(Rongeur's) - TD05H-R Turbo Build

[rongeur]

Introduction:
Since I have never made any sort of formal introduction thread, my name is Jesse and I have owned my B7 A4 since 2011. I was in residency when I purchased it as a 30 year birthday gift to myself. Due to significant time constraints (family and residency) and limited garage space, my modifications and progress has been limited to mainly bolt-on mods. Now, 3 years later, residency completed, I feel like it is finally the right time to build out my car the way I have always wanted to. Current stats/modifications are:

Model Year: 2008
Model: 2.0T A4 (true) S-Line
Transmission: 6-speed manual
Engine Mods: APR Stage 2+ Tune | APR HPFP | 034 Motorsport turbo intake pipe | CTS Turbo FMIC with SS piping | | Snow Performance W/M Dual Port Injection | JH Motorsport test pipe | Stasis Exhaust modified with the 1/4y branch delete | GFB DV+
Driveline Mods: AudiUP Snub mount | 034 Motorsports Street Density engine mounts | | Apikol Rear Diff Mount | JH Motorsports short shifter
Suspension Mods: ST Coilovers | 034 Density line upper control arms | 034 Motorsports rear sway bar | 034 Motorsports rear sway endlinks
Lighting Mods: OEM Bi-Xenons with ZKW-R clear lens swap | Clear Corner | Custom HID Projector Fogs 3000K | Red Interior LEDs (Floor / Floods)
Other / Aesthetic Mods: S-Line Filler plate | Clear markers | Alu-matte mirror housings | VEI Boost Gauge | 35% Tint all around | De-badged | VMR 701s






Build Goal:
Simply put, to enhance my daily driver. I am not looking to make the most power or the fastest 1/4 mile time but rather to make a reasonably reliable, fast and fun daily driver that will enjoy the occasional track day or group drive. I look forward to digging deeper into this platform/engine and learn more about my car in the process.

Plan:
Engine: bottom end with Mahle pistons, 83.5mm bore, 8.5-9:1 CR, IE rods (I-beam), OE bearings vs coated (machinists choice), ARP hardware, Balance shaft deleted with 1.8T oil pump conversion married to an already built head with oversized Ferrea and Supertech valves, polished ports, uprated springs/retainers
Turbo: GTX2863R, BSH tubular top mount manifold
Components: Tial wastegate dumped to downpipe, Synapse DV, custom intake routed to passenger side SMIC space, retain MAF sensor
Driveline: JH Motorsports clutch with addition of delrin bushings and stabilizer rod (complete the "trio"), 034 Motorsports tranny mount
Tune: Custom tune

(Running) Parts List - Updated 4/27/15
2006 BPY block with internals - 424.99
IE H-Beam Rods 144x20 - 399.99
Mahle Powerpack 83.5mm bore 9:1 CR piston set - 729.99
IE Press-on Crank Gear - 185.00

[rongeur]

Reserved 1

[rongeur]

Other (Notable) Modifications:

Snow Performance Water/Methanol Injection - Dual Nozzle - Trunk Mounted.

My goal for water/meth was to keep the installation as OEM+ (stealthy and clean) as possible. I felt that a nice trunk mounted install would accomplish this the best and as the installation progressed, I would have done it no other way. The entire installation can easily be done in one solid day, but due to my busy schedule, I did it in a few sessions over about 4 months. Here are some of the installation pictures I took along the way. I found there to be very few, well published and documented, water/meth installations. Hopefully these pictures I took throughout the process will help inspire others (and improve) upon this installation.

Final Components:
Snow Performance Stage 2 controller (MAF controlled)
Snow Performance pump
Snow Performance nozzles (#1 post TB, #2 post intercooler)
Snow Performance solenoid
Snow Performance 3qt reservoir modded with fluid level indicator and low level sensor.
Devils Own in-line filter
Devils Own 90 degree and straight low profile nozzle holders
Devils Own in-line check valves x2
USRT Post-Throttle Body nozzle mount
USRT Silicone Hose nozzle mount













CTS Front Mount Intercooler - Installation Notes and Review/Logs --> Clicky <--


Custom HID Projector Fogs - 3000K --> Clicky <--
I retrofitted blazer projector fogs into the OEM valeo fog housing. Powered with The Retrofit Source 3Five ballasts and bulbs.

[Audibot]

Looking forward to it.

Btw, nice jacket he's wearing--I know my nephews would both love it!

[ericpaulyoung]

I can't tell on my phone. Is that another 2.0 FSI ?

[ericpaulyoung]

He is getting tall!

[Jake@JHM]

Excited!

[rongeur]

Looking forward to it.

Btw, nice jacket he's wearing--I know my nephews would both love it!

Dino-Camo!

I can't tell on my phone. Is that another 2.0 FSI ?

Yeah, it is a 2006 BPY block with the crowned pistons. I needed a second block to build as this car is my daily, hoping to do a clean swap once everything is ready.

Excited!

Me too, nothing innovative with this build, just want more out of my daily and need a project. I will be heading your way eventually for clutch and misc seals/gaskets I'm sure :)

[Operator]

Good stuff!!!!

[mec]

Wooot! awesome!

[drumnjuny]

nice!

[mec]

wait 2867? I thought JR had a 2863

[aluthman]

He did

[mec]

He did

Correct me if I am wrong....but he bought a 2863....and he blew it up or something, then he bought another 2863 from brad, and then blew up his engine?

[aluthman]

Correct me if I am wrong....but he bought a 2863....and he blew it up or something, then he bought another 2863 from brad, and then blew up his engine?

Had ATP kit initially with, I believe, a 2867. He had lots of manifold problems, and then IIRC the comp housing came loose and resulted in damage to the compressor wheel. Then he bought Brad's 2863 setup.

[derrek]

This is jr's old kit?


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[drumnjuny]

idk i've been waiting for OP to clear i tup

[rongeur]

Just to put any spreculation to rest, the turbo kit I am using is JTs previous setup. I was mistaken in the thread title, the turbo is a indeed GTX2863r (CHRA PN 816365-5001s) per the product number stamp, I will measure the inducer and exducer when I get a chance though.

The problematic ATP manifold (bottom mount) is replaced with the BSH equal length tubular top mount manifold. This combination worked very well in JTs setup prior presumably hydrolocking and blowing his bottom end.

There was the incident of the housing bolts backing out but the wheel has been inspected and deemed in fine condition for continued use and I am confident those prior issues will not continue.

For now, I literally just recieved the block a few days ago and need to disassemble, catalog and take to the machine shop. Current plan is to add Mahle pistons 83mm bore, 9:1 compression and likely IE H-beam rods. I will post a full list of all components when I get a chance, stay tuned!

[mec]

Just to put any spreculation to rest, the turbo kit I am using is JTs previous setup. I was mistaken in the thread title, the turbo is a indeed GTX2863r (CHRA PN 816365-5001s) per the product number stamp, I will measure the inducer and exducer when I get a chance though.

The problematic ATP manifold (bottom mount) is replaced with the BSH equal length tubular top mount manifold. This combination worked very well in JTs setup prior presumably hydrolocking and blowing his bottom end.

There was the incident of the housing bolts backing out but the wheel has been inspected and deemed in fine condition for continued use and I am confident those prior issues will not continue.

For now, I literally just recieved the block a few days ago and need to disassemble, catalog and take to the machine shop. Current plan is to add Mahle pistons 83mm bore, 9:1 compression and likely IE H-beam rods. I will post a full list of all components when I get a chance, stay tuned!

A bit of advice if I may....do one thing at a time. If you are going to take apart that engine first, then take it to the machine shop and run it on k03. don't build it and slap the turbo on immediately, it makes diagnosis much harder.

One step each day.

[aluthman]

Jr's car was cursed before that turbo, so you should be fine. Stoked to see another BT build!

[rongeur]

definitely sound advice

[ericpaulyoung]

Screw that, change EVERYTHING at once.
epy

[drumnjuny]

JR hydrolocked? haha i didn't hear anything about that

i remember him tuning it himself and running 40psi like an idiot and then it very predictably blowing up... maybe i remember it wrong. lol!

oh and him blaming other forum members saying it was their tune... lulz

[aluthman]

oh and him blaming other forum members saying it was their tune... lulz

Did I miss this part?

[drumnjuny]

Did I miss this part?

haha maybe, idk, maybe i am the first to say that one on AZ. whoopsies!

but whoopsies!

[aluthman]

haha maybe, idk, maybe i am the first to say that one on AZ. whoopsies!

but whoopsies!

Well, I have more info on the subject that I've voluntarily withheld...

Don;t want to clutter Rongeur's thread with that crap though.

[drumnjuny]

Well, I have more info on the subject that I've voluntarily withheld...

Don;t want to clutter Rongeur's thread with that crap though.

this is audizine, if your thread doesn't have a controversy it falls into the abyss

do this man a favor lol... and me, since apparently i don't remember it right.

i'm just here to start fires

[Charles.waite]

JR hydrolocked? haha i didn't hear anything about that

i remember him tuning it himself and running 40psi like an idiot and then it very predictably blowing up... maybe i remember it wrong. lol!

oh and him blaming other forum members saying it was their tune... lulz

Yea there was that. I still maintain that his manifold problems were because of bad tuning that resulted in super high EGTs.

Mec's "one step at a time" is excellent advice. Begin patient and turning on the taps slowly will result is FAR less headache than shotgunning everythign at once, as tempting as that might be. Especially with an unproven bottom end that might require some rebuilding.

[mec]

Yea there was that. I still maintain that his manifold problems were because of bad tuning that resulted in super high EGTs.

Mec's "one step at a time" is excellent advice. Begin patient and turning on the taps slowly will result is FAR less headache than shotgunning everythign at once, as tempting as that might be. Especially with an unproven bottom end that might require some rebuilding.

Not exactly....he had some....peculiar ways of approaching diagnosis. Suffice to say that I would be nervous if I had his used turbo.....I would def take it all apart and inspect it on all angles before running it


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[Charles.waite]

Not exactly....he had some....peculiar ways of approaching diagnosis. Suffice to say that I would be nervous if I had his used turbo.....I would def take it all apart and inspect it on all angles before running it


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agreed.

[mec]

Arjun =

[rongeur]

While disassembling my spare block to ready to take to the machinist, I discovered that oil pump chain had snapped along with a sheared bolt that secures the toothed gear to the balance shaft assembly. It appears that one of the balance shafts is seized. I was hoping to retain the balance shaft unit and have the machinist simply rebuild the pump but may heading in the 1.8t oil pump conversion afterall.

[derrek]

While disassembling my spare block to ready to take to the machinist, I discovered that oil pump chain had snapped along with a sheared bolt that secures the toothed gear to the balance shaft assembly. It appears that one of the balance shafts is seized. I was hoping to retain the balance shaft unit and have the machinist simply rebuild the pump but may heading in the 1.8t oil pump conversion afterall.

What about the balance shaft in your car now? Also if it had oil problems check to see if the crank is usable still.

Any chance you can grab the part number off the balance shaft for me?


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[rongeur]

What about the balance shaft in your car now? Also if it had oil problems check to see if the crank is usable still.

Any chance you can grab the part number off the balance shaft for me?


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My stock engine is already spoken for as part of the turbo/components/built head package so the hope was that the oil pump will be rebuildable. I picked up the block for cheap with oil pump included but in unknown condition so it was a bit of a gamble. I will check with the machinist as JT has a similar failure with his pump and was able to rebuild it. If is isn't, I will have to check out the 1.8t conversion, but leary of the shimming / trial and error to get the pressure correct.

I will get that pn for you once I get home from work. It is from a 2006 bpy engine.

Hopefully the crank is fine, everything else moves very smooth, but I will remove the mains and rods tonight and check for scoring/wear.

Does anyone know what size socket the external star bolts are for the OEM rods?

[derrek]

My stock engine is already spoken for as part of the turbo/components/built head package so the hope was that the oil pump will be rebuildable. I picked up the block for cheap with oil pump included but in unknown condition so it was a bit of a gamble. I will check with the machinist as JT has a similar failure with his pump and was able to rebuild it. If is isn't, I will have to check out the 1.8t conversion, but leary of the shimming / trial and error to get the pressure correct.

I will get that pn for you once I get home from work. It is from a 2006 bpy engine.

I wouldn't chance rebuilding it, if it fails again your motor would most likely ruin the motor. No offense to jr but I wouldn't follow the stuff he did seeing as he ended up with one of the most messed up motors. I'm going to do what slimjoker and mec did and cut the weights out of the stock balance shaft. Well if I can find one.


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[mec]

I wouldn't chance rebuilding it, if it fails again your motor would most likely ruin the motor. No offense to jr but I wouldn't follow the stuff he did seeing as he ended up with one of the most messed up motors. I'm going to do what slimjoker and mec did and cut the weights out of the stock balance shaft. Well if I can find one.


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This^




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[rongeur]

Definitely want to avoid the same pitfalls, but to be honest, much of the issues with JTs build was too much all at once, initial tune was way overboosting and likely heat related. The manifold I have is solid, not ATP bottom mount ones that were having issues. The turbo has been evaluated and deemed good to go from ATP and garrett. In regards to the oil pump, my options are:

1 - rebuild with balance shafts, if possible for smoothest operation
2 - rebuild oil pump component only and have balance shafts replaced with dummy rods - may be best option to retain stock oiling pressure and not have to worry about shimming etc. sacrifice on cabin vibrations
3 - 1.8t pump conversion - have to worry about oiling pressures too high, shimming, vibrations still present, but increase in oil capacity
4 - purchase new unit altogether for 1200ish, expensive but still has potential of seizing like the unit I have on hand.

leaning toward option 2 at this point. Derrick, what are you planning to do with your oil pump?

[derrek]

Definitely want to avoid the same pitfalls, but to be honest, much of the issues with JTs build was too much all at once, initial tune was way overboosting and likely heat related. The manifold I have is solid, not ATP bottom mount ones that were having issues. The turbo has been evaluated and deemed good to go from ATP and garrett. In regards to the oil pump, my options are:

1 - rebuild with balance shafts, if possible for smoothest operation
2 - rebuild oil pump component only and have balance shafts replaced with dummy rods - may be best option to retain stock oiling pressure and not have to worry about shimming etc. sacrifice on cabin vibrations
3 - 1.8t pump conversion - have to worry about oiling pressures too high, shimming, vibrations still present, but increase in oil capacity
4 - purchase new unit altogether for 1200ish, expensive but still has potential of seizing like the unit I have on hand.

leaning toward option 2 at this point. Derrick, what are you planning to do with your oil pump?

I'm going to cut the weights off the balance shaft and run it like that.

Rebuilding a broken pump is just asking for problems imo. I'd avoid it at all cost.

If you do the 1.8t pump like I was planing on doing you have to make sure the oil isn't filled to high and make sure the crank isn't splashing. If it is you'll be making bubbles and might possibly suck some up.

To be honest if Slimjoker or mec didn't tell me they cut that balance shafts out I would have never known.


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[rongeur]

I'm going to cut the weights off the balance shaft and run it like that.

Rebuilding a broken pump is just asking for problems imo. I'd avoid it at all cost.

If you do the 1.8t pump like I was planing on doing you have to make sure the oil isn't filled to high and make sure the crank isn't splashing. If it is you'll be making bubbles and might possibly suck some up.

To be honest if Slimjoker or mec didn't tell me they cut that balance shafts out I would have never known.


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The good news then is the pump itself seems to be fine, it spins freely and spitting oil out at me last night when I was spinning it manually. It is just the primary balance shaft that is seized, the paired one can move submillimeter in all directions indicating it is free. I should post up a picture tonight, but by cutting off the weights, do you mean just the aluminum hemi cylindrical lobes closer to the back of the shafts and keeping the worm gears near the front intact? Martin's build description lead me to believe he removed the entire shaft and replaced it with a straight aluminum rod and passive sprocket just to keep the chain and tensioner in a stock like orientation.

[derrek]

The good news then is the pump itself seems to be fine, it spins freely and spitting oil out at me last night when I was spinning it manually. It is just the primary balance shaft that is seized, the paired one can move submillimeter in all directions indicating it is free. I should post up a picture tonight, but by cutting off the weights, do you mean just the aluminum hemi cylindrical lobes closer to the back of the shafts and keeping the worm gears near the front intact? Martin's build description lead me to believe he removed the entire shaft and replaced it with a straight aluminum rod and passive sprocket just to keep the chain and tensioner in a stock like orientation.

I haven't seen the picture in about a year or two but i think they just cut off the lobes. Btw the balance shaft that Martin had was Stefans old one


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