davkav's 300bhp daily avant

[davkav]

Hey guys,

I am going to try and keep this as up to date as possible and ask all of my questions here. I haven't really been active in a good while but as circumstances have changed I will be holding on to the A4 for another year or two anyway.

I have a few things on my list that I need to get sorted and they will be addressed in order of priority. My plan is to get the car to a nice comfortable ~300bhp specification as I am passed the days of solid mounts, loud exhausts and unbearable NVH.

1. Clutch
2. Chain Tensioner
3. Turbo
4. Turbo Inlet Pipe
5. Black Headliner
6. Replacement lower front bumper (I butchered mine when I fit the FMIC a few years ago)
7. Replacement headlights

A quick run down on the current state of my car as I have removed alot of the performance parts (built engine, exhaust etc.)

• Revo 550 file
• 550cc Injectors
• K03 turbo
• 034 Sports CAT
• Spec Stage 3+ with Dual Mass flywheel
• Fluidampr

Everything else is stock; inter-coolers, exhaust, engine and intake

At the moment I have my K03 fitted as I am debating on whether to send off my GT2871 to ATP to be replaced under the exchange program OR fit my hybrid K04 that I have sitting up from years ago.

The K03 although running safely does not do as the Revo file requests even on a low boost setting. If I set the Revo file to give me 10psi boost the K03 will only boost to 5 psi. 15 psi gives 7 etc.
I reckon this is due to the boost spike of the K03 turbo. The Revo file is probably looking for a nice linear boost curve and when it sees the massive spike it pulls back on the boost request.
This leaves me reluctant to fit the K04 as I more than likely wont be able to tune it myself properly with the SPS.

The GT2871 is probably going to be sent off for exchange.

Anyway.....
At the moment I am trying to decide the best clutch option for my goals. I have looked at most if not all options; ECS RA4, JHM RS4, Valeo Single Mass conversion.
My Spec Stage 3+ clutch is starting to slip. I have replaced the disc from a stage 3 to 3+ in the past and noted that there was scoring on the pressure plate so I plan on replacing the whole lot (pressure plate, disc and flywheel).
I also still have my steel single mass flywheel from Spec when I first bought the stage 3 clutch kit. The RS4 clutch kit is available for €350 from a local supplier (Ireland) so I have plenty of options.

So as I see it here are my options:

• Purchase the whole RA4 kit from ECS - single mass could potentially introduce clutch chatter
• Purchase RS4 clutch kit locally and have my Spec single mass machined to suit - is this possible?
• Purchase a new performance pressure plate and disk and new OE Dual mass flywheel.

Is it possible to fit the RS4 clutch kit to a Dual mass flywheel from the 1.8t?

[redline380]

If you don't have rods, I wouldn't go with the 2871.

As for the clutch, I have the RA4 and I like it a lot. It bothers a ton when people claim it will chatter and they have never even used it. Chatter is minimal to non-existent on mine. It has held my 2871 power fine.

But asking about the RS4 clutch kit on a dual mass brings up an interesting option. Most would say it is impossible, there is no 240mm six bolt flywheel available from Audi.

However, I recently discovered that 1.8t 337 and 20th GTI's used 240mm flywheels. This means it is very possible to use an S4 or RS4 clutch on a dual mass flywheel. However, stack height and ring gear would be the determining factors on using it. The flywheels are cheapish, like $200 on rock auto and I would personally love to find out if it is a viable option.

[davkav]

Thanks for the info.

I have had my GT2871 fitted in the past with no rods. Up to ~300bhp is fine. My plan is to only run it at around 18psi which is were I ran it before. I only cranked it up when I stuck in a built 1.9 engine.
Id probably go with the K04 only for the Revo software probably wouldn't be compatible with it, it will run with it but not to its full potential.

As for the flywheel, I hear you. I am only going on what I have read with regard to the 'chatter' but I have had a single mass fitted before and it was a wee bit 'chattery' and tough to pull off comfortably. How do you find pulling off from a stop. Would your mother comment if she was in the car?

I suppose it doesn't necessarily need to be the RS4 clutch kit with dual mass, more what clutch kit is the best value for money to be used with a dual mass.

[redline380]

As for the flywheel, I hear you. I am only going on what I have read with regard to the 'chatter' but I have had a single mass fitted before and it was a wee bit 'chattery' and tough to pull off comfortably. How do you find pulling off from a stop. Would your mother comment if she was in the car?

It does get a little boggy, but a well trained left leg gets used to it pretty quick. It isn't my daily driver now, but was for three years, both on stock power and 2871 power. Zero complaints. Also,

I also want to make a point of how good of shape the RA4 clutch is in. This thing has around 20k on it and looks effin awesome. I recommend the RA4 clutch all the time, and my recommendation definately won't change after I took it out again this time.

[davkav]

Its in pretty good condition thats for sure.


Just got word from my friend who works at parts supplier here in Ireland. He can get the LuK RS4 clutch kit for €220! Thats a steal, so now I need to find out what / if any flywheel can be used with it. Like I said I have my old single mass Spec flywheel sitting there gathering dust so if that can be machined to suit I'm set!

Edit:
I might just have to bite the bullet on the ECS RA4 flywheel.

If you look at the height of the ECS RA4 flywheel it has a flat profile on the rear side to were it mounts to the crank. Based on the pictures the Spec Single Mass will not be compatible even if machined as it has a different height altogether.

ECS RA4 flywheel:


Spec Steel Flywheel:

[texasboy21]

The ECS flywheel without a doubt 100% chatters. Its not bad, but with the AC on you can hear it pretty well. Some folks have minimized the chatter by adding a fluidampr crank pulley, but if you truly want to avoid adding any NVH go with a flywheel that is as close to the stock weight as possible.

Just a heads up, REVO does have a K04 file - should you decide to go that route. If you keep the 550 file with the 71r, keep the boost and timing tame and the rods will be fine.

[davkav]

The spec stage 3+ is compatible with the dual mass so that's an option. It's hard to beat the price I can get the RS4 clutch kit for though.

I forgot to mention I have a fluidampr fitted as well.

I'm not worried about the gt2871 to be honest, if I get it exchanged, which I probably will, I'll cap boost and timing so that the engine doesn't go bang. I ran with a stock engine on it for about a year before I put rods in.

I forgot they did the K04 but I'm trying to keep the expense to a minimum. The end goal is a nice daily driver with a bit of grunt.

Sent from my D5803 using Tapatalk

[davkav]

Right, about time I update this.

No major developments.

Ordered an ECS RA4 flywheel last week and have it here in front of me. RS4 Clutch Kit is being delivered today and just in time as the car is virtually undriveable now.

I also have a new rear main seal ordered which should be delivered tomorrow. Ill change this out at the same time as changing the clutch for peace of mind. I won't be surprised to find it leaking already as I find it hard to believe that K03 I have fitted produced enough torque to wear down the stage 3+ spec clutch....

After the clutch I plan on fitting a full front control arm kit, get the Garret sent off for exchange and then just enjoying the car.

Ill update with pictures from the weekend once the install is complete.

-Dave

[redline380]

Don't fuck up the rear main install....

Well, figured out all my oil leak problems. Hopefully the pictures are clear enough so you can see how fucked up the crank seal was from initial installation 10k miles ago. Feels good to get it done though. Mind you the dust seal on the rear main is completely gone. The picture shows how the lip of the oil seal was inverted about a quarter of the way around. My buddy installed very poorly. When I put the new one on, I lifted up the dust seal with a pick and ensured the oil seal lip was the correct direction.

I also want to make a point of how good of shape the RA4 clutch is in. This thing has around 20k on it and looks effin awesome. I recommend the RA4 clutch all the time, and my recommendation definately won't change after I took it out again this time.

[davkav]

Thanks man, been there done that.

Did you use a mk 2 / 3 golf rear main seal. The one in your pictures looks rubber based rather than the new nylon one.

I have a mk2/3 flange here and rubber seal that I plan on using instead of the shit factory one.

[redline380]

The actually lip seal is nylon I believe.

[FromS60toB61.8t]

The ECS flywheel without a doubt 100% chatters. Its not bad, but with the AC on you can hear it pretty well. Some folks have minimized the chatter by adding a fluidampr crank pulley, but if you truly want to avoid adding any NVH go with a flywheel that is as close to the stock weight as possible.

Just a heads up, REVO does have a K04 file - should you decide to go that route. If you keep the 550 file with the 71r, keep the boost and timing tame and the rods will be fine.

Is that what my noise was when i finally used the AC? haha. I thought it was the heat shield i tack welded on my test pipe to pass emissions rofl...

Can confirm, flywheel chatters at idle with A/C on. This is so far the only time i have ever heard it.