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  1. #1
    Active Member Two Rings casey_tuzziano's Avatar
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    Mar 25 2015
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    322686
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    '68 Chevy Nova
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    United States

    Big Turbo A4 Build

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    Here is my winter project! After being tired of my K03, I have decided to go all out and install either a Precision 5558 ball bearing turbo or a Garrett GTX3582r. I will be installing the following parts to complete the setup
    For the engine internals:
    ○ IE Rifle Drilled Rods
    ○ Wiseco 9.6:1 pistons
    ○ Clevite stock tolerance rod bearings
    ○ ARP main studs, head studs, and camshaft girdle (valve cover) bolts.
    For everything else:
    ○ Cast log-style T3 manifold
    ē Depending on fitment, the turbine housing may come in contact with the motor mount bracket since the manifold places the turbo further back than the stock location. With that being
    said, I can shave away at the motor mount bracket, or create or J pipe from the manifold so the turbo will be mounted on top.
    ○ While I have the engine disassembled, I am replacing all the gaskets, timing chains and guides, etc.
    ○ I am currently running ECS' Lufteknic Intercooler
    ○ Custom intake manifold with an integrated secondary fuel rail for port injection.
    Fueling!
    ○ As we all know with our B8's, when it comes to high horsepower, the injectors we have will not cut it.
    ○ For the in tank pump; I have a walbro 450 E85 compatible pump.
    ○ upgraded HPFP
    ○ the injectors I plan to run will either be Opel or Bosch injectors, but these will only get me to +- 400whp (from what I have researched).
    ē with the port injection; I plan to run bosch style injectors, controlled by AEM's FIC. I will need to figure out what size injectors I will need.
    ○ I have the option to run W+M, but I have not decided on it.
    Tuning!
    ○ Many people have recommended all sorts of tunes, and tuners. I will have to do my research, I would typically go to Mirza in NJ, but he seems to be AFK....
    Turbo!
    ○ I am in between the two turbos
    ē both will be t3 in/4 bolt out, with a .64 turbine housing.
    ○ For the water and oil feed/return
    ē IE oil feed adapter (-4 AN)
    ē IE oil return (-10 AN)
    ē ATP banjo bolt and crush washers for the coolant return, 3/8 hose from coolant feed into the return on side of block. (Not needed on the PTE or Garret)
    ē AN lines and fittings
    I will update the thread as parts come in!
    Last edited by casey_tuzziano; 12-30-2017 at 11:58 AM.

  2. #2
    Veteran Member Four Rings Audibot's Avatar
    Join Date
    May 20 2010
    AZ Member #
    59252
    My Garage
    Wrecked B7 A4
    Location
    Maryland
    Items for Sale

    Quote Originally Posted by casey_tuzziano View Post
    Here is my winter project! After being
    I think you got cut off!

  3. #3
    Active Member Two Rings casey_tuzziano's Avatar
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    Mar 25 2015
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    '68 Chevy Nova
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    United States

    you're right I did! but i updated the post

  4. #4
    Veteran Member Three Rings pierreb's Avatar
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    Sep 15 2006
    AZ Member #
    11476
    My Garage
    Q7 (4M)
    Location
    NH

    Subscribed

  5. #5
    Active Member Two Rings casey_tuzziano's Avatar
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    Mar 25 2015
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    322686
    My Garage
    '68 Chevy Nova
    Location
    United States

    I pulled the engine first week of December before it got super cold.



    Started to tear it apart and began to order the all the goods.




  6. #6
    Established Member Two Rings Perry01's Avatar
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    Jan 22 2016
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    367620
    Location
    Hawaii and Utah

    It sounds like a cool project. Since youíre going with some IE internals, you may want to email Peter Blais (owner and engineer at IE) and see if heís willing to write a custom file for you. He already has the box code for the B8 A4. They also sell turbochargers but only Borg Warner.
    2013 Q5 Primium Plus
    2008 Touareg 4.2 V8 FSI
    2009 A4 S Line
    2016 GTI Stage 2

  7. #7
    Active Member Two Rings casey_tuzziano's Avatar
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    Mar 25 2015
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    '68 Chevy Nova
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    Quote Originally Posted by Perry01 View Post
    It sounds like a cool project. Since youíre going with some IE internals, you may want to email Peter Blais (owner and engineer at IE) and see if heís willing to write a custom file for you. He already has the box code for the B8 A4. They also sell turbochargers but only Borg Warner.
    Very cool! I'll shoot Mr. Blais an email!

  8. #8
    Established Member Two Rings Perry01's Avatar
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    Jan 22 2016
    AZ Member #
    367620
    Location
    Hawaii and Utah

    IE is known for their hardware but Peter is also good at tuning as well. I just received my 6th revision on a custom Stage 2 e-tune. Iíve been sending him datalogs and each new file has improved the performance. It pulls really strong for a K03.

    Im thinking about putting a big turbo on my MK7 GTI. Peter tuned his brother Dave (co-owner of IE) MK7 Golf R to put down over 400 AWHP on the stock turbo. Iím hoping he can do something similar for me.

    Here is a cool article about Integrated Engineering, there is a video clip at the end with Pete showing off his 600 WHP MK6 GTI:

    http://motonetworks.com/integrated-e...tuning-finest/
    2013 Q5 Primium Plus
    2008 Touareg 4.2 V8 FSI
    2009 A4 S Line
    2016 GTI Stage 2

  9. #9
    Veteran Member Four Rings A4 Centaur's Avatar
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    Jun 05 2009
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    My Garage
    Ducati Panigale 1199S (Red of course)
    Location
    Denver Colorado

    Looking forward to this project! It's gonna be really nice to see something like what you have planned come together. SO much win!
    Black B8 A4 Avant S-Line Prestige Package, Tiptronic 8 speed, JHM K04-R, V1 & Beltronics, Eurocode HFC, APR FMIC, Alu Kreuz, Vogtland Coilovers, Stoptech 380mm BB Kit, H&R Swaybar, APR K04 Tune, Rev. "d" DV, R8 Coils, Folding Mirrors, S5 Rear Brakes, 034 Street Density Mounts, OEM Facelift LED Brake lights, Forgestar CF5, and more mods to come!

  10. #10
    Active Member Two Rings casey_tuzziano's Avatar
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    Mar 25 2015
    AZ Member #
    322686
    My Garage
    '68 Chevy Nova
    Location
    United States

    Happy New Year everyone! 2018 has some BIG plans for my car. (Pun intended)
    My IE H-beam rods and rod bearings came in today.



    Also went ahead and sand blasted then painted my valve cover wrinkle red on my day off. It honestly doesn't look that bad.



    I will be doing a turbo reveal soon as well!

  11. #11
    Active Member Two Rings
    Join Date
    Feb 25 2011
    AZ Member #
    71498
    Location
    Alpharetta, GA

    Iíve got some of the specific build tools if you need them. The large bar to hold the crank. The guides for setting up the cams etc.


    Sent from my iPhone using Audizine

  12. #12
    Active Member Two Rings casey_tuzziano's Avatar
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    Mar 25 2015
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    322686
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    '68 Chevy Nova
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    United States

    Quote Originally Posted by Mitchmarket View Post
    Iíve got some of the specific build tools if you need them. The large bar to hold the crank. The guides for setting up the cams etc.


    Sent from my iPhone using Audizine
    Haha thanks! But Im an Audi tech and i own most of special tools for the TFSI block lol

    Sent from my SM-G955U using Audizine mobile app

  13. #13
    Stage 3 Forum Advertiser Four Rings Jake@JHM's Avatar
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    Aug 31 2011
    AZ Member #
    80618
    My Garage
    16 MK7 GTI APR STG2 - 03 Grand Cherokee - 06 R6 Raven - 13 HD IRON
    Location
    Lathrop

    Cool build! Interesting turbo choice.

  14. #14
    Established Member Four Rings Spawne32's Avatar
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    Nov 20 2016
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    386232
    Location
    NJ

    loving the cam cover wrinkle red, i would have done that already on mine if it wasnt for the fact that it holds the cams down lol

  15. #15
    Active Member Two Rings casey_tuzziano's Avatar
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    Mar 25 2015
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    '68 Chevy Nova
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    United States

    Quote Originally Posted by Spawne32 View Post
    loving the cam cover wrinkle red, i would have done that already on mine if it wasnt for the fact that it holds the cams down lol
    Yeahhhhh there's no real good way to remove the girdle without removing the timing chain. I know one guy did it without removing the chain and once he removed the last bolt to the girdle the cams moved and it skipped timing. It was a mess lol

  16. #16
    Established Member Three Rings B8_Dude97's Avatar
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    Sep 05 2016
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    Antioch, California

    Subbed. Great build that valve cover is sick.

    I got a tiny leak on my valve cover so when I decide itís time to do my timing chain Iíll probably follow suit in a wrinkle blue because racecar


    Sent from my iPhone using Audizine

  17. #17
    Active Member Two Rings casey_tuzziano's Avatar
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    Mar 25 2015
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    '68 Chevy Nova
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    United States

    Quote Originally Posted by B8_Dude97 View Post
    Subbed. Great build that valve cover is sick.

    I got a tiny leak on my valve cover so when I decide itís time to do my timing chain Iíll probably follow suit in a wrinkle blue because racecar


    Sent from my iPhone using Audizine
    Thanks dude! And when you get around to it you should definitely post a pic of the wrinkle blue! Just a reminder you need to use a special anaerobic sealant for the valve cover. D 154 103 A1 is the sealer part number.

  18. #18
    Established Member Three Rings B8_Dude97's Avatar
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    Sep 05 2016
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    Antioch, California

    Quote Originally Posted by casey_tuzziano View Post
    Thanks dude! And when you get around to it you should definitely post a pic of the wrinkle blue! Just a reminder you need to use a special anaerobic sealant for the valve cover. D 154 103 A1 is the sealer part number.
    Will do! I got a laundry list of things coming up that I need to do. Replace all wheel bearings and full timing chain job and replace valve cover sealant and do a carbon cleaning and camshaft adjuster magnet.

    I will report back with pics of valve cover. I know a mk6 user said it could only be painted a special way but you say you just sandblasted and did the paint so Iím confused on that if you could shed some light thanks!


    Sent from my iPhone using Audizine

  19. #19
    Active Member Two Rings casey_tuzziano's Avatar
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    '68 Chevy Nova
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    Quote Originally Posted by B8_Dude97 View Post
    Will do! I got a laundry list of things coming up that I need to do. Replace all wheel bearings and full timing chain job and replace valve cover sealant and do a carbon cleaning and camshaft adjuster magnet.

    I will report back with pics of valve cover. I know a mk6 user said it could only be painted a special way but you say you just sandblasted and did the paint so Iím confused on that if you could shed some light thanks!


    Sent from my iPhone using Audizine
    You can paint it however you want lol, I've never heard of a special way to paint valve covers besides to prep the surface and make sure everything is clean and masked off. I only sandblasted it to get the smoothest surface as possible.

  20. #20
    Active Member Two Rings casey_tuzziano's Avatar
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    Mar 25 2015
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    My Garage
    '68 Chevy Nova
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    United States

    Parts are slowly rolling in! Went to Wiseco today (they're local to me in Ohio) and put an order in for the pistons. Should be getting a call Thursday the latest from them. On the other hand...

    Got the ARP main studs installed


    And the IE oil feed/drain adapters fitted


    Sent from my SM-G955U using Audizine mobile app

  21. #21
    Active Member Two Rings casey_tuzziano's Avatar
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    Got the bottom end all together and head bolted down!





    Sent from my SM-G955U using Audizine mobile app

  22. #22
    Active Member Two Rings casey_tuzziano's Avatar
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    Mar 25 2015
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    '68 Chevy Nova
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    United States

    I'm going to town on the engine! Turbo still has not shown up yet....I also need to tackle the fueling....oh boy



    Sent from my SM-G955U using Audizine mobile app

  23. #23
    Senior Member Three Rings Carlos74's Avatar
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    Mar 31 2014
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    168261
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    Palatine, IL

    Quote Originally Posted by casey_tuzziano View Post
    I'm going to town on the engine! Turbo still has not shown up yet....I also need to tackle the fueling....oh boy



    Sent from my SM-G955U using Audizine mobile app
    Subbed!!! Iím excited to see such a serious build bro!


    IG: @c_lowsb8
    APR l CTS l EUROCODE l ECS l 034 l PODI l GFB l MAGNAFLOW l H&R l SPC l STANCE l SPULEN l HANKOOK l NGK


    IG: c_lowsB8

  24. #24
    Veteran Member Four Rings Audi 4 Life's Avatar
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    Jan 16 2011
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    E46 325ci
    Location
    CA/NV
    Items for Sale

    Beautiful!

    Sent from my SM-G935T using Tapatalk
    RIP - JHM B6 3.0 6MTQ USP Denim Blue/Black w/ Nappa Silver
    Current- B8 2.0t Ibis white/black

    AKA: A4QuattroV6

  25. #25
    Active Member Two Rings casey_tuzziano's Avatar
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    Mar 25 2015
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    '68 Chevy Nova
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    United States

    Quote Originally Posted by Carlos74 View Post
    Subbed!!! Iím excited to see such a serious build bro!


    IG: @c_lowsb8
    Ayyyyyeee Carlos! We follow each other on IG haha. I think you're the first one to sub from there lol. Anwyays, I appreciate it a lot! I hope to get it up and running before car show season.

  26. #26
    Senior Member Three Rings Mina08's Avatar
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    Apr 30 2014
    AZ Member #
    203173
    My Garage
    Classic Mini, and lots of bikes
    Location
    Sweden

    sub
    Really interested with the turbo install, what exhaust are going with
    2011 2.0 TFSI S-Line Avant/S-Tronic/Quattro/Quartz Grey/19"OEM RS5 Rotors/
    CFBSWheel/VCDS+Mods/XCL+Mirracast/LED/R8Coils/3.0FMIC/K&NFilters

  27. #27
    Active Member Two Rings casey_tuzziano's Avatar
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    Mar 25 2015
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    '68 Chevy Nova
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    United States

    Quote Originally Posted by Mina08 View Post
    sub
    Really interested with the turbo install, what exhaust are going with
    Currently it's catless with a custom bent 2.5in piping. I welded in a vibrant bottle resonator and ultra quiet resonator. When I get the turbo mounted I'm going to have to make a downpipe, stock one will not fit. I'll attach a sound clip.

    Sent from my SM-G955U using Audizine mobile app

  28. #28
    Veteran Member Three Rings
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    NYC, US
    Items for Sale

    How much does it cost of all the internals? Would it be more expensive than buying a brand new S4? I know you guys are enjoying the process of building a engine. I wish someone can teach me how to build a car engine from scratch.

  29. #29
    Active Member Two Rings casey_tuzziano's Avatar
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    Mar 25 2015
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    '68 Chevy Nova
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    United States

    Quote Originally Posted by AutoRacer100 View Post
    How much does it cost of all the internals? Would it be more expensive than buying a brand new S4? I know you guys are enjoying the process of building a engine. I wish someone can teach me how to build a car engine from scratch.
    The rods, pistons and bearings came to +- $1300

    Sent from my SM-G955U using Audizine mobile app

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