Brilliant Black S4 revival and build ( Pic intensive )

[RedDefiance]

Hello fellow Audi enthusiasts, I recently acquired a 2000 Brilliant black S4. Ive got a colorful history in the VW world, recently finished up my B5 A4 BT build ( for now, Build: http://www.audizine.com/forum/showth...-My-A4-revival) and am now tackling this.

I have always wanted a B5 S4, my buddies over at AzEuros ( http://azeuros.com/ ) hooked me up with this. I got rid of my big turbo MK3 Jetta ( Build: http://forums.vwvortex.com/showthrea...ic-intensive-) ) and got this in its place.




Here is my A4, I will be swapping the wheels to my S4 once I reach that point.




Ok now that Im done with that, let me show you my S4 This is how i purchased it, only thing I did was give it a quick wash for initial pictures.

2000 Brilliant Black Audi S4
140k miles
Stock









I had a custom multi-tune installed by my buddy for now ( valet/stage1 16psi /stage2 22psi )

Parts Ive already acquired:

XS power 3" updated catless down pipes
Gates timing belt kit from ESC
42draftdesigns intake manifold spacer
H&R coilovers

Brought it to work, began tear down. It needs the usual S4 repairs.... every oil seal, links, mounts etc.








After some initial power washing, there is residual oil absolutely everywhere.






Upgraded the stock plastic in favor of the updated aluminum thermostat housing. I also installed a low temperature thermostat at this time.


Gates belt installed with all new rollers, tensioner and waterpump.


All clean


Used our shop parts washer to clean anything and everything I removed and had to reinstall.


Everything back together, new coolant bottle installed along with New Touareg coolant cap.


Installed a B5 Passat power steering fluid res cover.


Temporary grill until my RS4 grill arrives.


Once all the top end maintenance was done I gave it a quick wax until I get it professionally done later.






Reinstalled the intercooler ducts and radiator shrouds.


Trimmed the upper parts of the ducts






This car has a badly faded roof and trunk. I replaced the trunk lid with one supplied to me by my buddies at AzEuros and I am having the roof wrapped in 4D gloss carbon fiber vinyl.




Thats where I am at as of now, My focus is going to be:

1. Maintenance
2. Suspension
3. brakes
4. Bolt ons
5. Stage 3 FT

[FLACO X3]

Great to see a B5 being brought back to where it should be.

[RedDefiance]

Thanks!


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[Corradovolksb]

Dude those time laps vids turned out great.

[CJ_]

Yeah! Another Arizona b5! Looks like a solid build coming.

[rockcandy]

Which building are you in? I see the a4 out there all the time.

[rockcandy]

Never mind. I see the vw stuff.

[Meow]

At some point most of these "builds" will become restorations, you see a few like this one pop up slowly, then more and more. Keep cleaning it up! Good luck!

[getslideways]

looks like it will be very happy with its new owner

[Bordom]

At some point most of these "builds" will become restorations, you see a few like this one pop up slowly, then more and more. Keep cleaning it up! Good luck!

I think that's what's happening right now. There's been more than a few "builds" posted over the last few months that show very neglected B5 being brought back to life; mine included, even though she fights me and is stubborn about the simplest things lol

[hibiscusS4]

At some point most of these "builds" will become restorations, you see a few like this one pop up slowly, then more and more. Keep cleaning it up! Good luck!

this is very true i cant wait to pick up the nogaro im getting and bring that car back to life.
also great job so far op in for future posts

[RedDefiance]

looks like it will be very happy with its new owner

Thanks!

At some point most of these "builds" will become restorations, you see a few like this one pop up slowly, then more and more. Keep cleaning it up! Good luck!

This is true, at 16yrs old a restoration is generally going to be needed before the original intent of a "build" can be performed.

this is very true i cant wait to pick up the nogaro im getting and bring that car back to life.
also great job so far op in for future posts

I appreciate that man.

I think that's what's happening right now. There's been more than a few "builds" posted over the last few months that show very neglected B5 being brought back to life; mine included, even though she fights me and is stubborn about the simplest things lol

Absolutely, no sense in dropping money in performance mods when the patient cant handle it.

[RedDefiance]

Well, I took the $26 gamble and tried on a replica RS4 grill today.... not sure how I feel about it.



Took off the temporary bagdless I had on


Installed the replica grill.


Also, a while back I attempted the OEM upgrade rear diff mod on my A4 using 3M window weld.... it turned out fantastic and there was enough to do two mounts. I packed both the A4 mount and S4 mount, I finally installed it.














Installed

[getslideways]

I hope all your repairs and mods come this well documented

Keep us the great work

[hibiscusS4]

never actually seen the rear diff mod in detail like that very cool

[RedDefiance]

Thanks guys


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[RedDefiance]

Well its been a while, the S4 got put aside for a bit while I worked on some other projects ( im addicted ). Since the cold weather is finally approaching here in Arizona I got back to work on the S4.


Picked up some Stern engine mounts and 034 front snub mount from a friend in good shape.


After having them in the trunk for almost a year I finally got to installing my H&R coilovers.


Bought 034motorsports sway bar links and street density upper control arms.










Also, after being in my trunk for almost a year I installed my XS power turbo downpipes.




Fought this garbage out






Installed




Threw on some A4 wheels temporarily until I swap my 3SDM wheels from my A4 onto it. Front ftg 24.5" rear ftg 25"






Mods so far:
1. Custom 3 level tune ( valet, stg 1 16psi, stg 2 22psi ) with anti-lag and no lift shift.
2. Modded airbox with K&N drop in
3. Intake manifold spacer
4. Low temp thermostat
5. Stern & 034 motor mounts
6. XS power down pipes
7. H&R ulta low coilovers
8. 034 Motorsports sway bar links
9. Evolution Diverter Valves
10. Complete black silicone boost hose kit
11. Gates timing belt
12. Aluminum thermostat housing

So for the first time since Ive own the car Ive been able to drive it aggressively and I hate to say..... I hate the stock tubos. Im so used to the power of my A4 that Im going to go Stage 3 sooner than I originally planned. For those interested here is my Stage 3 A4 vs two buddies with will put together SRM K24 kits.


Brought it home, gave it a quick wash and parked it next to its other half lol.








Ive got transmission mounts on the way, after installation I'll be going on a canyon cruise with a buddy in his K04 B6 A4 I recently finished putting together for him.

Mods:
2004 Audi A4 1.8t Quattro 6-speed
BW K04 turbo upgrade
AWE turbo back exhaust
Custom tune
Audi TT Maf sensor
Audi TT injectors
Modified air box with K&N drop in
FSI ignition coil upgrade
Black Forest industries engine mounts
Dual side mount intercoolers
Evolution diverter valve
PODI steering column boost gauge
Cross drilled and slotted brake rotors front and rear
Power stop full ceramic pads front and rear
Koni coilovers
RS4 rear sway bar
All new front upper and lower control arms
New front sway bar links and tie rod ends
2013 Volkswagen Passat TDI 18" wheels
225/45/18 tires Pirelli tires
15mm front spacers
17mm rear spacers

Stay tuned, picked up some equippment for my GoPro so i'll have a good video of the cruise.

[Urbansk1]

Hell yeah! Can't wait for the cruise!!

[CJ_]

Awesome, Looking good!! Did the control arms make a big difference? just found out mine are shot and I think have been for a long time lol.. Going to be swapping those out soon.

Whens this canyon cruise taking place???

[Corradovolksb]

Hell yah man. Great pics as always.

[RedDefiance]

Awesome, Looking good!! Did the control arms make a big difference? just found out mine are shot and I think have been for a long time lol.. Going to be swapping those out soon.

Whens this canyon cruise taking place???

Thanks CJ, control arms feel great. As far as improvement I won't know for sure until I do my alignment and get some better rubber on. Next week my plans are:

Install trans mounts
Replace rear wheel bearings
Swap wheels with my A4
Install boost gauge in my new PODI mount
Alignment

Once that's done we plan to hit the mountain either first or second week of October you should come!

Hell yah man. Great pics as always.

Thank you sir

Hell yeah! Can't wait for the cruise!!

It's about time you're excited lol



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[Urbansk1]

It's about time you're excited lol

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I had no reason to be until now LOL

[CJ_]

Once that's done we plan to hit the mountain either first or second week of October you should come!


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Let me know when, I'm always down!

Also you should bring it to pavilions this weekend!

[RedDefiance]

Let me know when, I'm always down!

Also you should bring it to pavilions this weekend!

I am actually, i'll see you there!

[RedDefiance]

So good news and bad news....

The Bad: As I was pulling out of the shop to go to a car show and my clutch master blew :mad: I never took pics but a few months back I upgraded to the metal slave and braided stainless steel line from 034motorsports in the hopes to avoid anything like this. Well thank goodness it happened there, i'll have a new one in Monday evening.

The Good: I got the ride height dialed in perfect at 24.5" front and 25" rear FTG. I also installed 20mm rear spacers and 15mm front spacers, im actually really liking these wheels on this car.

All washed and waxed, ready to show for the first time before things came to a halt.














Oh and a quick shop of me pulling out my daily driver I just finished putting together, I currently own 3 B5's now.

[CJ_]

Heard about that, missed you at the pavs! haha b5s4 life.

[RedDefiance]

Heard about that, missed you at the pavs! haha b5s4 life.

Yeah I was super bummed out, I was excited to drive it out for the first time in the 10 months Ive owned it. Its all good, it'll be there next weekend.

[Urbansk1]

The car looks absolutely amazing with these wheels on it. I can't believe how well everything flows together. It's a bummer about the clutch master cylinder. It was a day full of unpleasant surprises.

[christianb5s4]

Wouldn't be a B5 S4 without a few (read: many) mishaps or unexpected problems!

[RedDefiance]

Wouldn't be a B5 S4 without a few (read: many) mishaps or unexpected problems!

Truth! Biggest difference I can say between my A4 and S4 is the S4 is on the big side of both love and hate haha.

Wanted to share my most recent B5 adventure before my big update tonight. This is going to be long so enjoy!

Purchased this 2002 B5 Passat V6 GLX from a customer like 2 months ago, I got tired of driving my truck as my daily.




Needed ALL the common B5 V6 needs: All gaskets, belts, mounts, etc. Got it into the shop and started digging in.














New belts, rollers, Aluminum thermostat housing as well as low temperature thermostat.




I wish it was a wagon lol.


All maintenance done at this point, so I had a professional 3-stage buff done. I think it turned out pretty good considering the age of the car.








I drove it for a few weeks then the transmission blew. So i took the opportunity to swap in a lower mileage unit as well as replace the radiator and flush all the lines. I also swapped on my stock B5 A4 wheels with 15/20mm spacers and replaced the broken headlights with after market units with HIDs.




Fast forward about a month, I did some more things. I swapped in B5 S4 front suspension and replaced the upper control arms. I swapped on my Audi A6 wheels and installed 10.5mm front and 20mm rear spacers.












Mods/maintenance:
Complete engine reseal
New timing belt, tensioner, rollers
Metal water pump
Aluminum thermostat housing
low temp thermostat
K&N drop in air filter
Modded airbox
New spark plugs ( NGK BKR7e )
New plug wires
100% carbon build up cleaning
New OE replacement engine mounts
New OE replacement transmission mounts
Black forest industries front snub mount
16" heavy duty puller fan, mechanical fan removal.
New radiator
Flushed transmission cooler lines
Low mileage transmission replacment
Complete transmission service ( fresh fluid, filter, seal )
New headlights
5000k HIDs
B5 S4 front suspension ( shocks,springs )
Front upper control arms
Audi A6 wheels

[RedDefiance]

So last night I replaced the failed clutch master cylinder as well as flushed the rear diff and filled with Redline's Shockproof gear oil.


I got my Podi gauge mount in.




Threw in an old VDO boost gauge for now, I'll be using the PODI/VEI dual digital display later once I go stage 3.


Back together and finally I can drive it home.


Drove home on the stage 1 file ( 16psi )


Again, mods at this point:
3" XS power catless down pipes
Custom Tune
K&N drop in air filter
Modified airbox
Evolution DVs

[CJ_]

Good to see she's back on the road! Interested to see how that redline does, I've read mixed reviews on it, at least for the tranny. How did you flush it? or did you just drain/fill? Reminds me I need to do my rear diff lol

[RedDefiance]

Yeah I've used a mix of it before in past projects transmission and no I would never use it again. Gear engagement when cold was horrible. I used 100% for the rear diff and wow what a difference on the highway.


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[RedDefiance]

Did some more work on the S4, replaced the:

Transmission mounts
Passenger inner and outer CV boots
Alignment
Exhaust modification
Wheel swap
Installed DEPO LED taillights













Had the stock resonator removed.... aside from the rasp at 2800rpm I like it. Unfortunately the rasp hate out weighs anything else so im going to order XS power true dual 2.5" cat back with dual mufflers.






Stock




DEPO's






Swapped on my 3SDM wheels from my A4, using 15mm front and 17mm rear wheel spacers.