Full STG III BW K04 Build

**A62TURBO** · 04-13-2012 04:51 PM

Started doing the timing service today. Swapped out the water pump and thermostat. Next I have to pull the cams and do the rest of the seals. Here are some update pics.

**A62TURBO** · 05-04-2012 05:41 PM

Progress, progress, progress, finally looking like a finished engine again. I finished all the seals up top and painted the valve covers flat red. Turbos and lines are completely installed, here are some update (iPhone) pics.

**8520** · 05-06-2012 04:33 PM

When's it going in?

**A62TURBO** · 05-06-2012 08:05 PM

I got a lot done today like all timing components back in, inlets in, injectors, fuel rail and all connectors as well. I can actually say next weekend is a possibility. I'll take some better progress pics tomorrow.

**A62TURBO** · 05-07-2012 05:10 PM

Some updated pics I took today:

**Vinchenzo51** · 05-07-2012 05:35 PM

Looks like she's ready to go back together, no?

**A62TURBO** · 05-07-2012 05:42 PM

Hopefully this weekend vin, got a few more odds and ends to take care of.

**A62TURBO** · 05-08-2012 06:24 AM

What do you guys think about the alternator, should I change it since the engine is already out? My car has about 80k on it.

**02 A6 2.7T** · 05-08-2012 06:46 AM

Originally Posted by A62TURBO

What do you guys think about the alternator, should I change it since the engine is already out? My car has about 80k on it.

In one word, YES. Based on the ridiculous location, now is the time to replace it. Ask a person who has had one fail (jmgraham78)...
A quality aftermarket rebuilt with a warranty should run about $180 to $200, and is well worth it...

**Vinchenzo51** · 05-08-2012 08:54 PM

Originally Posted by 02 A6 2.7T

In one word, YES. Based on the ridiculous location, now is the time to replace it. Ask a person who has had one fail (jmgraham78)...
A quality aftermarket rebuilt with a warranty should run about $180 to $200, and is well worth it...

yeah I kind of agree. Its in such a bitch of a position, and its relatively cheap comparatively speaking.

**A62TURBO** · 05-09-2012 03:58 AM

Sounds good, anyone have a good source for a good quality alternator for a good price? ECS wants almost $500.

**02 A6 2.7T** · 05-09-2012 05:13 AM

Originally Posted by A62TURBO

Sounds good, anyone have a good source for a good quality alternator for a good price? ECS wants almost $500.

This is the one J picked up to replace his failed unit. Despite the picture & description, it came with a new pulley already installed, & has a limited lifetime warranty...
http://www.oreillyauto.com/site/c/de...1468&ppt=C0330

**A62TURBO** · 05-10-2012 05:28 PM

Wrapped the Dp's with some DEI titanium wrap, and got the er's ready.

**8520** · 05-10-2012 08:08 PM

Tits

**A62TURBO** · 05-11-2012 06:54 PM

Can't wait to finish already.

**8520** · 05-13-2012 09:34 AM

Hey look, it's this weekend :)

**Vinchenzo51** · 05-21-2012 03:10 PM

Originally Posted by 8520

Hey look, it's this weekend :)

Hey looks, its after the weekend after the last weekend ;)

**A62TURBO** · 05-22-2012 04:27 PM

I don't know about you guys but my weekends have been full of weddings, baptisms, and graduation parties. I can tell you though that this Sunday will be the day, I told my family, my wife, my employees not to bother me. I will also have the final few parts needed to finish like alternator, new spider hose, axle, even a new shifter linkage joint on the trans. Here is how she sits right now.

**A62TURBO** · 05-24-2012 06:36 PM

Installed the new alternator and accessory tensioner but decided to return the tensioner because it looked like it was dropped and had a flat spot on the pulley. Here the clutch and flywheel ready to go.

**A62TURBO** · 05-28-2012 05:57 AM

Engina and trans are back in the car, it was hell but thanks to the extra help from my dad we got it in. I'll post some pics later today.

On a side note, the Spec stg3+ clutch feels much smoother than the RS4 unit.

**8520** · 05-28-2012 10:00 AM

If you ever launch the car, you'll be thankful you switched from the rs4 clutch. Trust me.

**A62TURBO** · 05-29-2012 03:05 PM

Finally downloaded the pics into my iPad today. Here are a few shots.

How she sits at the moment:

**Vinchenzo51** · 05-29-2012 07:13 PM

Need help breaking in that clutch, i'll be glad to swing down and drive it for a couple hours for ya

**Mantis** · 05-29-2012 08:38 PM

Looks good Greg, now just the fun part left

**A62TURBO** · 06-01-2012 06:53 PM

Yes Ryan, fun stuff is left. ECU in, intercoolers in, all plumbing connected, all I have left is pretty much radiator support and coolant.

**V8EATER** · 06-04-2012 08:12 AM

Update please!

**Vinchenzo51** · 06-04-2012 10:14 AM

Last I heard he is getting a base EPL file and will be starting the car soon!

**A62TURBO** · 06-04-2012 10:53 AM

Vin is correct, I just got off the phone with Rich about that flywheel bolt issue as well. I'm gonna give it a shot with the current OEM bolts, hopefully nothing will rub. I'm also going to the dealer today to pick up a connector and wire I broke while hoisting the engine. Hopefully the car will be ready to start by Friday (fingers crossed).

**A62TURBO** · 06-04-2012 06:28 PM

Getting closer, rs4 goodies are installed but I'll wait to install the air box last. Now it's staring to look like a complete car again.

Pretty much all I have left to install.

**8520** · 06-04-2012 09:34 PM

Looking good!

I sure hope those flywheel bolts don't become an issue.

**slick50** · 06-05-2012 09:09 AM

Just installed the same clutch setup in my car with oem flywheel bolts and didn't notice any issues, have others reported problems? Just finished my build which was almost identical, biggest pain had to be the intercoolers. Lots of trimming and fitting.

**A62TURBO** · 06-05-2012 10:05 AM

Originally Posted by slick50

Just installed the same clutch setup in my car with oem flywheel bolts and didn't notice any issues, have others reported problems? Just finished my build which was almost identical, biggest pain had to be the intercoolers. Lots of trimming and fitting.

Thanks for the reassurance, there was one other guy that had an issue with using OEM bolts but I think he just didn't know what he was doing. What did you have to trim for the intercoolers? For me the intercooler install was easy but I already see what a bitch the shrouds are going to be.

**slick50** · 06-05-2012 10:19 AM

on my allroad the shrouds hit the fog lights and different areas on the bumper, i don't have a lot of patience for the trimming process so I opted to remove the fog lights to minimize the the amount of cutting but still had to trim a fair amount.

**Vinchenzo51** · 06-05-2012 11:04 AM

By this point, I'd remove the fogs as well and cut out the supports. More airflow the better

**A62TURBO** · 06-05-2012 07:16 PM

I tried getting the lock carrier on today but it needed trimming to fit around the er's.

Trimmed passenger side

Cleaned up a little bit

Obviously the ER mounts don't line up with the a6

**slick50** · 06-06-2012 05:38 AM

Getting there! Like I said, lots of trimming. Not sure what you are using for tools, but I recommend either a dremmel or a cutoff tool for the shrouds. I started with snips, but the carbon is brittle and the cutoff tool made cleaner cuts. Wear a mask and goggles to keep the crap out of your eyes and if possible have good ventilation.

**A62TURBO** · 06-06-2012 06:55 AM

What the hell is the lock carrier made of? As I was cutting it with the grinder it reminded my of fiber glass a bit.

**slick50** · 06-06-2012 07:01 AM

I was thinking fiberglass

**A62TURBO** · 06-06-2012 06:55 PM

A little bit more trimming for the intercoolers and the lock carrier is back on. Gonna fill it with coolant tomorrow and possibly prime and start on Friday. I just need to find a way to get a good Internet signal in my garage to download the base file from EPL. I forgot the DSLR in the house so here's an iPhone pic of how she currently sits.

**A62TURBO** · 06-08-2012 07:52 PM

I took my ECU to EPL today, had tony solder my base file on. Great guys, awesome shop! I'm gonna try to fire her up tomorrow, wish me luck!

Thread: Full STG III BW K04 Build

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