Allroad REFRESHER BUILD

[canadianA4B7]

I own a 2001 allroad that reached 305000kms on the stock turbos! Well mintained. Still rocking oem air ride and works with no issues. Looks like this this past summer. 19" rotiform NUE's spaced 25 rear 15 front. 402'd 18 front 22 rear i think. I did full exhaust 2.5" w magnaflow mufflers, ecs brakes front and rear drilled n slotted. And it was pretty much stock completely stock. Now at the kms the turbos were making some racket. Started having electrical issues. Replaced batt and alternator. Only to find out i was sold the wrong alternator which left me stranded about 100kms from home. After a tow and some thinking and web searching on the long tow home i decided just for now to just "freshen" up the car. So i bought a 2001 S4 engine complete timing belt done less then 40,000 kms ago. (missing 1 heat shield drivers side so anyone reading that can spare one pm me) i got smic, all piping. With this engine out i did a lil upgrades, new spider hoses, new after run switch upgraded one, replaced the front coolant lines all them hard and rubber lines some bought, some custom made from parts off of other bnib audi lines i purchased. I bought a drakes stage 2 clutch, and rs4 pressure plate (b5) as well an 034 aluminum lwfw. Stern motor mounts also as i had a new snub mount installed at about 302000kms For coils i recently grabbed a set of toureg adaptors, and i had 4 coils from my b7 A4 so i bought 2more new, and the other parts needed to change the car over to the fsi coils and icm delete. Im also replacing the passengers side turbo since its got a bit of movement. Minimal but i have the chance to just replace so figured do it now and save some in the long run. Aswell changed the oil drain lines out for complete stainless braided. As the ones on the engine i bought are slightly bent ( someone put it down on a tire and didnt use there brain when doing so.

So i dont have many pics of the progress but ill snap a few pics tomorrow. Some may say ive wasted my time not doing a complete full blown engine build. But that wasnt the goal w this minor project. Ill do a mild tune and just drive it! Its no track or show car (yet worthy in it condition to show) but it is just my grocery getter!

Thanx for looking ill take critism or suggestions for future progress with a smile. Im happy to be an allroad owner and enjoy its capabilities as they are!

[canadianA4B7]

Anyone have thoughts on a 3.0 crankshaft for $400 canadinan? Ive got a lead in 1 from a parts car locally. Just wondering if price is decent?

[canadianA4B7]

And today got some updates on the car as I bought a new chra and 2 k03s so I rebuilt the passengers side turbo as it seemed to have a c-hairs worth of movement to it. Likely would have been fine for some time but I figured the price was right and the timing is good so I swapped out that turbo for one with a brand new chra. 034 supplied me with an awesome gasket kit some time ago which will help with the turbo being swapped and all new gaskets will be used on the replacement motor. Also bought some new an fittings, and all the stuff required to change my Oem oil return lines to upgraded stainless stuff just for safety's sake. So the time line looks like Friday it should be all back together and after they check and double check the install they say either Friday or Monday next week I can pick it up.

[8520]

How was rebuilding ko3's? I might go this route.

[canadianA4B7]

Easy as hell! I wish i would just bought another k03 chra and done both. Removing the cold side was being a pain in the ass. So i used a socket that fit into the inlet. Set it up so that i could just tap the crap chra outta the housing. Then just put the bnib chra into the old housings. Seriously simple as ever. About 12 bolts i think. I soaked the bolts in wd40, then later realized if you just tap the metal triangles that hold the hot side to the chra they will easily turn allowing you to remove the hot side a bit easier. Took bout an hour and a bit. I would search ebay or i recieved a link from the seller who gave me the resource which he bought the chra from.

this is the link he used to buy what he sent me: http://www.xsboostturbochargers.com/...3s-078145704s/

but I found this guy and a few others:
http://www.invasionautoproducts.com/bowak0chca5310.html

http://www.pureturbos.com/store/borg...037100511.html

I think anything that's less then say under $250 is likely a Chinese CHRA. but most of the stuff that ive posted is actually a BW

[canadianA4B7]

Car should be done by this friday. I havent been to the shop in over a week. Its been nearly 7 weeks without the ar and im patiently waiting to turn it over and drive it home.

With it done ill likely have some spare parts going up for sale.

[canadianA4B7]

Would 2.8 heads be worth it? Ive found a set of 2.8 heads off of 2002 A4 thats i can pick up for cheap. So ive cleaned up the replacement motor and done a few things so it wont crap out on me sooner then it should. Clearly above dobe the 1 turbo as the other was actually in great shape and was 100% oil free.

So would it be worth it to drop a set of 2.8 heads onto the stock 2.7T motor? Ill likely pick them up just cause they are in good shape and a good price. But will it be worth it to install on the motor im running? Or just save them for the 2.7T spre motor ill have and plan to stroke and rebuild? Give me yer thoughts please.

[8520]

From what I remember, 2.8 heads sacrifice low end power and give you more top end flow, which unless you're running rs6 turbos or bigger, is worthless. Less bottom end, and more flow to a ko3/ko4 that is already maxxed out......

Do some research though, I'm not 100% on this.

[canadianA4B7]

Yes i believe you are correct, my thought would be more flow is better in all rpm ranges. But seems like it doesnt do alot down low. Im going to read/search more today. I just got the info late yesterday evening and im interested in finding out wether worth it or not, and if anyone has done it.
Side note: if not in the allroad, perhaps the spare motor ive got i can rebuild, 3.0 crank, 2.8 heads, and rebuilt bottom end. Then get some rs6-r turbos or something else.

[canadianA4B7]

Good news is that it's done! Running with replacement S4 engine! Will be picked up today and I'll do some logs to see how it's performing! And hope to get a tune on it to increase performance. Very happy to get back into the allroad! Been a long time!

[canadianA4B7]

So little review for anyone reading! The 034/jhm aluminum lwfw is insanely light! The car revs up and down like a turbo k04 turbo spool, it revs so fast now its crazy! I love it but will take time to get used to. The new motor is so much more powerfull then the old 305,000km 2.7t that was removed. Since it sat for some time i think the suspension is getting lazy, and being the rear bags were replaced not too long ago id like to keep the air ride. Maybe new shocks would solve the problem. But back to the engine! Cooler after run pump sensor installed the temp is lower then b4, refresh motor runs awesome, sounds amazing, 2.0t coil conversion has stopped the old random missfires.

So anyone suggest shocks for the ageing air ride would be appreciated, i believe arnott is likely the best source. Or can i fit nearly any shock into the air bags?

[urAllroad]

With that lightweight flywheel, how is the clutch pedal feel? Heavier? Softer? I'm interested in this if/when my flywheel goes out since it's an OE dual mass.

Sweet thread :)

[canadianA4B7]

It feels like it has more weight to it, but its smooth. Its close to the oem feel but a bit more force to get it to go down. Now ive also upgraded the pressure plate to a RS4 style one and a stage 2 clutch (drakes performance). As to the weight, its nothing un comfortable. Ive heard some ppl who cant hold the pedal down at a longer then normal stop light. But its not the case with this setup. aswell I installed a set of stern motor mounts they feel just as if they were stock. No vibrations, nothing out of the ordinary.

and what an idiot I am. just found a set of K04 28/29 turbos today..... so in 2014 the motor will be pulled again.... and ill have to do a lil bit of upgrading to install the RS6 K04's!

[da9b16]

NICE build sir!!!! Looking forward to seeing more. Have you thought about 2.8 cam swap?

[canadianA4B7]

NICE build sir!!!! Looking forward to seeing more. Have you thought about 2.8 cam swap?

Im working on finding a set of 2.8 heads! And ive got a line on a 3.0 crank aswell just need to go and pick it up...... Im sure most can understand where this build is headed! This is not going to be rushed at all. Ive got nothing but time on my hands. The ar is 100% awesome right now with the current S4 motor and the few goodies i put on it. The spare motor will likely go through some shops to get cleaned, ported, and bored out a bit. It will be a great project for me as i do plan on hopefully assembling this motor myself.... With help.

Any way there will be more to come from me and the allroad.

Few things i forgot about, temperature is just amazing now the old motor used to sit near 250, now this one is usually around 200 or lower for that matter. I went on a good highway drive yesterday and temp never got anywhere above say 210. Anyone else ever use the lower temp after run pump sensor and noticed the same results?

[canadianA4B7]

Anyone suggest new plugs and gap to run on new 2.0 coil conversion? I seem to be getting shit mileage and assume the plugs were not gapped when shop did the conversion. Figure changing them out at this point wouldnt be bad idea anyway.

[V1nny]

I run newest release black ignition coils from 2.0t TFSI and have plugs gapped to .9mm. Ajusted the gaps down from 1mm, was getting occasional misfires under heavy acceleration once in a while. Plugs are NGK BKR7EIX.

[canadianA4B7]

Ok car runs smooth. But when i get to approx 4000rpms it seems to bog a bit. Anysuggestions of what i should log w VCDS? Im guessing wastegate duty, boost requested and actual, fueling?, knock?, EGT, im just not sure what it might be. Passenger has said they feel it slightly jogging repeatedly like its possibly not getting fuel. Or maybe ive got a wastegate out of wack? Any one have some ideas or suggestions. Ive got new plugs waiting for snow to stop to install them out in the bitter cold.

[canadianA4B7]

It seems my S4 motor has a bad injector or 2. Would i be able to install a set of RS4 injectors and run the car with no upgraded tune? Or would a slight tune be required to run the larger injectors?

[V1nny]

It seems my S4 motor has a bad injector or 2. Would i be able to install a set of RS4 injectors and run the car with no upgraded tune? Or would a slight tune be required to run the larger injectors?

find a local shop that can clean and balance your old injectors, maybe replace rubber rings. If you absolutely have to go to larger injectors, you would need to use either adjustable or lower pressure fuel pressure regulator.

[canadianA4B7]

Gotcha for the time being ill pull off the original motors injectors. Im having a nightmare with VCDS it seems to not want to log on the allroad... Logs for like 1 min then just asks to save the file. So im losing my shit trying to see if its actually fueling or not. Could it be a bad DV? Like the bogging im experiencing. If im at full throttle it will say stutter or bog at 4200rpm, then it will clear abd continue increasing rpms then bog again shortly after. Say at 5000rpm.

[canadianA4B7]

So i recently picked up 4 piaa 6" lights for the allroad. 1 is shot! I can repair it but it may just not be worth it. Now being that they were bought from ebay as usual they were missing parts. Contacted piaa over the phone asking to purchase the parts i require. They tell me "give me yer name and address and how many are you missing?" So i told them all 4. Being that they are a kick ass company free of charge im getting new mounts sent to my door! What a happy day!

[MCargill12]

So i recently picked up 4 piaa 6" lights for the allroad. 1 is shot! I can repair it but it may just not be worth it. Now being that they were bought from ebay as usual they were missing parts. Contacted piaa over the phone asking to purchase the parts i require. They tell me "give me yer name and address and how many are you missing?" So i told them all 4. Being that they are a kick ass company free of charge im getting new mounts sent to my door! What a happy day!

Are you going to mount them on the grill?

[canadianA4B7]

Nope for now a piece of 2" L bar i picked up. Just mounted it to the front bumper where the plate mount was. Tapped a couple holes into the aluminum. My plate mount is kinda beat up. So for now the L bar. But i am working on a bull/brush/light bar. Similar to the MTM one made in stainless all mandrel bends. Only thing i need to figure out is mounting it. I will somehow mount it to the bumper screws through the lower side grills. All in the works. And im thinking 4 lights would be better then 3 and somewhat resemble the 4 rings on the grill. Anyway im open to suggestions.

[canadianA4B7]

So ive had some recent electrical issues as posted above. Was fishing around today and found the ground post under my coolant tank had no nut on it! Lookin a bit more the wires were snug as the last stake on connector had looked to be drilled to fit tight! But the nut was sitting between the heat shield and firewall. Someone must fucked up and figured "this will do!" But it seems the issues may be figured out! Also installed some PIAA lights. Pics shortly need to upload them.

[canadianA4B7]

installed these, and found a ground lug that didn't even have a nut on it!! electrical problems hopefully solved!! the one under the coolant tank had no nut on it, but it was sitting stuck between a heat shield and the firewall. anyway the PIAA lights are on now will likely upgrade to 100W HID in the future but wanted to get them on and see how they looked for now. need a bull bar that's for sure. anyone who knows anyone who purchased the MTM bar please forward me their info. im just looking for measurements and I build one myself. but for now 2 ill add the 3rd one when I get me PIAA mounting brackets, I made some up myself last nite cuz I couldn't wait any longer!!

just the PIAA lights


highs and PIAA


lows and PIAA


the yellow im not a fan of but I guess that's how PIAA bulbs are, maybe the housing has a hue of yellow to the lens as well. ill go out on the road in a bit to see how they are!! but I think 1 more is necessary id like to get a pencil beam style for it but have not been able to find anything in a 100W.

[G0to60]

Nice on the lights! Can you post up some more specifics and how you mounted them? I assume you went with a relay setup but are they independent or on the stock switch?

[canadianA4B7]

I hooked them up via the wiring provided by PIAA so yes to a relay, and they are completely independent. not hooked up to anything else in the car just the battery. so I can select when I want them on. I thought about hooking them up to the low beams or so that they go out with the lows on and on only when high beams are on. but I figured if I aim them a bit low I can call them fog lights and not have to worry about blinding ppl. so they are pointed a little low.

mounting wow super cheap LOL. I used a piece of 2x2" L bracket, drilled through the cover and into the aluminium tapped the holes for 1/4 20 stainless bolts. so ya I just tightened the L to the bumper the plate sits below it and is mounted via the holes I drilled aswell, I stood on the thing and it held me up at 190lbs. so I think its ok. im trying to get specs on that damn MTM bull bar!!! my thought is to just buy some mandrel bent pipe2.5" or 3 and make it similar to the MTM one. its not that hard being that I have some idea of how to weld. the only part I cannot sort out is how to mount it. thought was to bolt it to the bumper bolts, but want it to look right. then where it bends across the front of the bumper I would have 2 mounts that would actually bolt to the bumper itself. will see what happens the neighbour and I are working on idea.

[G0to60]

I've seen pictures of two different approaches to mounting. There is one that mounts similar to the MTM one that ties in behind the fog light grills. There is also this mustache one that is in place of the front plate bracket.

[canadianA4B7]

the top one is similar to what I have done just I used a straight piece of steel no wavy mustache look to it. I had to flip the lights down to the bottom of the bracket I made.

now the MTM bull bar is what im going to have to make. then ill mount the lights on the bottom side of the bull bar. cover over my plate with lights!! what I really want to know is the white squares ive made on the image you posted. im a hack so it looks like shit. but the lights will be the yellow the squares I would pay money just to know how they mounted the thing through the lower grill. anyway laugh Christ I always do at the hack work I come up with!!