My very own update thread - AZ edition (picture heavy)

[BaseDrifter]

Current Mod List

Engine

18psi tune
Forge 007 DV
034 Motorsports high flow cat
Borla catback
TyrolSport SMIC
Carbonio air intake
034 Motorsport fuel pressure g
Silicone intake hoses
034 Motorsports breather hose
Shaved and bead blasted intake manifold, valve cover, upper coolant pipe, and oil cap
Euro passat driver side engine cover
Facelift rain tray cover

Suspension/Drivetrain

RA4 Stage 1 clutch
USP Motorsports metal slave cylinder and SS slave line
Vogtland GT3 coilovers and 034 Motorsports street density strut mounts (to be installed)
034 Motorsports rear sway bar
034 Motorsports street density engine and transmission mounts
Apikol blue street rear differential carrier bushings
ECS Tuning polyurethane rear differential mount
JHM Trio Shifter Package
Meyle HD control arms and tie rods
Rebuilt steering rack
034 Motorsports driveshaft center support bearing
ECS Tuning SS brake lines
A8 brake upgrade (A8 rotors and TT carriers)

Interior

Black heated sport cloth seats
AWE Tuning boost gauge (center vent)
GlowShift oil pressure gauge (left driver vent)
Podi AFR gauge (center column)
Sport steering wheel
Facelift ebrake handle and air vent housings
Redline shift boot
Osir Orbit shift knob
A4 marked aluminum pedal covers
Cluster swap to FIS cluster with matte silver gauge rings
Bose door cards
BlackVue DR650 2 channel dash camera
Custom sound system with sub

Exterior

2.8 16" 5 spoke wheels with Falcon Zeix ZE912 225/50/R16 tires
RS4 grille
Euro 96 trunk
Facelift head lights, tail lights, and fog lights
Independent fog lights mod
S4 gloss black B pillars
Smoked side markers

TIMELINE

Updated 12/30/2015

Engine

1. 18psi tune
2. New turbo oil feed line
3. Forge 007 (Pictured on Page 26)
4. R8 oil cap (Page 11)
5. Carbonio CF intake (Page 13)
6. New blue silicone vacuum lines (Page 15)
7. Shaved/bead blasted intake manifold (Page 1, 4, 5, 6, 22, 34)
8. Shaved throttle body/beadblasted (Page 20, 21, 34)
9. Plasti dipped fluid caps (Page 14)
10. Timing belt service including cam chain tensioner, serpentine tensioner, seals, etc. (Page 26, 27)
11. Bead blasted valve cover (Page 25, 27)
12. Installed stainless steel fasteners (Page 31)
13. Port matched intake manifold to throttle body (Page 32)
14. Installed shaved/bead blasted intake manifold, 034 breather hose kit, replaced all fuel inector o-rings and clips, replaced dipstick funnel (Page 34)
15. Installed B5.5 Passat Engine/battery cover (Page 45) (Replaced with facelift A4 cover)

----- Start of Audizine thread -----

16. Junkyard turbo swap, installed 034 HFC, replaced a bunch of seals and gaskets (Page 1)
17. Replaced cracked AEB SMIC with AWM replacement (Page 3)
18. Diagnostics, compression test, sealed injector seats (Page 4)
19. New shaved and bead blasted oil cap, grommet plug (Page 7)
20. Facelift windshield cowls and rain tray installed (Page 7)
21. Shaved and polished ABS module (Page 7)
22. Installed euro passat driver side engine cover
23. BIG job: Pulled motor to replace clutch and oil pickup tube, replaced oil cooler coolant lines, throttle cable, all intake and exhaust gaskets, cam chain tensioner seal, valve cover gasket, new spark plugs, Newsouth Performance intake manifold gasket, bead blasted all top parts and clear coated them, new oil pan gasket, rear main seal, pilot bearing, etc. (Page 11, 12", 13)
24. Tyrol Sport upgraded SMIC (Page 12")
25. Silicone intake hoses (Page 15)

Suspension/Drivetrain/Brakes

1. Meyle 12 piece HD control arm kit including TREs & sway bar end links
2. New motor mounts
3. Neuspeed snub mount
4. S4 rear sway bar (Mentioned on Page 11)
5. 034 street density transmission mounts (Page 14)
6. Sport shocks and springs (Page 23)
7. New tires - Falcon Ziex ZE912, alignment (Page 36)
8. Replaced VSS & magnetic gear ring (Page 37, 38)
9. A8 brake upgrade, front calipers rebuilt, SS lines, new reservoir (Page 36, 43, 44)

----- Start of Audizine thread -----

10. JHM shifter linkage and bushing upgrade (Page 1)
11. Apikol blue street rear differential carrier bushings
12. Stern Power Ring rear diff brace (Page 11)
12. Replaced clutch with ECS RA4 stage 1 clutch kit, USP Motorsports stainless steel slave cylinder and braided line, new input shaft seal, throwout and pilot bearing (Page 11, 12)
14. 034 Motorsports rear sway bar and support brackets with Meyle HD end links (Page 11, 13)
15. Replaced steering rack (Page 12)
16. ECS stainless steel rear brake lines (Page 13)
17. Replaced Power Ring with ECS rear differential mount (Page 13)
18. OEM modified strut brace (Page 15, 16
19. Installed used metal driveshaft and new 034 center support bearing (Page 16)

Interior/Electronics

1. Sony Xplod stereo, 8" sub in trunk (PO installed)
2. Chrome gauge rings (page 1) (Removed with old cluster)
3. Sunglass holder (Page 3)
4. iPhone integration and mount (Page 6)
5. AWE vent boost gauge (Page 8)
6. Osir shift knob (Page 8)
7. Red LED under dash lights (Page 10)
8. Funk switch (for under dash lights) (Page 10)
9. LED interior lights
10. Sport steering wheel (Page 11)
11. Facelift vent housings (Page 11, 14)
11. Hardwired GPS (Page 11)
12. "A4" marked pedal covers (Page 13)
13. eBay short shifter (Page 13)
14. Redline short shift boot (Page 13)
15. LCD cluster swap (Page 18, 20, 21, 23)
16. Updated flip key remote (Page 20)
17. Leather facelift ebrake handle covers
18. Installed headlight relays using OEM equipment (Page 28, 29)
19. Installed G1W dash camera (Page 41)

----- Start of Audizine thread -----

20. Sport cloth seats (Page 2, 3)
21. Installed GlowShift Elite 10 oil pressure gauge (Page 5, 6)
22. Satin Silver gauge rings (Page 6)
23. Installed hidden constant power switch for dash camera (Page 8)
24. Put Dynamat on the door inner skins (Page 15)
25. Installed Bose rear door cards (Page 15)
26. BlackVue DR650GW 2 channel dash camera (Page 15)
27. Black rear deck (Page 16)

Exterior

1. Clear side markers (Page 1) (Replaced with smoked side markers)
2. Lower chrome grille (Page 4) (Removed)
3. M3 lip spoiler (Page 6)
4. Shaved badges (Page 6)
5. LED license plate lights (Page 6)
6. RS4 grille (Page 10)
7. Plasti dipped 5 spoke wheels, grille trim, and side mirrors (Page 8, 14)
8. Painted brake calipers red (Page 14)
9. Smoke side markers (Page 24)
10. S4 gloss B pillars (Page 16)
11. Facelift tail lights (Page 16)
12. Facelift independent fog lights (Page 17, 24, 29, 31)
13. Restored front grilles (Page 39)
14. Restored fog light lenses, installed yellow lamin-x/bulbs (Page 39, 43)

----- Start of Audizine thread -----

15. Replaced passenger side Audi fender logo (Page 8)
16. Euro trunk and new hood (Page 10)
17. Facelift one piece headlights (Page 10)
18. Installed new passenger side doors (Page 15)

Advancing stages of the exterior

1. 4/23/2010 - See below
2. 5/23/2010 - Essentially stock
3. 8/12/2010 - With 16" 5 spoke wheels
4. 10/8/2010 - Added RS4 grille, chrome lower grille, lip spoiler
5. 9/5/2012 - Plasti dipped wheels, mirrors, red calipers
6. 1/8/2013 - Facelift tail lights
7. 1/26/2013 - Dipped grille, snow photos
8. 2/11/2013 - On sport suspension
9. 2/20/2013 - With updated fogs
10. 3/25/2014 - Yellow fog lights, painted grilles

----- Start of Audizine thread -----

(Intro post moved down for cleanliness.)

[R1CH-5100]

Nice write up. Can you tell me what you used for the LEDs under the dash? I've been wanting to do that forever.

[BaseDrifter]

First a little intro.

I bought my A4 in 2010 after my FC RX7 blew an apex seal. My dad was already on his 2nd A4 after his first black 2.8 A4 was totaled in an accident, so the cars weren't new to the family. I had a few requirements for my new car. I wanted it to not be FWD, to be a manual, look decent, have aftermarket support/capability to modded, and be under $5k.

I found a blue 1997 A4 1.8T Quattro manual after a few months of looking. The guy was asking ~$5000, after having the car inspected and learning it needed a new front end along with some other work I talked him down to $3700.

As stock as could be! (I learned later that the car had been chipped by the original owner, so not quite stock.)



The car did come with an aftermarket radio, speakers, and an 8" sub. I added a dash mount for my iPhone and hardwired it in for power and audio.





And here are some of my favorite pictures of the car.

I just realized I don't have a good daytime front view of the car as it sits now. Guess I'm due to take some new pictures! These first few pictures with the silver wheels are quite old, back when I still on stock non-sport suspension.























Ah yes and here's a video of me blowing my cat off the turbo from last week. The car is currently in service position to fix it and do some other maintenance.

Nice write up. Can you tell me what you used for the LEDs under the dash? I've been wanting to do that forever.

Thanks. I used 7" red LED bars (one in each footwell and one under each front seat) and wired them to a funk switch.

http://www.superbrightleds.com/morei...light-tube/50/

[BrucexL33]

Hey did you use to know anyone with a FC in San Jose? Anyways great thread! gotta get a bigger turbo soon!

[AudiB5owner]

Awesome ride! That engine bay looks freekin awesome, like the carbonio. The video of your cat falling off is great, it actually sounds super aggressive, instant cutout. I must learn how to photo edit better, your pics are sick. I actually literally just bought a set of Falken Ziex, going to try them out this weekend

[BaseDrifter]

Hey did you use to know anyone with a FC in San Jose? Anyways great thread! gotta get a bigger turbo soon!

Nope, I wasn't really involved in the FC community since I wasn't working on the car. It was just my mode of transportation. Thanks, I'll start with hopefully a better working K03. A Frankenturbo is in the plans for the next year or two.

Awesome ride! That engine bay looks freekin awesome, like the carbonio. The video of your cat falling off is great, it actually sounds super aggressive, instant cutout. I must learn how to photo edit better, your pics are sick. I actually literally just bought a set of Falken Ziex, going to try them out this weekend

Thanks! The car did sound great with the cat disconnected, hopefully it still sounds nice with a HFC.

The photos with a watermark were taken by my friend Ben Tappe, the others were taken by me. I just use iPhoto to make some adjustments.

I don't have any complaints about the 912s. They grip well enough in dry weather and I didn't have any problems with them up in the snow the one time I made it up to the mountains last year.

[BaseDrifter]

..

[BaseDrifter]

..

[OverSpun]

OP,

This thread wasn't exactly necessary since you can have edited your original thread. I can properly merge them if you want me to.

If you thought your 45 page thread was too long... (http://www.audizine.com/forum/showth...le-Turbo-setup)

[BaseDrifter]

OP,

This thread wasn't exactly necessary since you can have edited your original thread. I can properly merge them if you want me to.

If you thought your 45 page thread was too long... (http://www.audizine.com/forum/showth...le-Turbo-setup)

What original thread are you referring to? I don't recall making a timeline on AZ before.

[OverSpun]

What original thread are you referring to? I don't recall making a timeline on AZ before.

Your thread that you referred to with all the links in your first post since I didn't click any of them until I realized that you wrote the thread on another site. AZ members (who haven't registered on the other site) and they may not want to bother juggling 2 forums. Otherwise, you could have copy/pasted your main points from the other forum if you wanted to.

[BaseDrifter]

Your thread that you referred to with all the links in your first post since I didn't click any of them until I realized that you wrote the thread on another site. AZ members (who haven't registered on the other site) and they may not want to bother juggling 2 forums. Otherwise, you could have copy/pasted your main points from the other forum if you wanted to.

Nick, I'm not sure what you're getting at...I spent many hours creating that table of contents for my old thread so that people could easily link back to each project for more information. There's nothing linked that requires people to log in to AF to view the content. I will be using this thread for all my future updates/questions/problems. Please PM me if there is an issue.

On that note, my family got me a few goodies for xmas.

3 quarts of Redline 5w40
JHM Motorsports solid shifter linkage upgrade
JHM Motorsports solid shifter stabilizer bushing
PureMS metal wheel hanger (on the way)
2x Protech side lift jack pads (also on the way)

[BrucexL33]

Did you get your HFC installed yet?

[MetalMan]

Nice! One year I asked for transmission fluid for Christmas, and since then I haven't heard the end of it from my aunt (who bought it for me). So I no longer as for fluids for Christmas haha.

The solid linkage upgrade is a HUGE improvement. I didn't bother with the stabilizer bushing as I heard it transfers extra vibrations/noise or something like that. In any case I'm interested to hear your feedback on it.

[BaseDrifter]

Did you get your HFC installed yet?

Not yet, cars still in service position. Hating life not being able to drive it. I'll be buying a used 034 HFC from a local AZ member when he gets back into town on the first and my order from ECS should arrive on the 27th (cat hardware, expansion tank, various gaskets & seals.)

Nice! One year I asked for transmission fluid for Christmas, and since then I haven't heard the end of it from my aunt (who bought it for me). So I no longer as for fluids for Christmas haha.

The solid linkage upgrade is a HUGE improvement. I didn't bother with the stabilizer bushing as I heard it transfers extra vibrations/noise or something like that. In any case I'm interested to hear your feedback on it.

Oh I caught a bunch of shit after opening them. My mom said it was the most useless looking $120 she had spent. Couldn't believe she was getting me "some bolts." My brother didn't really care about getting me the oil, though he only wrapped one quart since they aren't the most wrapping-friendly shape.

This shifter linkage upgrade has been on my list for a long time, there were too many other more important things to do first though since this is far from a "necessary" improvement (though I hope I say otherwise after the install.) I have heard about some increase in NVH with the bushing but I don't expect it to be an issue. We'll see once I get them in.

[BaseDrifter]

Received a package from ECS today.

Manifold to turbo gasket
Turbo to cat gasket
Cat to DP gasket
3 new turbo bolts, nuts, and studs
Turbo coolant and oil line sealing washers/gaskets
Oil cooler o-ring
Oil filter adapter gasket
OEM PTFE cam seal
Coolant tank



Does anyone know what purpose the black cylinder on the waste gate actuator arm serves? It just slides around.



I've drilled all the way through the broken bolt on the turbo with a brand new cobalt left hand bit, but that thing hasn't budged yet. Going to hit it with the oxy acetylene today and try the EZ out again before I start to chip away at it..

[AudiB5owner]

New Coolant Tank completes the clean look of any B5

Looks like you took a trip to Gasket City lol, prepping for the HFC install?

I think the WG clip is to keep the nuts in place someone correct me if I'm wrong. My turbo never had one.

[BaseDrifter]

Definitely, just never got around to changing it again. It was one of the first things I replaced when I bought the car in 2010, guess they don't last too long.

Haha yeah, might as well while I have it in service position. Something always needs fixin'!

Not the clip, that cylinder in the middle of the arm.

[BaseDrifter]

Got the cam seal pulled out and replaced today. The sealing lip of the PTFE seal I ordered caught an edge on the camshaft key notch and got nicked. Had to pull it out and replace it with one of the non-PTFE seals I had laying around. Oh well.



I also noticed something a bit troubling on my lower TB cover. It looks like the TB contacted the cover and melted through it at the intermediate shaft pulley…the belt looks alright though. I don't see any damage compared to the pictures of when I first installed it. It's also possible that mark was there before I did the TB, I can't remember and didn't take a picture of the cover.

[BaseDrifter]

Got the old turbo pulled out today. A couple weeks of spraying the turbo bolts with thread penetrator helped them break free without much trouble. The same bolt that broke when I pulled the replacement turbo was completely rusted and broken on mine. It looks like the lost tension from the broken bolt allowed the exhaust to break through the gasket causing a leak. The broken bolt looks different than the other two and has a smaller washer so I wonder if someone tried to replace it before.









You can see where the exhaust was blowing by on the manifold.









"The catch of the day."

[BaseDrifter]

Replaced the oil cooler o-ring today. I'll write up a little DIY article since I couldn't find one when searching.

This really should be the last oil leak..I'm hoping to have a clean under engine tray next time I pull it off. I'll deal with the crusty coolant hoses next time around.

[BaseDrifter]

Used ceramic coated 034 HFC.

[BrucexL33]

WOW! that's a steal for the HFC! when are you installing it?

[redline380]

My thread on AF is on page 45 and it has devolved into bhusted, metalman and I talking to each other.

I'll have you know I have replies to that thread as well, thank you very much

[BaseDrifter]

WOW! that's a steal for the HFC! when are you installing it?

Whenever I get this damn broken bolt out of the turbo.

I'll have you know I have replies to that thread as well, thank you very much

Of course, how could I forget the legal mooderator.

[redline380]

Of course, how could I forget the legal mooderator.

No bowing necessary. I have been missing since 12/20 since I went home for a week or so and when I got back to my place, the internet was out. But I am back now and even moved your oil cooler to the DIY section already

[DeltaAlpha9]

You should post up how you installed the stabilizer arm bushings and shift U-joint. I got the set for Christmas as well but have so far only gotten to the short shifter due to a lack of garage space.

[BaseDrifter]

Sure thing. I haven't got to those yet. Maybe tonight..

[BaseDrifter]

Got back to attacking the broken bolt in my turbo tonight. For the past few days I've been trying to think of how to get the turbo secured to my drill press and came up with this solution.

I used the exhaust gasket to transfer the holes to a piece of 1/4" steel, mounted the turbo to the piece of steel and clamped it to the drill press' table. I put a transfer roller underneath the turbo to provide some more support and keep it from deflecting. Still haven't got it out though…theres a tiny bit left but I'm going to wait until I get a new drill bit to finish it off.

[BrucexL33]

damn hope you get it done soon.

[BaseDrifter]

Hell yes, success!

After burning up or chipping three drill bits I switched to a cobalt bit and finished drilling out the hole. I should've used a cobalt bit to start with, lesson learned. Once it was drilled out I ran an M10x1.5 tap to try and clean the threads out. And it worked! The bolt threads in beautifully now.

[BaseDrifter]

I attacked the turbo with a steel brush today and got it cleaned up. I also set up my new shifter rod with the JHM linkage. Tomorrow I'll remove the linkage from my car, get the new one put in place, and hopefully get some of the turbo/exhaust put together.

Since my car is a 97 (where everything is slightly different) I had to get the updated shift rod from a 98+ A4. The linkage on the car is a different style that doesn't work with the JHM linkage I pulled the updated one out of the junkyard for about $15.

Before:



After:



Drilling out the rivets on the stock linkage.

[BaseDrifter]

I just finished installing the new shift rod and bushing. Wasn't so bad. Luckily the dust boot has two little tabs on it that allow you to pull it away and slip the rod out. Still not easy, but not as hard as I predicted. The shifter feels great with the new linkage and bushing. The old one was ripped so that probably wasn't helping to keep things stiff. We'll see how it does when the car is back together..









Some not so nice deflection!












2:20am update: Turbo, HFC, and down pipe mostly installed.

[BaseDrifter]

Well, the car is back together and running, but I'm still only getting 12-13psi…

Pretty disappointed with the results after putting in a "new" turbo and the HFC. I do hear the sounds of what could be a boost leak so I'll have to check that out. Tomorrow I'll scan for codes, but there's no CEL thankfully.

I can definitely hear a whirring sound from the transmission, probably from the delrin bushing. The sound is only there when moving. It almost sounds like a supercharger whine when accelerating. Not sure if I'll leave it in or not. Probably won't be able to hear it with some music on though.

Damnit why can't I get 15psi again! Tune is written for 18psi.

Here's some more pictures. Grrrr.

[redline380]

I wont go back through the whole thread, but how much attention have you given to EVERY boost controlling device? Goes for n75 and anything connected to it

[BaseDrifter]

I opted to replace the turbo after only getting 2psi from the original turbo with the waste gate vac line disconnected. I haven't tested or replaced the N75 since I noticed a decrease in boost. I do have another stock one laying around as well as a "race" N75 I could try.

Tomorrow I'll disconnect the vac line and see if I can get 5psi out of this turbo. Open to any and all ideas at this point.

[DeltaAlpha9]

Haha I was about to ask you if you were getting that same racket from the transmission. Mine sounds like I tore the boot but there was no air rushing through the shifter area. I may go back to the rubber bushing for the stabilizer bar if it really bugs me.

[BaseDrifter]

Do you get a type of whirring sound as well? Wonder if I could add a little more sound deadening inside the shifter box to quiet it down. I don't feel any increase in vibrations though which is nice.

[DeltaAlpha9]

Ya it's kind of a lower pitch whine when the trans has some heat in it, higher supercharged sound when it's cold. I also thought of just taking some insulation and cramming it in the extra space around the tunnel.

[BaseDrifter]

Yep sounds about right, definitely an interesting sound..let me know if you do anything to try and deaden it. I've only driven the car for 15 minutes with the radio off so I don't have a good long term impression yet.