Some Guy's Mediocre S4 Build Thread

[pwest15]

On my lunch break right now but here's where I'm at. I removed the catback, front bumper and radiator support. I just finished disconnecting all the plumbing necessary to pull the engine (in the picture the a/c lines are still connected). I guess I'll try and unplug all the wiring this afternoon but the actual pulling of the engine and tranny will have to wait until tomorrow because all my friends are busy and no one can help me with it

But I'm happy with my progress

[pwest15]

Another quick update before tomorrow

[Gosser]

Coming along nicely. Looking forward to some updates.

[pwest15]

Coming along nicely. Looking forward to some updates.

I got your update right here man!

Well it's like 3:00 here and about 100 degrees so I don't want to spend any more time in the garage until it dips below 85 again. Here's where I'm at.

Pulled the motor and tranny


Separated the two


Admired this emptiness


Then removed the electrical harness, the coolant hardline, the SAI things on the back of the motor (EC somethings ECG's?), the clutch and flywheel, and finally the exhaust manifolds which I'm now realizing that I didn't need to do. Oh well



Next up is to clean the whole block with some brakleen and then pull off the valve covers for powder coating and then take of the intake manifold and separate the top to get that powder-coated as well. Tomorrow, I'll try asnd take the parts to get powder-coated and I'll also try and wrap the bottom and sides of the intake manifold in some heat shielding as well as the throttle-body, just like what JimmyBones did. I'll also probably to the valley pan gaskets and check valve service tomorrow as well.


Oh and by the way, HUGE thanks to Eric, B6_4.2 for driving over to my place to help me pull the thing out of the car. Couldn't have done it without him

[pwest15]

Cleaned the whole back of the motor and removed my intake manifold to separate for powder-coating. Surprisingly, my valley-pan was that clean already. I haven't touched it yet

[Gosser]

Looks like it is moving along nicely.
What colors are you powder coating?

[Lucca M]

looks great, if i were you id do secondary air delete and inspect all the vaccum hoses, regret not doing it when i did my engine. now i have a leak somewhere in the pcv valve area and it pisses me off ! :D

[brandonrsx]

Awesome thread

[pwest15]

looks great, if i were you id do secondary air delete and inspect all the vaccum hoses, regret not doing it when i did my engine. now i have a leak somewhere in the pcv valve area and it pisses me off ! :D

I will regret it too... and will continue to regret it while doing the rest of this project because I don't want to pay an extra $50 just to have to reflash my car again to get the JHM tune with SAI delete. I really really really should've done it when I bought the tune because blockoff plates would be soooo easy to make utilizing the old ECG's or whatever they're called but whatever....... maybe I should stop being a little bitch and do it......... I'll decide later ...lol

Looks like it is moving along nicely.
What colors are you powder coating?

Classified information

Awesome thread

Thanks!

[pwest15]

So here's what I was able to do today. First, I cleaned... naturally. Then I installed the oil cooler plate and the Improved Racing oil cooler thermostat that they include with the kit. I just want to say that it was a major bitch to get those lines through the motor mount bracket and then wrapped back around in lieu of the starter being placed right there where the lines need to go. I ended up taking the motor mount bracket off entirely, routing the cables and then reinstalling the bracket. Here's a picture I snapped of the JHM oil cooler plate.



Then, Josh (Evildsmer) came over and we hung out and did the check valve service as well as the valley pan gasket and the front crank seal. I'm actually pretty concerned about my front crank seal as it's supposed to be a major pita to get in but once I had the lip of the seal around the crank, I was able to just push it and it slid all the way in. I should mention it was a Victor-Reinz seal and not an official OEM seal. SHould I be concerned with the ease that I got it in? (Innuendos aside)

I removed the old idler pulley, belt tensioner, and the alternator pulley with it's spacer. I intalled the new alternator pulley and the bracket for the JHM automatic tensioner and I fully intended to finish the 6-rib kit install but I ran into a spot of trouble when it came to removing the old crank alignment dowel. I sprayed it with a ton of PB Blaster on the old crank pulley but I just couldn't remove it! I tried for quite a while but all I succeeded in doing was sort of mangling it. Does anyone have any suggestions as to how to remove it?



Lastly, I've been working on this on and off for the past two days but I finally finished wrapping up the lower half of my intake manifold and throttle body elbow in some serious heat shielding. I know, I totally copied JimmyBones but I really liked the idea from the moment I saw it. Just like him, I used Heatshield Products 1/8th inch thick heat shield rated to 1100 degrees constant and 2000 degrees intermittent. This mod, along with the JHM intake spacers, should seriously help eliminate the heatsoak issues that these motors have. I'm excited to see if and how much it helps.






So now I just really want to figure out how to remove that dowel from the crank pulley so I can finish the 6-rib kit install.

[Audibot]

I sprayed it with a ton of PB Blaster

First mistake is using PB Blaster. Step your game up and get some Kroil and/or Sili-Kroil. If you can't get it off after applying Kroil, you wouldn't have no matter how much PB Blaster you sprayed on. Amazon Prime that stuff to your house.

Also, is that dowel pressed in? I have never done extensive engine work (which is why I enjoy build threads), but if it's a press fit, in which case no amount of spraying will help anyway.

[Jake@JHM]

Looking good! Any reason for opening up the manifold?

[Gosser]

My dowel came out with ease, but wouldn't go into the JHM crank pulley easily, I got it started, then drew the rest of it in with the bolts while installing it. Get out the digital calipers or bring the JHM pulley to the hardware store, they should have some brass kicking around.. Or install it without? I don't know if that little amount of mass contributes to the weight of the balanced or not.


Nice work on the heat shielding too. Kind of regret not doing mine. Never even crossed my mind.

My bet is on lime green covers and a black IM. When do you get them back?

[pwest15]

First mistake is using PB Blaster. Step your game up and get some Kroil and/or Sili-Kroil. If you can't get it off after applying Kroil, you wouldn't have no matter how much PB Blaster you sprayed on. Amazon Prime that stuff to your house.

Also, is that dowel pressed in? I have never done extensive engine work (which is why I enjoy build threads), but if it's a press fit, in which case no amount of spraying will help anyway.

Hmm, may have to try to find some of that stuff. I assume it's just been installed in there and oxidized to the crank pulley making it a royal pita to get out

Looking good! Any reason for opening up the manifold?

Thanks! I opened it up to clean it and to powdercoat the top half. It was nasty in there. So much oil. Really made me want to install a catch can but I bought a new PCV in that order so that might help for a while. PM'd you about some tips for the crank pulley dowel if you guys have any.

My dowel came out with ease, but wouldn't go into the JHM crank pulley easily, I got it started, then drew the rest of it in with the bolts while installing it. Get out the digital calipers or bring the JHM pulley to the hardware store, they should have some brass kicking around.. Or install it without? I don't know if that little amount of mass contributes to the weight of the balanced or not.


Nice work on the heat shielding too. Kind of regret not doing mine. Never even crossed my mind.

My bet is on lime green covers and a black IM. When do you get them back?

I really feel like installing it without the dowel because I'm fairly certain it's only there for alignment.

JimmyBones said he saw a noticeable difference with the heat shielding he installed so I'm hoping for the same so we'll see. It's super easy to take off the IM to wrap it in heat shielding. It's even easier to order the stuff online! You should do it up!

Also, neon green and black? What do you take me for? A Honda owner?

[pwest15]

Okay, can I just say... HOOOOOOOOOLYY SHIT!!! Jace (@BoostedAvant) is by far the most talented person behind a camera that I've ever seen! Here are some pics from a photoshoot we did two weeks ago

Que the pic whoring

IMG_3926-2 by Jace Stout, on Flickr
IMG_3973 by Jace Stout, on Flickr
IMG_3898 by Jace Stout, on Flickr
IMG_4183 by Jace Stout, on Flickr
IMG_4162 by Jace Stout, on Flickr
18949617929_a7174934db_o by Jace Stout, on Flickr
IMG_4080 by Jace Stout, on Flickr

A few of Josh's amazing Imola too

19135597105_c2151146cb_o by Jace Stout, on Flickr
18514973173_817434a64e_o by Jace Stout, on Flickr
18947999958_6e7653bf42_o by Jace Stout, on Flickr
Absolutely stellar work. I couldn't be more impressed! Thanks again Jace

[Mr. Corey]

Cars looking good!!

[Gosser]

Also, neon green and black? What do you take me for? A Honda owner?

ha gold and black?

[Gosser]

Oh and wicked pictures btw, both Ss look great.

[pwest15]

Cars looking good!!

Thanks! I appreciate it!

Oh and wicked pictures btw, both Ss look great.

Thanks! We're like S4 bros

ha gold and black?

Pssssssssssssssssssssssssssssssssssssshhhhhhhhhhhh hhhhhhhhhhhhhhhhhhhhhhhhhhhhhhh maybe


maybe not

[pwest15]

So Martin and Jace came over for a little while on Saturday so we could finish the 6-rib intall (needed to borrow Martin's grinder to grind down part of the Alternator) and to start the timing job. Unfortunately we didn't get too far because I don't own a 15/16 wrench to hold the end of the cam while trying to break the cam adjuster bolt free. We did remove the PTO and chain as well as the tensioners and guides for both banks. It's really just a matter of breaking the cam adjuster bolts now and then I can move on.



Also, does everyone think this crank lock pin is in all the way?




Anyways, we had to cut short work on Saturday night and I wasn't able to wrench on the car at all yesterday because I really had to sort out some personal problems but I should be back on track now.

[Jake@JHM]

Do you have any pics of the alternator case?

[pwest15]

Do you have any pics of the alternator case?

Not really but I can describe where we had to grind. So when I installed the bracket to hold the automatic tensioner, the bolt that I have to stick through the tensioner to hold it on wouldn't go in far enough because right after the bracket, the bolt would hit part of the alternator case. There were maybe 3 or four millimeters of the alternator case behind that bolt hole preventing me from finishing the install so we just busted out the grinder and ground down the corner of the case where that lower bolt hole is that meets the alternator bracket.

All installed now though, my only concern is belt slippage on the alternator pulley. I tried cranking the engine from the alternator with the new belt and it just wasn't having it. Might have to order an Audi special tool to crank the motor

[Jake@JHM]

Not really but I can describe where we had to grind. So when I installed the bracket to hold the automatic tensioner, the bolt that I have to stick through the tensioner to hold it on wouldn't go in far enough because right after the bracket, the bolt would hit part of the alternator case. There were maybe 3 or four millimeters of the alternator case behind that bolt hole preventing me from finishing the install so we just busted out the grinder and ground down the corner of the case where that lower bolt hole is that meets the alternator bracket.

All installed now though, my only concern is belt slippage on the alternator pulley. I tried cranking the engine from the alternator with the new belt and it just wasn't having it. Might have to order an Audi special tool to crank the motor

We have seen a couple Alternator cases that are just way off spec from the rest. It is pretty rare though.

Yeah, you shouldn't crank the engine by the alternator lol!

[pwest15]

Yeah, you shouldn't crank the engine by the alternator lol!

:P Fine Jake

Here's a super amazing professional rendering of where we ground

[evildsmr]

Just put two bolts in the flywheel and use a screwdriver wedged in-between them to crank the engine.

Sent from my Nexus 6 using Tapatalk

[pwest15]

Just put two bolts in the flywheel and use a screwdriver wedged in-between them to crank the engine.

Sent from my Nexus 6 using Tapatalk

Yeah we ended up doing that but it's so hard to do. Even with the spark plugs removed.

Y u no answer texts?

[pwest15]

Got the mechanical adjusters off as well as their chains. Then I replaced the guides and tensioner on the main drive chain.


My double cracked guide


Does anyone know what these two o-rings and one seal go to by any chance? I have no ideas

[pwest15]

Another quick update! Everyone loves more updates!

I assembled the JHM updated mechanical adjusters!


A shot of the wallowing on my old adjusters

[mark_ma]

looking nice!!!!

Is this something you know how to do as far as taking the engine apart? or are you learning as you go?

[pwest15]

looking nice!!!!

Is this something you know how to do as far as taking the engine apart? or are you learning as you go?

Certainly my first time taking a modern engine apart. I've messed around with a porsche 993 3.6 engine but this is totally different. I'm learning as I go and I probably wouldn't be this far without the helpful support from the local Audi community

[Jake@JHM]

Woot!!

[pwest15]

Woot!!

Jake! Martin had a question about the materials over on the AR thread, maybe you could answer it for him? You know much more than I do

[mark_ma]

Certainly my first time taking a modern engine apart. I've messed around with a porsche 993 3.6 engine but this is totally different. I'm learning as I go and I probably wouldn't be this far without the helpful support from the local Audi community

If i can invite myself i would
So i can give a hand and learn this stuff too, or just be a spectator and still learn.

Maybe in like 2 years ill have do do the same thing too

[evildsmr]

If i can invite myself i would
So i can give a hand and learn this stuff too, or just be a spectator and still learn.

Maybe in like 2 years ill have do do the same thing too

Um why don't you just invite yourself and come hang out man!!!

[B6_4.2]

Um why don't you just invite yourself and come hang out man!!!

I was gonna drop by again today and help out, unfortunately my plans were hindered...

[evildsmr]

I was gonna drop by again today and help out, unfortunately my plans were hindered...

YA ya YAA!!!!!................... ;)

[B6_4.2]

YA ya YAA!!!!!................... ;)

Haha well if it didn't take me 20 minutes to lower myself into a car I might've considered dropping by...

[mark_ma]

Um why don't you just invite yourself and come hang out man!!!

Awesome, if you message me the location and contact.
Having a job that's on call is kinda hard to have a social life, but ill do my best to hang out

[JimmyBones]

We have seen a couple Alternator cases that are just way off spec from the rest. It is pretty rare though.

Yeah, you shouldn't crank the engine by the alternator lol!

The Bentley manual says to turn the engine by the alternator.

[Jake@JHM]

The Bentley manual says to turn the engine by the alternator.

Bentley also told slick to remove the cam bars :(