Tahoe's Stage 3 Build official thread w/ Pics

[LakeTahoeQuattr]

This thread is pretty extensive now and over a few years old. Lately with the photobucket issue none of these old build thread pics work. Ill try and post up a few here and there with a different svc at the end of the thread



Newest on the list is:

*Turbo Concepts TC2-T Snails
*Vehicle Wrap
*35% Ceramic Tint
*19" D3 sport wheels w/ conti DW 275/35/19
*New front wheel bearings AGAIN
*034 Adjustable uppers
*New Arnott front struts

Down the Road:
*Alcantara headliner









Some more pics from the highlights of the build
TC2-T Turbos



The reason why I needed to upgrade from the K04s to the Turbo Concepts


Coil Conversion - no performance differences that I can see


Custom 85m MAF setup


Setrab Oil Cooler Custom Setup w/ RS4 sandwich plate - This works GREAT!



Fun time removing rear diff bushings



TTV all the way!



SRM V3s / 2.5"



Diesel Box from Scotty - smooth as silk


Hitch


Non heated or MFSW --> Heated & MFSW retrofit




RNSE + MMI + OEM Bluetooth Retrofit





Missing lots of stuff but thats the jist of it.. New updates are at end of thread.



Here is the old thread with broken photobucket links...

[LakeTahoeQuattr]

So my next step was to install the tranny. The issue here was that the tranny bolts that came off the old engine did not match the ones in the bentley manual. Only the 10x60 were listed. Does any one have any input here?


Next, when installing the serp fan pulley behing the lower crank cover, I am not able to get the pulley to spin freely anymore. When I tuck the fan pulley behind the cover, it pushes the cover out at an angle so that it rubs. Without the fan pulley on it spins freely. Any one ever encountered this issue? You can see from the pic that the cover is bent for some reason.



Last, the new RS4 inlet pipe on the driver side mounted does not appear to be aligned properly. When I bolt it to the mount it does not sit close enough to the head to allow the other pipe to correctly sit with it, as well the line will not reach the fuel rail. The passenger side sits about 5 mm away from the block and fits fine. Any ideas would be great.

[8520]

Looks good.

330ohm resistor won't take care of your cel.

[Vinchenzo51]

Nice! Love when people go with K04's, nice to see.

Remove the heat wrap on the inlets. That type of wrap keeps heat trapped inside, and retains heat itself to keep the piping warm. The reflect-a-gold is what you'd want on the inlets, that repel heat from the manifolds.

[4ringAR]

do work! awesome!

[khalimadeath]

Nice work man

[MCargill12]

stage 3 tip!?

[Korben007]

stage 3 tip!?

Stage 3- for now.

[LakeTahoeQuattr]

After a busy weekend I was able to finally install the engine. Got the drive line (2 hours) and axles bolted on. Alternator wired up. Wiring harness is slowly getting plugged in. Siemens 80lb Deka injectors installed w/ spacers. Still need intercoolers.

Engine ready w/ home brew piggies:


Before this point I seriously opened the bleed valve on the cherry picker too quickly and dropped the engine 6 inches onto the tranny mounts hitting the sub-frame. Quite scary, horrible experience. Nothing was damaged thankfully



Next door neighbor Jason (long travel toy taco http://www.tacomaworld.com/forum/1st...-toy-taco.html) wielded on my $5 home brew downpipes/testpipes:


More to come soon...

[MCargill12]

Coming along nicely

[freetobelee]

Do you need and OEM battery or do you have one?

Mine came with an extra (I believe the original) OEM battery that was replaced, but the issue turned out being the alternator, so the owner held on to it. If you're interested, I can bring it down tomorrow.

[LakeTahoeQuattr]

Yes please I do, please bring it. Thank you

[LakeTahoeQuattr]

So a lot has happened since my last couple of posts, but in short, I got the engine running, and drove it around the block. The VAG test drive resulted in no codes but the Cat 02s which was expected. This was a nice test of the transmission, and it ran fine thankfully! I will also however still do a ATF filter and fluid flush before I finish. I did encounter a problem with the driver side turbo, it is leaking somewhere from one of the oil lines, enough to cause a significant amount of smoke when the engine is warmed up and running. Frustrating to say the least because the visibility around the turbo is null, as well I spend a lot of adequate time and finesse installing new gaskets/washers on both turbos so I am very surprised to have a leak. I removed the heat shield and moved it to the side, and noticed that the oil is not coming from one of the lines on the top, but I think it is the one coming from the front of the turbo. I will have to remove the ac compressor to hopefully diagnose this issue and resolve it with the engine in the car. On a separate note, here are some other advancements and pics.

A funny picture of my makeshift exhaust lines running outside the garage so I could start my car and keep the garage warm. With the fireplace going it is 70 degrees in there, 30 outside.


Heater Core flush with hot water from the house:


Last week I was able to pick up an evolution skid plate for $30. Huge find being that these are $300 new. It is for an a6, but I can retrofit:


Also found a 98 a6 with perfect climate buttons, another huge find. When taking the climate control unit out, it is nice to blow out all the dust that had accumulated inside it and on the thermometer:



Bagpipeandys AC compressor rebuild kit, worked perfectly. Car raised between all levels quickly. I am thankful this thanksgiving that I also don't need to replace any air shocks yet!


I hope to get this oil leak fixed soon so I can progress with the painting.

[LowA4]

Nice to see another Allroad in the area on here. I'm in Gardnerville and down to help from time to time.

[Korben007]

Steve this is my neighbor. Been going over doing alot of vag-ing

[LakeTahoeQuattr]

LowA4, your name is Steve? I saw your s4 the other day I am sure up at the lake. I am always down for people to come check out my build. Thanks

[LowA4]

Swesome, sounds like it's running well... Nothing like the feeling of new turbos and more power :)

[LowA4]

Sold it to a kid in Incline in may. Not sure if he still owns it or not. I kinda miss it

[LakeTahoeQuattr]

It was a silver lowered s4 with NV plates. Who knows. So in your ar, how do you like your 517 tc? Did you do the jhm or giac tcu chip?

[LakeTahoeQuattr]

Finished the trim:

[khalimadeath]

vinyl? ^

[ENDEE666]

Pretty sure it's the 3M Tamo Wood or similar. Been growing on me since I first saw the thread on it. There's a whole thread dedicated to it somewhere, recent.

[LakeTahoeQuattr]

Yes vinyl Tark Tamo Ni-Doc. Takes fooorever. Here is where I got the inspiration: http://www.audizine.com/forum/showth...-allroad/page2

[LowA4]

I need to have the tcu tweaked for the higher stall. If you arent super easy on the gas it takes off hard so i want to see if I can smooth that out. I'll probably have jhm do it but it will go 6mt once this trans decides it's had enough but no signs of this car dying anytime soon.
Did the s4 have a front mount? After I got mine, seemed a few people up there got silver S4's

[LakeTahoeQuattr]

If you ever want to sell your 517 Ill put it in our 2.8 family car. I have a feeling that the tc could be on its way one day. The s4 didnt have a fmic from what I saw.

[edheymann]

Bagpipeandys AC compressor rebuild kit do you have anymore detail on the rebuild kit? Got an '03 AR sitting on bumps...

[LakeTahoeQuattr]

In regards to detail I would say it is an easy change, however time consuming. The hardest part is getting the pump out and then installed back in again on the float springs. I followed a diy somewhere. I also cleaned the air compressor inside in and out and all the inlet lines and inlet line filter. Also cleaned the compressor housing. The compressor made loud grinding noises before the new compressor washer and after replacement the sound was gone. The car also raised much more quickly. Before the rebuild the front bags sat on the bump stops and afterwards they appeared to be holding air correctly. This was odd to me because the compressor has nothing to do with this, however my problem is fixed. For now I am not going to mess with the air suspension system any more unless something happens again. I was pleased with this rebuild kit in general. I don't have any more pictures because the new compressor washer only took 10 minutes to replace when the compressor was out of the car.

[LakeTahoeQuattr]

Just another few examples of the condition of this vehicle, just stunning:


Of course these were the before pics, it is all nice and clean now and I found about 2 bucks in change! I also went to the extent to blow my air compressor thru the hvac vents. Took the blower motor off and cleaned it:


The blower was working before I did this. Plugged it back in, blew air for 5 sec and shut off. Now wont turn back on. This has turned from a "stage 3 build" to a full rebuild...

[G0to60]

Nice work! I too have used the rebuild kit from bagpipingandy with great results. One thing to watch out for, although I think he switched vendors, is that the bolts that hold the cylinder head can shear at the split. I had one go but it was easily fixed.

[LakeTahoeQuattr]

I am so so excited I was able to fix my oil leak after three weekends of diagnosing. The rear cam seal was leaking down my head and onto the exhaust manifold. I replaced the rear cam position sensor cam seal with the traditional spring loaded cam seal and not the plastic kind.


The one on the right is new and AGAIN bent upon instillation. This happened to me 3 times so I tried the kind on the left, spring loaded and it installed and seals great. I read somewhere that this seal may not last as long or something but it works for now so I am happy.

So now the fabric wrap on the exhaust manifold is ripped from removing the heat shield a million times and coated in oil and will not quit smoking. I removed the wrap and smoke is gone.

I also replaced one of my clamps on the power steering pump feed line and the air leak is gone. The PS pump was sucking in air and would not settle and was very noisy, this fixed the problem. Again very happy about this.

Next issue. Now that there are no oil leaks, my engine was not satisfied and decided it needed to leak somewhere else. I noticed my pink gold running down my tranny oil cooler lines dripping off the alternator. People say that this is the thermostat/water pump/plastic coolant bottle leak. Not sure because I cleaned and carefully installed these parts when I rebuilt the timing belt.


1) Remove the timing belt to find the leak?
2) Leave the leak, monitor it, hope it goes away?
3) Add coolant stop leak as discussed here.

[LowA4]

Most likely te plastic thermostat housing leaking. I just did ours the other day when it decided to break. I swapped thermostats and housings without removing bumper or timing belt so it's not too bad.

[LowA4]

Ours had a small leak that I monitored but ended up pretty much exploding.

[LakeTahoeQuattr]

I just put in new water tank, thermostat, and water pump, etc with timing belt change. No reason why this should be leaking it is brand new. But sadly I am sure it is coming from that area...

[LowA4]

Was the thermostat housing new as well? Could just be a little corrosion on engine side of it. Some thermostat seals aren't the best either. What brand t stat?

[LakeTahoeQuattr]

No the housing was used but I cleaned it and it was in perfect condition or I would have replaced it when I put it back in. I did an engine swap so everything that I put back together was spick and span clean thus my dilemma... I ordered the timing belt kit from 034 so it was some German brand, I forget. Frustrating haha

[LowA4]

The plastic housings are prone to leaking. My S4 and the AR's housings looked good but leaked. I was able to retighten the S4's but the AR's was bad.

[LakeTahoeQuattr]

UPDATES

So its been a long two months, Christmas, etc. Some new progress on the Allroad. Should be on the road in just weeks!

Plastic sanded ready for primer:


Plastic primed:


Front fender sanded, primed chip repair:


Plastic color match painted and cleared:


Complete car re-cleared:


Bad Orange Peel in areas needing sanding:


Clear Coat runs needing sanding (first time auto painting btw):


New rear lift gate from silver 3.0 Avant color matched "no more huge dent"


Custom 2" allroad hitch made by Justin "JustMtnB44"



Aluminum VW Passat W8 Wagon gas lift supports:


Custom Allroad K04 Badge made by Caschy. The "K04" will replace the 2.7t on the lift gate:


Parts waiting to be installed after clear coat polish:
JHM Tip-Chip
Alcantara S6 seats
Silva IPP Arms

[LakeTahoeQuattr]

Update - Shark Fin Install

So I got a shark fin at a local dismantler for only $25! This was from a 2003 c5 2.7t sedan. It is not a curved mounting piece so it will fit on the flat roof of the avants. My goal is to erase the ugly rubber antenna that is all DE-composed and put the shark fin in for looks at this time. As bentley manual states, the FM reception comes from the side windows, etc. As time progresses I will be able to use the functuality of the GPS or Sat radio when I get an RNSE or something. I may just do this. Here is a teaser pic of the finished product. I painted and cleared it yesterday:


Here are some interior pics of the shark fin for those of you who have never seen inside. Supposedly it has Sirus, GSM extender, and GPS.




Four wires leaving shark fin, all coax:



I will post more info with progress, my goal tomorrow is to lower the head liner enough to get it installed and hope that my allroad was pre-wired with some of these.

UPDATE

So I could not wait any longer and had to install it. Headliner was easy to remove under the antenna as it is held in by 4 push locks. At this point antenna is non functioning and none of the wires were pre-wired that I can see. I will have to wire them for the rnse myself. FM radio still works fine.

[LakeTahoeQuattr]

Cashy badges installed:

[PipeHitter808]

Love the new emblems. The antenna is way more clean. My allroad has a shredded looking antenna and it needs a swap.