CJ's Stage 3 RS4+ Blueberry Build Thread

[CJ_]

So in honor of successfully pulling my motor last night, I think its time to start an official build thread. I know its not a crazy build, but I want to keep track of everything here and post incase of questions, recommendations, etc. (I already know theres going to be a lot.)



Background:
So I ended up with this car in a trade, I didn’t really know much about B5s at the time or Audis in general really. The moment I took it on the test drive, I was hooked. I loved pretty much everything about the car. The car was an APR Stage 2, it had 180k on the chassis when I got it, but was surprisingly clean. The owner claimed it had a newer motor with around 65k miles on it, but didn’t have any paperwork to prove it. I’ve never had any problems with it, thus the reason why I’m going Stage 3. So far since I’ve had it, I’ve only done maintenance stuff and a few small mods here and there.

My goals for this stage 3 is to keep it moderate and reliable. Im going to be doing quite a bit of highway driving over the next year or two, so I want to have something fun but reliable. Also, I want to clean and detail the shit out of everything. It bugs be to have dirt and road grime everywhere. My goal is to have a showroom worthy car, I know it may sound far fetched, but a lot of time is planned for detailing and cleaning. Anyways, on to some details and pics.

So far installed:
APR Stage 2 tune
APR intake
APR Catback
Agency Power DVs
SSAC Downpipes
Samco boost hoses
Koni Coilovers
RS4 Clutch
ECS Tuning Drilled/Slotted Rotors
Podi AFR Gauge
AWE Vent Pod Boost/Vac Gauge
ARP Stud Conversion
Flat bottom Alcantara/Air Leather Steering wheel

Parts to install:
SRM RS6 K24s!
SRM Inlets
SRM Oil Feed lines
Bosch ev14 630cc injectors
Walbro 450 fuel pump
SRM 85mm cold air intake
3 Bar MAP Sensor
Daz Tune
JHM Solid Short Shifter
JHM Shifter Linkage/Bushings
034 Street Density motor mounts
034 Street Density tranny mounts
APR Snub mount

Maintenance stuff:
JHM 01e Rebuild kit
ECS Ultimate Plus timing belt kit
Coolant Reservior
Porsche Coolant/oil caps
Brake master cylinder

Parts needed:
FMIC
Radiator
Ecodes
JHM 4:1 Center Diff

Future:
BBK
Bi-Pipes
W/M Injection

Heres a quick overview of some stuff I’ve done.
The day I brought her home:



First things first, get rid of all that ugly plastidip:



RS4 bumper mod (I like the look of it, more subtle than a full RS4 front end.)



New wheels:



And how she’s been sitting for a while now:





And an interior shot:



Right before surgery:



Overall, the motor pull really wasn’t that bad. It was my first time pulling a motor, and it actually went really smooth. It was just a lot of checking over little things. Took us about 3-4 hours total. Forgot to start the go pro at the beginning, oh well..
Timelapse of the motor pull:

[MarlinFoundNemo]

Woo a santorin build thread! :D

[Corradovolksb]

Good looking car man. It's good to see some Arizona people representing. I will be starting my K24 build soon so I'm sure I'll see you around sometime. I'm interested to know how the srm rs4 turbos perform. If you need tuning help let me know. Daz is really good but can get busy.

[cinimod25461]

Looks like this is going to be a sweet build. Can't wait to see how these turbos perform. Good luck, and santorin ftw!

[CJ_]

Good looking car man. It's good to see some Arizona people representing. I will be starting my K24 build soon so I'm sure I'll see you around sometime. I'm interested to know how the srm rs4 turbos perform. If you need tuning help let me know. Daz is really good but can get busy.

Yeah! I'm living up in flagstaff right now for school, but Im back and forth between here and phoenix all the time. And that would be awesome, Ive never tuned anything before, so ill probably need all the help I can get

Looks like this is going to be a sweet build. Can't wait to see how these turbos perform. Good luck, and santorin ftw!

Im stoked to see how they perform! I ordered everything through daz and my original plan was to go f21s, but he highly recommended these instead. I was a bit skeptical at first just cause theres no reviews or anything on them, but I think these were the better choice

[christianb5s4]

That's awesome, pretty great to see you doing so much yourself. Are you shooting for a certain level of power?

[aysix]

Are you in flagstaff?

[CJ_]

Are you in flagstaff?

Yes I am

[CJ_]

That's awesome, pretty great to see you doing so much yourself. Are you shooting for a certain level of power?

Thanks! Yeah I plan on doing everything myself except the tuning. I'm most worried about doing the transmission rebuild, but they include that DVD, so I don't think it will be too bad. haha

[christianb5s4]

Thanks! Yeah I plan on doing everything myself except the tuning. I'm most worried about doing the transmission rebuild, but they include that DVD, so I don't think it will be too bad. haha

I'm contemplating doing the transmission rebuilt myself as well, just concerned about doing it correctly even with their DVD guide and getting all the right tools for the job.

[CJ_]

I'm contemplating doing the transmission rebuilt myself as well, just concerned about doing it correctly even with their DVD guide and getting all the right tools for the job.

Yeah, I know what you mean. Ill definitely post up here when I start tearing into it and share my experience/tips/pics/etc.. And to answer your previous question, I'm shooting for between 400-420hp. Probably more when I go WMI

[christianb5s4]

That would be awesome, would love to get some real world feedback on it. Even if a bunch of special tools are required, still would be more cost effective than sending it out most likely.

[MarlinFoundNemo]

What'd you do with your steering wheel?

[CJ_]

That would be awesome, would love to get some real world feedback on it. Even if a bunch of special tools are required, still would be more cost effective than sending it out most likely.

That was exactly my thought, I could either send it out, or do it myself and buy their short shifter/linkage/bushing package also, which was still cheaper.

What'd you do with your steering wheel?

The one in the picture or the old one?

[MarlinFoundNemo]

The one in the picture haha

[CJ_]

Oh, its one of the flat bottom wheels from the guy in poland. I found him on here and he makes custom wheels. I got alcantara top and bottom with air leather sides and red stitching. I know he has a Facebook too, Ill see if I can find it

Edit: here it is, https://www.facebook.com/reggicustoms/?fref=ts

[MarlinFoundNemo]

Oh, its one of the flat bottom wheels from the guy in poland. I found him on here and he makes custom wheels. I got alcantara top and bottom with air leather sides and red stitching. I know he has a Facebook too, Ill see if I can find it

Edit: here it is, https://www.facebook.com/reggicustoms/?fref=ts

Sweeeeet! Bookmarked for when I've got a 6mt haha

[CJ_]

Anyone have any experience with these DVs? Are they quality or should I look into different ones? They came with the car and I can't seem to find any reviews or tests with them. They've been working well with APR stage 2 at 17 peak psi, holding 15

[landfill]

The DVD is very helpful and it literally walks you through every step
from disassembly to reassembly and more. It's priceless IMO. As far
as tools you don't need any specific Audi tools. You just need a hydraulic
press, gear pullers, snap ring players, and then just your regular hand tools
& sockets. It would also be wise to have some spare pipe and old bearings
or drivers to use in the press for reassembly.

[christianb5s4]

That's good to know for sure, I wonder what kind of cheap hydraulic presses are out there that could handle what's needed for the rebuild.

[CJ_]

The DVD is very helpful and it literally walks you through every step
from disassembly to reassembly and more. It's priceless IMO. As far
as tools you don't need any specific Audi tools. You just need a hydraulic
press, gear pullers, snap ring players, and then just your regular hand tools
& sockets. It would also be wise to have some spare pipe and old bearings
or drivers to use in the press for reassembly.

Good to hear! Sounds like I should be pretty set then, might need to invest in a good set of gear pullers though.

[CJ_]

^ I have the harbor freight 12 ton, so Im hoping that will work okay

[CJ_]

Got the turbos off tonight. Pulled the fuel rails, intake, and exhaust manifolds off as well. Only broke a few lines/plugs
Turbos really didn't look as bad as I thought they would. Minimal shaft play, previous owner claimed this motor and turbos had just over 50k miles when it was installed, which would put them at around 70k now.





A little cleaning on the headers before and after.. Planning on porting and ceramic coating them.







Next up:

1. Separate engine and tranny
2. Replace timing belt
3. Rebuild tranny

And then continue on from there

[Mr. Merk]

subscribed

[CJ_]

Cleaned up the engine bay today, its been bugging me for a long time. Nearly 15 years of pebbles and grease in every nook and cranny. Took about 5 cans of degreaser, 2 cans of brakleen, and a bottle of simple green, but Im pretty happy with the result..

Before:





After:






Also got the engine and transmission separated! Debating whether I want to do the timing belt or the trans rebuild first.

[CJ_]

Got a nice surprise from UPS this morning! SRM wasn't going to be able to get any K04s in for while, so they were kind enough to send me out a set of K24s instead! Could not be much happier since I always had a little regret after going with the K04s with the lack of data/reviews on them. I think I'll like the k24s better in the long run anyways.









Haven't made much progress since this past week has been finals week. Should be able to get a lot done in the next few weeks.
I was able to get the timing components off and cleaned up, and also get the valve covers off and ready for all new seals. Everything looked pretty clean to me under there.

[88ninety9]

Cleaned up the engine bay today, its been bugging me for a long time. Nearly 15 years of pebbles and grease in every nook and cranny. Took about 5 cans of degreaser, 2 cans of brakleen, and a bottle of simple green, but Im pretty happy with the result..

Before:





After:






Also got the engine and transmission separated! Debating whether I want to do the timing belt or the trans rebuild first.

I was so happy when i finally got my bay cleaned. It's such a good feeling to know the motor is going back into a clean home build is looking great!

[CJ_]

Was able to get quite a bit done today. Got all the cam seals done, minus the cam chain tensioner gasket and half moon because my dumbass thought I could do it without the tensioner tool. With that said, its being overnighted from amazon. So hoping to have the valve covers and timing belt done by the end of the week.

On a brighter note, I got the valve covers and IM dressed up. Was gonna paint the IM a dark grey, but as I was sanding it down it turned into this nice shiny sliver, so I decided to polish it instead.
Painted the valve covers with VHT Wrinkle red. Followed the directions and did the 3 heavy coats, then let dry for 2-3 hours, then cured in the oven at 200 for an hour. I was actually really surprised and pleased with the results..

Prepped for paint:



End Result:



Closeup of the wrinkle finish:

[Yesmar]

Looks great polished!

[rani_aridi]

Ooooooh what did you use to polish it? Everything looks great

[CJ_]

Ooooooh what did you use to polish it? Everything looks great

Thanks! I started sanding it down with 180 grit > 220 > 400 > 600 > 1000 then wire wheeled it with my grinder and thats how it turned out. I tried a little bit of chrome polish, but it didn't really do anything.

[S4 00 2.7]

IM and VC's look good.

[CJ_]

Made it all the way to here, then could not find my new damn idler roller anywhere. Im 90% sure I had it when the timing belt kit arrived, but somehow lost it. So now on hold once again, waiting for parts/tools/etc to arrive. Was hoping to have the motor buttoned up this week, but looks like its going to be next. On a brighter note, I got all of my seals done on the top end!





Also, does anyone know where this leak might be coming from on top of the oil pan? Im thinking its power steering fluid, but its hard to tell.

[vavJETTAw36]

Can you identify the fluid? Could be oil. Could be PS running from the pump. Was the leak already there is it leaking without even starting the engine/pressure?


Sent from my iPhone using Tapatalk

[CJ_]

It was already there after I pulled the motor. It seems like an old build-up of something. Hard to identify the fluid. Is this just a common spot for build-up/road grime, etc?

I know I had to top off my power steering fluid about once every month or two, still don't know the source of that leak.

[das4]

It was already there after I pulled the motor. It seems like an old build-up of something. Hard to identify the fluid. Is this just a common spot for build-up/road grime, etc?

I know I had to top off my power steering fluid about once every month or two, still don't know the source of that leak.

I had the same build up on mine. I didn't have any leaks up top outside of the normal seals and gaskets. cleaned it up and it hasn't shown any signs of leakage yet, although I just got mine back together. mine was so bad the entire face and crevices were covered in nearly a 1/4" of grease/oil/road grime

[zillarob]

Is that a Geba pump? Have seen the bearings go on two that looked similar to that.
Im sure none are 100%, but I try to use Hepu when I can.

[JayCar]

Subbed. Awesome job CJ_. Love seeing this!

[CJ_]

Is that a Geba pump? Have seen the bearings go on two that looked similar to that.
Im sure none are 100%, but I try to use Hepu when I can.

Yep it's Geba, it's the one that came with the ecs timing belt kit.. Thats not good to hear.. Might just try my luck with it, it feels solid, but idk.

Subbed. Awesome job CJ_. Love seeing this!

Thanks! Its a slow process for now, but its coming along

[CJ_]

Transmission time!!