Turbo Nerds "Bout damn time" build thread

[Turbo Nerd]

Ok so I think it's time to make this....

2001 Audi A4 1.8TQM

Motor:
-JE 82.5mm pistons, 9.25:1 CR
-JE piston rings
-IE Rods
-ARP head bolts
-ARP main studs
-ARP rod bolts
-ARP crank bolt
-OEM main bearings
-OEM rod bearings
-OEM thrust washers
-OEM head gasket
-OEM oil pump, pick up tube, screen
-Full timing belt kit (Gates racing belt)
-AEB head
-Supertech valve springs and retainers
-Supertech Inconel +1mm exhaust valves and stainless +1mm intake valves
-CAT 3658 Cams
-IE intake manifold
-80mm hemi throttle body
-Stern Motor Mounts
-034 snub mount with cage

Turbo setup/exhaust:
-PTE6768 .82 A/R Billet Ball Bearing
-SPA mani
-TiAL 38mm wastegate
-3" 034 SPA downpipe
-3.5" exhaust

Fueling/tune:
-ID2000 injectors
-Adjustable FPR
-Aeromotive Eliminator Pump
-Surge tank
-AMD tuned
-Hallman Pro MBC

Transmisson:
-CMFX850SS
-JHM "Trio" package
-034 Track Density tranny mounts

Interior:
-Bride Seats
-S4 Cluster
-Custom gauge pod
-AEM 52mm digital boost gauge
-AEM 52mm Uego wideband
-AEM Oil Pressure

Exterior:
-Casablanca white
-S4 front bumper
-S4 side skirts
-S4 grill (ordering RS4 grill)
-96 A4 euro style trunk
-Painted lower rear bumper
-Tints
-16x7 Mercedes CLK320 wheels
-Hoosier slicks
-Depo Ecodes

Miscellaneous:
-Euro valve cover
-New expansion tank and cap
-Rebuilt steering rack
-New front axles
-Stern power ring and bushing
-FSI coils

[Turbo Nerd]

[Turbo Nerd]

Then the overheated block I bought....









After I cleaned it up and honed it a bit so I can see how deep the pit in the cylinder wall is...






I'll get more pics up when I get my block back from the machine shop and when more parts come in....

Couldn't find the pic of the gauge pod, it's a custom dual gauge pod that uses the middle A/C vents (1st and 2nd vent are used, and 3rd is normal.... fiberglassed and the gauges face towards me). It's being made right now and I should have it soon, I'll be sure to get the pics up when I recieve it.

[Turbwhistle]

Subscribed!!

[Seerlah]

I learned in the B6 A4 section that JE's clearance spec sheet is wrong, just in case the person who built your block went by that (piston to wall clearance is wrong). There are people in the B6 A4 section who have had piston slap because of going by the JE clearance spec sheet. Just a heads up. And nice build.

http://www.audizine.com/forum/showth...ht=piston+slap

[jaychen]

Nice build,

Are you side skirts painted or do they come factory painted?

[Turbo Nerd]

I learned in the B6 A4 section that JE's clearance spec sheet is wrong, just in case the person who built your block went by that (piston to wall clearance is wrong). There are people in the B6 A4 section who have had piston slap because of going by the JE clearance spec sheet. Just a heads up. And nice build.

http://www.audizine.com/forum/showth...ht=piston+slap

I'm not too worried about piston slap, I really shouldn't have any since I have rifle drilled rods. Thanks for the head up though, I'll talk to the machinist about this. I'm leaving to go to the machine shop in a couple minutes to drop off a few things so they can balance it. I'll take some quick pics of the block while I'm there.

Nice build,

Are you side skirts painted or do they come factory painted?

They were a different color that came off an S4 so I had to paint them.

[bw86]

..

[CCA4]

Lookin good so far man, I envy that you can do your own bodywork. When you upgrade to the PTE 6262 I may want to take that elim kit off your hands

[Dan[FN]6262]

Coming this winter/early next year....
-PTE 6262
-Treadstone T3 stainless steel cast manifold

6262 will not fit on that manifold. You have to get a tubular or SPA

[Turbo Nerd]

Thanks for the good replies, as far as bodywork I don't do it myself I just sanded that ish down for a couple hours. The S4 bumper is red, the santorin blue, and the filler plate is silver lol.

Dan, that kind of sucks it won't fit on that manifold because that mani is pretty sick. My initial mani I was going to go with was the full race one which is nice. When time comes for the new turbo setup I'll have to find out what I want to do but I have nothing but time.

Little update already, I went to the machine shop to drop off my flywheel and crank pulley/harmonic balancer/whatever you may call it to have it balanced and resurfaced. I seen my block sitting there all purdy and brand new but I didn't take any pics since they had it wrapped up, it shouldn't be too long before I can pick it up.... These guys are fast and top notch. I seen all the big block's sitting there and I'm thinking to myself "wow my motor looks like a small turd compared to these big boys lol.

I'll update again when new parts come in or something happens, again thanks for the comments, recommendations, and info.

Btw I'll let you know when I want to get rid of my elim kit, it only has like 12-15k on it.

[CCA4]

Thanks for the good replies, as far as bodywork I don't do it myself I just sanded that ish down for a couple hours. The S4 bumper is red, the santorin blue, and the filler plate is silver lol.

Lol gotcha. I tried to do body work on my old Bronco and it was decent, but I no longer have anyplace to do that kinda stuff :(

Btw I'll let you know when I want to get rid of my elim kit, it only has like 12-15k on it.

Thanks man!

[melomandn]

Btw I'll let you know when I want to get rid of my elim kit, it only has like 12-15k on it.

x2 on this!

[ZimbutheMonkey]

Looking forward to seeing progress. As for the detonation that did the engine in, any idea as to why it occurred?

[MOtown A4]

Thanks for the good replies, as far as bodywork I don't do it myself I just sanded that ish down for a couple hours. The S4 bumper is red, the santorin blue, and the filler plate is silver lol.

Dan, that kind of sucks it won't fit on that manifold because that mani is pretty sick. My initial mani I was going to go with was the full race one which is nice. When time comes for the new turbo setup I'll have to find out what I want to do but I have nothing but time.

Little update already, I went to the machine shop to drop off my flywheel and crank pulley/harmonic balancer/whatever you may call it to have it balanced and resurfaced. I seen my block sitting there all purdy and brand new but I didn't take any pics since they had it wrapped up, it shouldn't be too long before I can pick it up.... These guys are fast and top notch. I seen all the big block's sitting there and I'm thinking to myself "wow my motor looks like a small turd compared to these big boys lol.

I'll update again when new parts come in or something happens, again thanks for the comments, recommendations, and info.

Btw I'll let you know when I want to get rid of my elim kit, it only has like 12-15k on it.

what machine shop are you going to? im pulling my motor and building a 2.0 pte6262 this winter, so it would be nice to have a referral from someone who has had experience with a shop, and since im local to you it would work out even better.

[quattro4me]

do'n work

[Turbo Nerd]

what machine shop are you going to? im pulling my motor and building a 2.0 pte6262 this winter, so it would be nice to have a referral from someone who has had experience with a shop, and since im local to you it would work out even better.

Automotive Machine Shop they are on the corner of Utica and Garfield in Roseville. Here's there number (586) 294-4311. Goodluck with your build, if you need any help let me know.

[Turbo Nerd]

Looking forward to seeing progress. As for the detonation that did the engine in, any idea as to why it occurred?

My thoughts were dying fuel pump. It had a S4 fuel pump in there and it whinned a bit, I could feel the power drop off at about 6k (like I hit a brick wall) which I think I was running lean. I didn't have a wideband at the time but I can assure you this won't happen again.

[Turbo Nerd]

Clutch and ARP main studs should be here this week, still waiting on the custom gauge pod, probably will go to the dealer sometime this week to get a new pilot bearing, flywheel bolts, and a few gaskets.

Edit: after looking at my funny looking bumper I think I'm going to run it like this for the winter and put a euro plate on that says "Frankenstein".

[TConklin821]

I like that. Most Euro plates are 10 digits though. It'll have to be Frnknstein or something to that effect

[Turbo Nerd]

I'd really prefer not to get the car painted during winter since I would be scared to drive it. I might just primer it my self and shoot it with paint for winter and in the spring get the whole car painted. Here's a pic from February....

Looked pretty funny but I could car less.

[Turbo Nerd]

Oh yea that vid is for you since it made me remember it from reading your sig lol.

[Turbo Nerd]

Machine shop called me a little bit ago they said the motor is ready and I'll be picking it up tomorrow morning, clutch is going to be here tomorrow also. Total cost for machine work was $605, includes bore, deck, hot tank, balance, gap rings, and resurface the flywheel..... I don't think that is too bad.

I'll be sure to take pics when I get it tomorrow.

Martin.

[Turbo Nerd]

Woke up a little late today so I didn't have a chance to pick the block up, I'll do it first thing tomorrow morning. CMFX400 came in this morning before I left for work (didn't have a chance to take pics as I was kind of late).... Hopefully it will hold for a while. Still waiting for ARP main studs to come in and since the machine work, clutch, and other things drained my paycheck I have to wait till next week to hitup the dealer to get a few odds and ends.

Plans this weekend remove my axles and steering rack, then go to town on cleaning my filthy engine bay. I'll get the pics up of the clutch tonight when I get home and pics tomorrow of the block.

That's about it for now.

[jaychen]

What was wrong with your last bumper?

Build is coming along quickly!

How much power are you hoping to put down with the new setup?

[Turbo Nerd]

What was wrong with your last bumper?

Build is coming along quickly!

How much power are you hoping to put down with the new setup?

Nothing just the usual rocks chips and bullshit, I sanded it down before I blew my motor and was going to paint it but I didn't see a point at that time to do it since I wouldn't be driving it. As for power I want at least 340-350 wheel on pump gas and meth on this setup, my next setup I want 500+ whp on pump gas.

Here's the clutch that came in.....







Question, can I re-use my pressure plate bolts from my old one or do I need to buy new ones?

[ThatA4T]

Replace them

[Seerlah]

How much more would it have cost to have the shop assemble your block? Or you just find comfort in knowing that you yourself assembled it?

[Turbo Nerd]

How much more would it have cost to have the shop assemble your block? Or you just find comfort in knowing that you yourself assembled it?

I will only pay for service if there is something I cannot do or don't want to do. I'm not sure how much thy would of charged to assemble the bottom end but it isn't brain science and this isn't the first motor I built. The machine shop asked if I wanted them to hang the pistons and I said no ($75), the only thing they did that I didn't feel like doing was gapping the rings.

I feel like a bigger man knowing that I built it myself and not some shop. Also for piece of mind "I know" I torqued everything, I know I greased this, I know I installed that right ect. I'm certainly not saying I'm a pro engine builder or anything but I'm not a noob at it and I think this motor should be very healthy, I don't care for max power I'd rather have a engine that is strong and healthy.

/rant lol

[Seerlah]

Why so mad? haha

[Turbo Nerd]

Lol not mad just excited to drive this thing again.

[Turbwhistle]

Common, where are the pictures of this block?

[Turbo Nerd]

Lol Monday for sure I will pick it up. This weekend I was pretty busy we had a family party Saturday and Sunday (today), so Friday before work I had to set up tables, chairs, and what not. If I didn't have anything planned for this weekend I would of started assembly of the motor, but then again the ARP main studs are going to be here Thursday.

[Turbo Nerd]

So I picked up the block and couldn't take any pictures since I'm at work right now, I will snap some when I get home later on. Machine shop said they couldn't resurface the wheel since it's a dual mass and that I could run it like that, got me a little skeptical. They said they mic'd it and checked for out of round, came out fine they said. So should I just go over with it with 100 grit sandpaper? Also they didn't label or mark my rods, I'm not trying to put the rods in backwards and have problems.... I have the IE rep rods rifle drilled, anyone know what I should do? The pistons aren't marked either but I can figure that out.

[Seerlah]

I thought only thing that mattered was having the tangs on the connecting rod facing the intake manifold? Since the block and parts are fresh, I am not sure the orientation of the other parts (pistons and wristpins) matter. If I'm wrong, someone please correct me (still learning).

Also, why the 228mm over the 240mm clutch? Simply because of cost?

[Turbo Nerd]

Thanks I will let other chime in too but thats what I figured.

Yes because of cost at the moment. My main priority is to get the cat back on the road asap, so it was either 540 shipped of 1075 shipped, and if this one starts to slip than I will have enough money later on to upgrade to a 240mm. I could of bought it right now but than other parts would of been delayed and like I said I need this thing back to life.

Thanks for the info though.

[Turbo Nerd]

As promised.

ARP Head Bolts


Polished Crank, Rods, and Pistons


Close up










From this.....


To this.....



I got the dilemma figured out about my question, I was thinking too hard for some reason.... better to think than to not think at all.

[Seerlah]

I got the dilemma figured out about my question, I was thinking too hard for some reason.... better to think than to not think at all.

So, only tang orientation matter in your case?

[Turbo Nerd]

So, only tang orientation matter in your case?

Pretty much, I was just confused for a little bit how they actually balance a motor..... The rods are all the same weight as is the pistons so they don't take anything off (as far as the rods) to balance the assembly. So pistons or rods can go in any cylinder they want (tang orientation like you mention) and there is really no way to put in the pistons wrong (I mean there is but I won't lol), since I have the beveling for the valves on my pistons I can't really mess up.

[Turbo Nerd]

This weekend is plasti-gauging, engine bay clean up, remove axles, remove steering rack, remove center diff (ship to JHM), swap cams, change lifters, change one valve (I don't like the way it's looking me in the eye, I can tell she wants to go) and probably start putting the motor together but depends on how late it is. Have to hit the stealership (or All European or S&G Imports) sometime this week to pick up flywheel bolts, pressure plate bolts, pilot bearing, exhaust gaskets (turbo to dp, turbo to mani, mani to head), oil and coolant line gaskets, and some other little things.