2000 A4 B5 1.8T turbo & valve train upgrade

[VanCityA4Q]

So my last post was a year ago or so. I was doing a complete stock rebuild on my 1.8T motor. After it was done I installed a used k03 turbo that I acquired from a local shop as being rebuilt recently. Everything worked great, I broke the motor in slowly over 10,000km then proceeded to put another 15,000km on the car over the summer with a cross country road trip. On my return trip I was climbing some fairly long and aggressive hills along the north shore of Lake Superior running around 5000RPM, I noticed a burning smell and pulled over to find a small fire had started under my car next to the flex pipe on my exhaust system, I quickly got come water and splashed it under the car and got the fire out, it was at this time I popped the hood as well and noticed my turbo was literally glowing red. I let everything cool down and continued on my drive for another 4000km to home.

When I got back I ran some tests with my ODBII tool and found my boost to be around 3psi max at wot, also my compression checked at cold was 30psi, 160psi, 140psi, 35psi.

I pulled the head flipped it over and filled the combustion area's with water, instantly the water was dripping out both exhaust valves on #1&2 cylinders. Now I have the valves out and fount they are bent.....not sure how this would have happened, possibly due to heat?

Regardless I've got a project on my hands, here is my build list so far. Any advice would be appreciated.

Supertech valve springs & TI retainer kit
Supertech intake & exhaust valves
Integrated engineering street cam set
Supertech valve guides
44lb Bosch injectors
255lph HP fuel pump
2.0 coil upgrade kit,
Aluminum fuel rail
Cold air intake with heat shield
Cat test pipe (no more emission testing in BC WOOT!!!)
not sure what I want for a tune yet tho, seriously considering Malone tuning as they will code out my sai and Evap codes.

Now I'm sure I'm going to take some flac here but I bought one of the e-bay turbo kits, it comes with a FMIC, 38mm waste gate, BOV, boost adjustment valve, diverter valve, oil cooler, turbo timer, oic catch can, and a t03/T04 hybrid turbo, fuel pressure regulator adjustable from 5-140psi and lastly and stainless exhaust manifold.

Now even if the turbo is garbage, all the other stuff in the kit is will worth the money as far as I'm concerned, I'll just have to wait and see how the quality is when it shows up and keep my fingers crossed.

P.S
The head is an AEB that has already been ported and polished, the original ATW got tossed in the last build.



Cheers!

[B5A4coastie]

Everything seems sold, but the injector size, MAF requirements and the need for a HF/HP fuel pump will be up to the tune you pick.

Figure out what tune you want to pair with your turbo, then buy the air and fuel requirement that the tune calls for.

[Davdraco1]

Most tunes for our cars will delete the SAI, EVAP and rear 02 so I wouldn't worry about that too much. I know Motoza can do remote tuning and from what I read, they are easy to work with and people love their tunes.

[VanCityA4Q]

Thanks a lot guys, I'm still learning all the tricks of the trade with these B5's and tuning in general. I already bought the injectors and fuel pump so I'll just wait and see if I get lucky I guess. I'll check out Motoza. By remote tuning do you mean like over the Internet? That sounds very convienient :)

I'll post some pics once I start receiving parts and get to assembling things.

Also is there a DIY on here for a AEB head rebuild? I don't need it, but I do have some free time and would consider doing one :)

[VanCityA4Q]

so, just a little update.

The head I built last time had a few minor issues. Leaking Valve guides (not the seals), when I changed the valve guides last time I drove them out from the combustion chamber side of the head. When I did this the carbon build up on the guide galled the bore on the way out causing a few of the new ones to leak. I was also less informed on my last head build and went to town porting and polishing the intake and exhaust. Little did I know, when porting intake's its very important to match all ports as close as possible and to not remove too much material unless you have access to a flow bench and know what you're doing, which i didn't lol. I hogged them out and removed all those nice bumps between the valleys lol, regardless it wasn't ideal and I'm sure I had more air going to one cylinder than the others and so on.

So on the weekend I went down to the auto wreckers and happened to find a 98 A4 1.8T with a good AEB head on it. Obviously the guy at the yard I went to didn't know what they were selling me as I got it for $40 lol sweet deal!

So I get this thing home and start ripping into it, everything looks great, so far I've stripped it down to just the aluminum head itself had the face decked as my buddy told me it was .009 out of flat which Isn't too bad for a head that's had over 180,000 km put on it. Then I got to the task of gasket matching the Exhaust port and after doing hours of research I ported and polished the exhaust side of the head, I removed a fair amount of material off the short turn radius and on the sides of the ports next to the valve guides, blended in the valve seats to the walls, and then started sanding with my handy Dremel, 120 grit barrel sanding rolls all over until I had removed all the casting bumps and pits, then i smoothed it out with 240 grit followed by rubber polishing bits. then I spent the next 16 hours or so with 4 different grades of buffing compound and hard felt polishing bits.

I'll be starting on the intake side tomorrow but this time I know to just smooth out the rough casting lines and bumps and give it a nice polish, no hogging out material like one would do on the exhaust side.

Also I attached some pic's of my progress so far, I'll be sure to keep taking pic's and posting them on here.

Any Ideas on what else I could do to this head while I have it out and apart like this?

https://onedrive.live.com/?cid=2FCCC...%21313&o=OneUp
https://onedrive.live.com/?cid=2FCCC...%21313&o=OneUp
https://onedrive.live.com/?cid=2FCCC...%21313&o=OneUp
https://onedrive.live.com/?cid=2FCCC...%21313&o=OneUp
https://onedrive.live.com/?cid=2FCCC...%21313&o=OneUp
https://onedrive.live.com/?cid=2FCCC...%21313&o=OneUp
https://onedrive.live.com/?cid=2FCCC...%21313&o=OneUp
https://onedrive.live.com/?cid=2FCCC...%21313&o=OneUp
https://onedrive.live.com/?cid=2FCCC...%21313&o=OneUp

[VanCityA4Q]

So my build has snowballed into so much more now, the head is all built now, I didn't do the cam upgrade. But did do the single groove valve retainer upgrade. I'm now in the process of installing a 13 row oil cooler to keep by build cool and calm. I've also purchased the TT MAF housing, and the hemi 80mm TB to feed my beast. I also decided against going with the cheap Chinese turbo kit off eBay and bought a Turbonetics T3/T4 with .63ar and .50ar respectively. I've also upgraded to a 3" custom straight pipe exhaust with no muffler. Ive also decided to go with a Unitronics stage 3 big turbo tune. I talked to a few different places one being eurodyne and found their staff to be quite ignorant and not really willing to help me at all. I think the guys name was Chris. He basically told me my 2000 a4 was not a common car to tune and they didn't offer anything for my car, nor would he explain why, or how I could get it done elsewhere. The guys at Unitronics were much more helpful and very willing to take on my custom tune project. It's turning into quite the build, I'll post more pics when available.

[Corrado_Guy]

I have a Unitronic Stage 3 440cc tune and was not really happy with it on the ATW engine management and upgraded. What Eurodyne did not mention was that your ATW is a one year car (in the Audi 1.8T world, I think the Passat used it longer) so there is not much support for it and what makes it worse is it uses a narrow-band O2 sensor which is not great for tuning. I don't know how flexible Uni is but the tune I was running was out of the box so as long as I had the required turbo and upgrades it would work and be fairly close. What I did was upgrade the engine management to the 2001 1.8T AWM system was as simple as running different wires for the wide-band O2 sensor, adding a resister for the VVT which is not present in our car, change the MAF, change the ECM, and installing a wide-band O2 sensor. Other than those items I am running the ATW wiring and sensors and then you can flash it with what you want. I went with Eurodyne because it allows me to adjust the tune and if I change my setup like upgrading the turbo I can adjust the tune and do some logging and tweaks and be set.

BTW, where did you get the head?

[VanCityA4Q]

I got the head at a place called pick a part, it's just an auto wreckers that's open to the public.

I'm gathering all my stuff now for the wideband conversion. I got a wideband ecu today in that same auto wrecker from a 2001 Passat that I was told would work. I also ordered the Unitronics cable for the conversion to wideband. I wish I knew I needed the MAF sensor too, it was right there lol! The more I'm looking into it the more I like Eurodyne as well. The maestro suite looks enticing. I also don't like the idea of not being able to tweak the tune myself.

[Corrado_Guy]

The Passat can be either wide or narrow band in 2001 so confirm with the part number. The sensor housing itself is the same on wide or narrow band but he electrical sensor is different. Before you get too far into it you want to figure out what diameter intake you are going to use as the tune will need to be scaled for that diameter MAF. My car was originally running a Uni Stage 3 tune with a GT28RS, 440cc injectors, and a TT225 MAF so I kept the MAF but upgraded the injectors to Bosch 550's. When I upgraded I just used the electrical part from the new MAF in the old TT225 body and I could keep all of my larger intake system. Maestro allows you to easily scale for standard MAFs or custom ones. What I did notice was my car would go for 100kms more on a tank of gas with Maestro and bigger injectors than it did with Uni and it was much smoother with more power. I also run a big front mount with an S4 bumper which really helps keep the temps down...



If you want to do basic tuning Maestro is great because it gives you a lot of base tunes and then you just run them and do some logging and then tweaking the tune. Maestro comes with a basic logging suite or you can use something like ME7 Logger which you can customize to your wants. Maestro comes with launch control and no lift shift which some people enjoy but it is also limited. There are only so many things you can tweak with Maestro and when you make a change using Maestro you don't really know how many tables you are really changing. You can also tune these by yourself and there are a lot of good sites like the S4 Wiki and Nefmofo that you can learn anything you want as far as tuning these things go. I didn't want to do the learning so I went the easy route and bought Maestro and it works well enough for my needs. I can also upgrade my system such as a bigger turbo or injectors and then easily adjust the tune and go through the logging and tweaking once more.

[VanCityA4Q]

Ive got my TT225 MAF housing on the way as well as my 80mm TB. Youre really making me lean towards Maestro as well. I like the idae of tuning it myself for sure. I'm also looking for an S4 or RS4 front bumper, Ive got a 27x8x2.5 FMIC on the way as well with 2.5" ports. Just need to decide what intake manifold to strap in and I'm all set! Turbo kit is showing up this Monday so Ill start posting more pics as it goes along.

[B5A4coastie]

IE intake manifold is very easy to install, I'm very happy with my purchase.

[VanCityA4Q]

ITS FINALLY ALL ORDERED!!!!! My Ebay turbo kit has arrived and I promptly threw out the ssqv bov that was made of chinese pot metal, when i dropped it it broke into 3 pieces lol. The 38mm wastegate that came in the kit is actually decent quality, and the T3 Turbonetics turbo is genuine with serial numbers traced back to the factory (thank god lol). Intercooler is also good quality and pressure tested to 40 psi for an hour and it held. Over all the kit is not too bad. I did order the forge FMDVSPLTR just to see how that works out. if I dont like the BOV function I can always cap it :). I finally decided on the tune and Bought Motoza, ecu shipped today so Ill have that back in a couple weeks and I bought my SEM intake manifold as well with a phenolic spacer. From talking with Dave @ Motoza it sounds like I'll have no problem making 400 Crank HP, that will translate into 300-325 awhp. I'm STOKED!!!! All these parts cant get here fast enough lol!

[Seerlah]

The spacer with sem manifold may make the manifold sit too high. People have already had clearance issues without running the spacer.