fill ups, ~8 months, Madd will make up that "lose" and you will be the one throwing money away from that piss poor mileage. Also, Mad also as 30+whp then your k04 and matching torque. Making his DD, mathematically, a better choice. Maybe you should have put the time in to figure that out on your own.

Max, we look forward to the numbers that the 2.8 pushes out. Like some of the 2.8er's have said, post up some stock block friendly numbers and a tune with it. Will you guys be making a kit once all is said and done?

[Max@034]

Whoa there fellas! Don't get your panties too much in a bunch!

K04 on the 1.8T is perfect for most folks who just need a bit more top end and a slightly more reliable turbo setup (pushing 16psi through a K04 is more reliable then pushing 16psi through a K03). However, yes, it is barely more to start throwing on a GT Eliminator, but you are opening up the possibility of more issues simply by running more power.

The point of this build is not practicality (none of my projects ever are, except for my track car possibly), but moreso the fact that I don't know how to leave anything alone. So instead of dropping in a VR6 with a GT35R on it, I figured doing a small, easy, and low pressure turbo kit would be a great alternative.

I am obsessed with boost; especially displacement with boost. The 2.8L V6 is pretty fun already, and its been enough to give me 3 speeding tickets in the last few months and the top end power is just fine, but I feel there is a lack of low end power. I have a very long commute that involves about 3000 vertical feet of elevation gain on the way home in a short period of time.

A GT2871 running under 10psi should be plenty to give me a nice horsepower boost, but without much risks. While the AHA/ATQ isn't as robust as the 2.7T APB, it isn't a piece of crap either. I have plenty of faith that even my 175,000 mile engine will be ok. But the other reason I want to do it, is simply to find out and to help the community. I want to know what the max power output is the 2.8L can handle, and superchargers just aren't the same so I do not think its fair to compare. I firmly believe a turbo 2.8L can put down more power safely then a supercharger. However, I also have the advantage of working with a dyno, so I can get the car tuned very safely.

I will be running our 034Motorsport Wideband Controller, which besides being awesome and having barometric pressure correction, it also has EGT so I can keep an eye on everything and make sure nothing runs to hot and lean.

As I've mentioned a few times, the goal is simply 250whp, which is a bit of 300bhp at the motor. This is about the power of a Stage 1 B5 S4, and having owned and driven many Stage 1 S4's, they are at a perfect power level for daily driving. Considering I don't track this car at all, I'm going to be running a fairly small intercooler, but for safety, I will be running meth injection too.

I see this evolving into something more than 6psi & smallish turbo at some point.

You my friend could not be more correct. My original plan was to pickup an A4 and use it as the daily driver, and make my S4 the weekend/track car. However, awhile back I decided that I wanted my S4 as my daily driver, since the car is surprisingly comfortable with the Ohlins Motorsport suspension and such. What this means is that eventually, this B5 2.8L V6 will become the project car. I also made this decision since my S4 has a clean title, and my A4 has a salvage; I'd rather have the project car be salvage.

Max, we look forward to the numbers that the 2.8 pushes out. Like some of the 2.8er's have said, post up some stock block friendly numbers and a tune with it. Will you guys be making a kit once all is said and done?

Part of this project is to check out the viability of producing a kit. Making one isn't going to be that difficult, but unless we can sell 10+ a year, its probably not something we will produce on a larger scale. Doesn't mean the kit won't be available on a semi-custom basis, but we won't know anything until I finish my own and see how it runs. So if it ever is going to be available, expect it to be a year away.