2005 A4 Quattro EFR 6758 .64 Re-build

[2006b7a4]

In January I bought a new B7 to replace my old one which was totaled last year. The car was supposedly RAI's development car for their Red Label EFR kit and basically got their whole catalog of parts for the B7 back in 2012. Made about 315 wheel hp back then but it definitely does not anymore. Overall the car is not in the greatest shape, only thing is the body/interior are pretty clean. Problems i noticed right off the bat with the engine were multiple vacuum leaks, crack/leak in the exhaust manifold, and catch can not setup properly causing it to leak oil from pretty much everywhere. Otherwise the front end and shocks are completely shot, but I am in the process of swapping the complete front end and shocks from my old car.

Mod List

Engine/Drivetrain:
RAI red label kit: EFR 6758 turbo with stainless log manifold and test pipe
S3 injectors
Autospeed HPFP
Eurodyne boost/methanol manager
windshield washer tank repurposed as meth tank
RAI front mount intercooler
JHM rs4 clutch and flywheel

Suspension:
Bilstein sport shocks and struts
Eibach pro springs
rs4 rear sway bar

Pic when it was first towed to my house:
https://i.imgur.com/Lrfu0uG.jpg

Turbo and manifold
https://i.imgur.com/rmumPXo.jpg
You can see in this picture the evap output on the valve cover goes no where, I assume that is no good?

More recent pic. cleaned up a little bit but missing front bumper
https://i.imgur.com/1eA9TVF.jpg

I'm in a little over my head with all this, I've only ever worked on stock cars but I hope I can get it back to the condition it once was.

So far I have had the manifold repaired, replaced blown out exhaust/turbo gaskets, replaced leaking AN turbo line, converted from bad catch can to stock PCV, new intake with bungs for pcv and evap hoses, new cam follower (was close the being blown out) and swapping over the suspension from my old car. Still haven't started it yet as i am still waiting on some parts in the mail but I think that will be enough to get it running halfway decent.

[SouthSidePsycho]

Great project car and do it right to bring her back to glory.

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[Operator]

Get the turbo and downpipe powder coated, they'll look like new! Nice pick up, I think you'll enjoy the end result!

[texasboy21]

Very nice, I have a similar setup. [up]

[2006b7a4]

Thanks everyone, i'll be sure to post pictures and videos when it is done.

[canadianA4B7]

Pcv and evap are both sucking from atmosphere. You’ll need to connect both of those to the TIP pipe for proper operation. Building quite a lot of crank pressure at this time.

[2006b7a4]

Pcv and evap are both sucking from atmosphere. You’ll need to connect both of those to the TIP pipe for proper operation. Building quite a lot of crank pressure at this time.

funny, that's how it was done by RAI originally [>_>] I'm finding a lot of things that are half assed.

[Operator]

Did you buy it from RAI?

[canadianA4B7]

funny, that's how it was done by RAI originally [>_>] I'm finding a lot of things that are half assed.

It’s also mafless. Which could give you some headaches. Have you pulled the file with maestro? I’d like to see it. I have same turbo.

[aluthman]

funny, that's how it was done by RAI originally [>_>] I'm finding a lot of things that are half assed.

That doesn’t surprise me...

[2006b7a4]

Did you buy it from RAI?

No previous owner did I think but I found the picture here: https://www.raimotorsport.com/RAI-B7-2-0T-Red-Label-EFR-Turbo-Kit-p/rai_b7_redlabel.htm is actually my car, catch can is set up the same way in that pic as it was when i got it.


It’s also mafless. Which could give you some headaches. Have you pulled the file with maestro? I’d like to see it. I have same turbo.

Yeah i plan on setting up the intake to be able to incorporate a maf and having it re tuned. I honestly have no idea how to pull the file, I don't have the maestro software


That doesn’t surprise me...

Seems like the turbo, manifold, and lines are decent quality at least

[Operator]

Seems like the turbo, manifold, and lines are decent quality at least

I've had mine since 2013. No complaints...

[2006b7a4]

I've had mine since 2013. No complaints...

That's good to hear, I'm hoping I can get a few more years out of it.

[aluthman]

No previous owner did I think but I found the picture here: https://www.raimotorsport.com/RAI-B7-2-0T-Red-Label-EFR-Turbo-Kit-p/rai_b7_redlabel.htm is actually my car, catch can is set up the same way in that pic as it was when i got it.



Yeah i plan on setting up the intake to be able to incorporate a maf and having it re tuned. I honestly have no idea how to pull the file, I don't have the maestro software



Seems like the turbo, manifold, and lines are decent quality at least

That’s a plus. When that car was built, RAI was developing a very bad reputation for poor quality in this forum.

[2006b7a4]

I have the engine all put back together and it is running very badly, only thing i changed other than regular maintenance was the intake with ports for pcv and evap and I removed the catch can and replaced with the early rev pcv valve. I think it has something to do with the pcv system not working correctly for some reason, lots of suction on the oil cap.

not really sure what else i should be looking for on vagcom but so far i have seen:
No engine codes despite running very bad
fuel trims within spec (3.5 and 0)
misfires on all 4 cylinders at idle

This is weird because it actually ran alright before i did this, besides the excessive crankcase pressure and oil leaks.
open to any suggestions. did a once over and everything is connected as it should be so i'm kinda stuck here.

[seal66]

What are your knock sensors doing? You are using vcds or obdii?

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[viperdsa]

Is it the R revision pcv? The one with the check valve in the pcv itself.

[2006b7a4]

Is it the R revision pcv? The one with the check valve in the pcv itself.

yup


What are your knock sensors doing? You are using vcds or obdii?

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vcds, i can check that out.

[2006b7a4]

Update:
after bleeding the coolant and allowing the car to fully warm up a few times, it starts and idles pretty well now. I noticed the short term fuel trim changed to zero and the long term fuel trim changed to 6.5 which is technically within spec but is a little high. maybe it needed a few heat cycles to adjust to the new intake/pcv setup? I thought mafless speed density tunes were limited to how they could adjust. Now I just have to get the suspension on and i'll actually be able to drive it and get some meaningful logs.

[EvolutionArmory]

Update:
after bleeding the coolant and allowing the car to fully warm up a few times, it starts and idles pretty well now. I noticed the short term fuel trim changed to zero and the long term fuel trim changed to 6.5 which is technically within spec but is a little high. maybe it needed a few heat cycles to adjust to the new intake/pcv setup? I thought mafless speed density tunes were limited to how they could adjust. Now I just have to get the suspension on and i'll actually be able to drive it and get some meaningful logs.

6.5 for long term fuel trim is not high. Zero would be near impossible and 20 will most likely throw a code.

Around +10 is considered pretty normal.

[2006b7a4]

6.5 for long term fuel trim is not high. Zero would be near impossible and 20 will most likely throw a code.

Around +10 is considered pretty normal.

oh that's good to know, my old tuner said he usually brings it up when it is above 5

[Seerlah]

That’s a plus. When that car was built, RAI was developing a very bad reputation for poor quality in this forum.

Yep!

I ran (past tense) this kit on my B5 with a different turbo (standard T31 38mm EWG configuration). Sent the manifold in for another cracked weld to be fixed under warranty, and they just added globs of weld over the cracked weld. I mean, really?!?! The original welds are crap to begin with (looks like stringed bubble gum, just like your manifold). Put so much heat to it welding, they warped it some type terrible. So after paying shipping to get my manifold there, waiting to get it repaired, paying for shipping back, what I got back was just a poor excuse of ethics or lack there of. Made me quite livid, to say the least, going from sending in the manifold for a weld repair and getting back what I got that now needs more money spent on at the machine shop to correct.

After that happened, I made a thread about it in the "Buyer/Seller/Shop Feedback" section. Didn't take long before people started pouring into the thread with their stories of dealing with RAI. They were paying advertisers/sponsors for Audizine at the time, and I had no idea they had already built this rep behind them. With all the stories that people were posting, RAI never once posted in the thread to refute any claims of the people telling their stories. Next thing you know, they are no longer paying advertisers/sponsors on Audizine. True Story!

[texasboy21]

How are things progressing?

[2006b7a4]

How are things progressing?

Still haven't driven the car, engine is running well enough. at least at idle.
got the front end all done with with basically new everything. the rear end is a mess, i have the subframe and everything taken off to replace the bushings and upper arms.
should be driving in a week or two i'll post an update.

[texasboy21]

Still haven't driven the car, engine is running well enough. at least at idle.
got the front end all done with with basically new everything. the rear end is a mess, i have the subframe and everything taken off to replace the bushings and upper arms.
should be driving in a week or two i'll post an update.

How difficult of a job was the rear?

[2006b7a4]

On my old a4, not too bad. But this car was not easy, basically every bolt was seized. Rear shock bushings are both stuck to the knuckle. And the nut for the upper control arm that is originally pressed in is no longer tight and just spins so the subframe had to come down. Gonna take the opportunity to clean and paint the rusty subframe and replace the bushings.


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[2006b7a4]

https://i.imgur.com/qeLtgCpr.jpg

car runs noticeably better except for a hard cut around 6k rpm. I think it has something to do with fueling. I was going to log lpfp pressure and duty %, any other things I should check out with vcds?

[2006b7a4]

update:
https://i.imgur.com/jN7DOar.png

second gear full throttle from about 3k rpm until it cuts. from what i am seeing fuel pressure is seriously low.
Thinking about upgrading to a 340LPH pump with an RS4 controller and getting the car retuned, probably by motoza.
I'm open to suggestions if anyone knows a better set up for the lpfp, or tuning companies.

Also,
does anyone know much about the eurodyne boost manager? I can't find much information about it as it was discontinued years ago. I kinda want to just get rid of it and replace with a regular controller for the meth instead of complicating things

[Operator]

My car with a 6758 and RAI's log mani has been tuned by UM since 2013. No complaints (outside of since I'm a TIP they won't give me LC). They'd be about a 3hr drive for you, or they do remote tuning too.

[Operator]

Also unless whatever tuning company you go with is going to use EBM to its capabilities, I'd sell it, and go with something more streamlined. I've been fine with probably the most basic setup there is, a simple boost switch.

[EvolutionArmory]

Under 2 bar at 6K is stupid low. Throw in a Walbro 450 and either a RS4 or R8 controller and not have to worry about fuel again.

A lot of people had had issues pop up when running 340 LPH pumps. I think DW is the biggest pump with longevity issues. Maybe AEM works better but I’d consider going with a Walbro.

[2006b7a4]

thanks for the replies. will the 450 fit in the stock basket with some cutting? I see that the r8 controller is a lot cheaper than the rs4 controller but is there any difference between them in this application, like does one perform better than the other?

[i3oricua]

You'll need the the JHM fuel pump kit to get the 450 in. JHM also has a good video that shows you how to prep the basket.

The R8 and the RS4 controller should be similar I would think since the early R8 and RS4 used similar parts. The Q7 controller is another option which might be the same as the R8 controller but you'd have to research the part numbers to know for sure.

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[2006b7a4]

ordered the pump and install kit, excited to see what that and a new tune does for the car.

Also trying out using a stock diverter valve, I don't expect it to last long but it is much, much quieter. Which is good because all the noises it would make were kind of embarrassing [>_<]

[2006b7a4]

4 months later... the car is finally running 100%
Stock fuel pump with R8 controller holds almost 4 bar to redline so that is good enough for now.
Goes 60-100 in about 6 seconds which is pretty fast I'd say but I will have a dragy next week and get some actual stats.

[Operator]

Glad you've got it up and running smoother! Hopefully it's to the point of being an enjoyable ride.

[2006b7a4]

https://youtu.be/O8x5nNGSq94
3rd gear.
Not bad but the new diverter valve and meth injection I have might help

[texasboy21]

Seems to be reving really slowly. Are you able to post some airflow, fueling, and timing logs?

[i3oricua]

I think there's a misconception of how fast the revs look on camera vs real life. I know a lot of us watch videos where we see or hear the needle bouncing off the rev limiter. I can tell you first hand that i don't have a ton of time to look at my tach because my real life speed is climbing so fast. But on video it probably looks really slow, i guarantee you it's not.

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[2006b7a4]

Seems to be reving really slowly. Are you able to post some airflow, fueling, and timing logs?

I could log fuel and timing but not airflow as it is mafless. The fueling is still on the low side at high rpm so I'm hoping the meth will help with that a little. That will probably be the last thing I do to this motor because I plan on ditching the 2.0 for a 2.7 in the summer time.


I think there's a misconception of how fast the revs look on camera vs real life. I know a lot of us watch videos where we see or hear the needle bouncing off the rev limiter. I can tell you first hand that i don't have a ton of time to look at my tach because my real life speed is climbing so fast. But on video it probably looks really slow, i guarantee you it's not.

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I agree