Stage 3 Build @ 300K+ Miles

[christianb5s4]

I bought my 2001 Imola S4 back in August 2014 from a marine out in 29 Palms the day after I sold my 370Z, always wanted one from the first time I drove a B5 S4 in high school. Bought the car with 286K miles and it was not in good shape from previous owners and neglect, although the chassis felt solid and it had a lot of parts on it already so I figured it was nothing I couldn't fix. But driving 3 hours in 100 degree heat without working AC made me instantly question my decision to buy it.

Here's a comprehensive list of everything I've done to put it into perspective the kind of commitment you're in for bringing back a 286K mile B5 S4 to good health:

Done before ownership:

- AWE intercoolers
- Equus boost gauge
- JHM 1 to 2 gear syncros/collar
- Driveshaftshop 1 piece driveshaft
- JHM single mass flywheel, unknown clutch
- JHM SS
- Koni coilovers
- LaBree catless downpipes
- Miltek twin 2.5 exhaust
- New brake pads and discs
- Newer engine, trans
- New radiator

Done during my ownership:

- Samco intercooler hose set $30
- New coil packs, ICMs, spark plugs $70
- New front driver’s axle $225
- New coolant reservoir $20
- New coolant temp sensor $15
- New driver’s primary o2 sensor
- New G89 AC temp sensor $15
- New hood strut $25
- New headlights/ballasts/bulbs $170
- New front tires $280
- Center muffler removed $70
- New auxiliary cooling fan $40
- New Infinity rear deck speakers $45
- JFonz stage 2 tune $420
- 034 Motorsports DVs $200
- New driver’s interior kick panel $30
- Turn signal issue $0
- Trunk lip $30
- VAG-com scans $0
--- No more airbag light
- New BKR7E spark plugs (0.026 gap) 3/18/15
- Oil change Shell Rotella @288,700 miles $60
- Valve cover gasket, painted VCs $91
- New windshield fluid reservoir/pumps $30
- Timing Belt w/ all components @ 293,800 miles $670 (incl. labor)
--- AZ Ultimate Kit (Pure MS), fresh G13
- Oil change Shell Rotella @ 293,800 miles
- Rear driver’s wheel bearing @ 294,000 miles $200 (incl. labor)
- Spark plugs @ 294,000 miles
- New battery tray cover, engine covers, trans tunnel heat shields, and fuel level sender $60
- New updated vented oil cap, Continental vacuum lines ($60) 7/18/15
- Compression test complete:
--- Driver’s side: 170/175/180psi (front to back)
--- Passenger side: 185/170/176psi (front to back)
- New sparkplugs (7/27/15)
- Stern Power Ring and rear differential mount bushings $120
- New fuel level sender installed, confirmed Bosch 044 pump installed
- New rear passenger’s side wheel bearing @ 295,500 miles
- New 034 Motorsports F hose and new 90 degree hose from check valve
- New front sway bar end links (gold)
- New spider hose assembly, y-pipe $40
- New transmission and rear diff fluid FUCHS Titan 75W-90
- SRM/SSAC K03/4/RS6 universal dps and Twin 1 $800
--- New JHM exhaust hardware
--- DEI Titanium wrap on downpipes
- New OEM Bosch primary o2 sensor (driver’s side) $100
- Oil change (11/16/15)
- New Hella OEM oil temp/level sensor $70
- H&R premium coilovers $950 shipped
--- New FCP front control arms $200
--- Lemforder HD tie rod ends $82
--- New hardware $35
--- New spring perches $40
--- 034 density line front strut mounts $50
- Full alignment $140
- New NGK BKR7e plugs (11/22/15) 298,160 miles
- Redline Goods alcantara shift boot $65
- Infinity 4022i front speakers installed $80
- New Vaico Turn Signal Relay $26
- New OEM 4 Bar FPR $75
- AWE Boost Gauge, new vacuum line, ECS gauge pod $150


The day I bought it, does not look bad in pictures but it was absolutely filthy and needed a ton of TLC to bring it back.



How it looks today:

[CJ_]

Thats a ton of maintenance! Looks good though, cant wait to see this!

[jballou]

There is only one problem...
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It's yellow. Ewwwww

[christianb5s4]

For the build, it's a relatively simple stage 3 build but with a ton of preventative maintenance parts. I want to do this once and do it right and have a reliable 450whp car that I can drive to my heart's content. I set my budget, then quickly realized I was going to smash through it. I tried to get every single thing that could be taken care of while the engine and transmission are out, and fully expect a few things unexpected to pop up as well. Jballou will be doing the build completed before Wuste, he's a great guy and I'm 100% confident.

Build list:

- Compturbo K04 Hybrids with RS6 wheels hot and cold side
- Clutchmasters stage 4 clutch w/ steel flywheel
- RS4 airbox/MAF/accordian
- XS Power K04 inlets
- Advanced Automation built 01e w/ JHM 4:1 diff
- JHM solid linkage, stabilizer bushing, and centering spring
- Etspec tune
- 3 Bar MAP
- EV14 72lb injectors
- New turbo oil return and feed lines
- New turbo coolant lines
- Cinesnow wastegate lines
- New CPS sensor
- New N75
- New vacuum lines
- 034 intercooler hose set
- Stern engine & trans mounts
- Turbo hardware
- New JHM snub mount
- New fuel filter
- Afterrun low temp switch
- New power steering lines
- New slave cylinder
- Valve cover gaskets
- Cam plugs
- New heater core supply/return couplers
- New Coolant drain plug
- Oil filter
- G13
- Pentosin CHF202
- Motul 5.1
- Fuchs Titan Sinto
- NGK BKR7EIX

[y3ti]

whens this happening? I wanna check it out, if I'm free.

[christianb5s4]

Dropping the car off at Justin's Saturday, I will figure out a schedule with him so I can come up to help and speed up the process. Most likely weekends or after I leave the office week nights.

[bmoreS4]

Very similar to my build, looks good man.

[Trb1]

I'd look into induktion motorsports/SRM oil feed lines. They're steel braided and the passenger line runs around the manifold with a nice heat shield instead of through the manifold. It prevents oil cokeing from the heat. Just cheap insurance and piece of mind for expensive turbos.

[hibiscusS4]

thats a good option didnt cinesnow also make feed lines? i could be wrong but i thought he did.. either way in for updates on the build

[jpurre]

If your oil lines don't leak, just clean them really well and reuse. Otherwise the SRM oil lines are a good idea.

[christianb5s4]

As for the oil lines, I'm going with the OEM lines that will be cleaned up prior to re-installation just because they are more than adequate for my needs. However, I hate the design of the factory wastegate lines and want to get rid of that entirely pending seeing how the lines that are on the car now look once the engine is out.

Yes, Cinesnow makes the oil lines as well and we've talked about it. Will know more once we take a look at the stock lines to see what we will use!

[bmoreS4]

I went with SRM lines, very nice product.

[cameron90]

I thought my 02 had alot if miles with 144k, but over 300k goddamn


02 b5 s4
(Black Betty)

[xalents23]

You're in good hands with jballou. He's a great guy and knows his stuff. Congrats on going Stage 3.

[Drehmoment]

OEM oil lines are superior to any aftermarket " improvements ".... That's the reason it lasted 300 k , factory R&D vs backyard "engineering"

As far as the Chicom turbos are concerned, wake me up when a set hits 200 k

[jpurre]

As for the oil lines, I'm going with the OEM lines that will be cleaned up prior to re-installation just because they are more than adequate for my needs. However, I hate the design of the factory wastegate lines and want to get rid of that entirely pending seeing how the lines that are on the car now look once the engine is out.

Yes, Cinesnow makes the oil lines as well and we've talked about it. Will know more once we take a look at the stock lines to see what we will use!

I would highly recommend you replace the wastegate reference lines. Mine exploded after F21's were installed, and it was very difficult to replace with the engine back in.

[y3ti]

As far as the Chicom turbos are concerned, wake me up when a set hits 200 k

what "chicom" turbos are you talking about?

Comp Turbo is based in CA. Idk if he is using OEM k04 housings, but even then it doesnt matter; it's a Comp Turbo chra.

[Drehmoment]

I am familiar with Comp turbo......I was referencing to the shoe string budget crowd....and no , Comp turbo ain't Chinese budget

[seanf86]

hows the jhm driveshaft? I just dropped mine off at a local driveshaft shop to have them cut the ends off and make me a custom 1 piece, I have seen mixed reviews about vibrations on the highway with a 1 piece.

[Tjtalan]

Cant wait to do some pulls on the way to Vegas!

[christianb5s4]

OEM oil lines are superior to any aftermarket " improvements ".... That's the reason it lasted 300 k , factory R&D vs backyard "engineering"

As far as the Chicom turbos are concerned, wake me up when a set hits 200 k

That's the thought process behind getting new OEM lines, also this is certainly not a shoestring budget build as my wallet has found out. These turbos use OEM BW K04s as a base.

I would highly recommend you replace the wastegate reference lines. Mine exploded after F21's were installed, and it was very difficult to replace with the engine back in.

I am 99% sure I'm going to replace the entire lines, the ones on the car are not in good shape that's for sure. Going with Cinesnow's.

hows the jhm driveshaft? I just dropped mine off at a local driveshaft shop to have them cut the ends off and make me a custom 1 piece, I have seen mixed reviews about vibrations on the highway with a 1 piece.

I actually found out a while back it's a driveshaftshop driveshaft, but it's been great with no issues. Of course I don't have any reference to what it's like compared to stock since it came on the car.

[bmoreS4]

I am familiar with Comp turbo......I was referencing to the shoe string budget crowd....and no , Comp turbo ain't Chinese budget

Ahh now we get it, you where taking shots at people because of a difference in preference..........classy.

Way to contribute.

[bmoreS4]

And OP, I also went OEM KO4 as my base turbo as well.

I'm super satisfied.

[christianb5s4]

And OP, I also went OEM KO4 as my base turbo as well.

I'm super satisfied.

I'm so excited, do you have a build thread by chance? I'm shooting for 450whp on 91 but that might be optimistic. Having a conservative E85 tune done as well.

[Trb1]

OEM oil lines are superior to any aftermarket " improvements ".... That's the reason it lasted 300 k , factory R&D vs backyard "engineering"

As far as the Chicom turbos are concerned, wake me up when a set hits 200 k

Ah, You're correct. Blindly following OEM spec products is always the correct answer. Audi didn't make any other mistakes with the motor, so why would the oil lines be an exception...

I'm not faulting the OEM oil lines, but you can't argue that moving the oil supply line away from the manifold is going to do any harm.

300,000 miles on the chassis, not the motor or trans. Especially not the turbos.

[bmoreS4]

I'm so excited, do you have a build thread by chance? I'm shooting for 450whp on 91 but that might be optimistic. Having a conservative E85 tune done as well.

01.5 Stage 3 Build Progress Thread
http://www.audizine.com/forum/showthread.php?t=642905

[Shhmaudi]

Justin is the man, if anyone knows about 300k S4s its him.. All jokes aside hes very thorough and knows his stuff good luck with the build

[Drehmoment]

Ahh now we get it, you where taking shots at people because of a difference in preference..........classy.

Way to contribute.

I recommend you retreat to a safe space to heal your infantility.

[eagano]

Dropping the car off at Justin's Saturday, I will figure out a schedule with him so I can come up to help and speed up the process. Most likely weekends or after I leave the office week nights.

Justin did my PJK04 build just over a year ago. I helped out as much as I could. He does awesome work, knows these cars inside and out, and you can learn a hell of a lot from him just by being there.

[Peter1.8t]

Congrats on finally taking the plunge into crazy land.

It sounds like you've done plenty of research and parts gathering beforehand, which will help eliminate many of the unforeseen headaches that pop up. Probably the highest miles yet I've heard of someone going stage 3. 5 or 6 years ago when I converted mine over about 110k miles on the car I remember some people telling me it wouldn't last. All these years later and constantly driving the car hard, it still performs flawlessly and beats up on cars it shouldn't. Your build will be a testament to the b5s4 chassis.

[christianb5s4]

01.5 Stage 3 Build Progress Thread
http://www.audizine.com/forum/showthread.php?t=642905

Thanks for the link, I remember your thread but must have missed it when I searched. So awesome, did you end up using the silicone couplers and cutting the inlets or just running them as is?

Justin is the man, if anyone knows about 300k S4s its him.. All jokes aside hes very thorough and knows his stuff good luck with the build

That's for sure, he's done the timing belt and a wheel bearing on my car before this. I knew my car wasn't perfect but it was hilarious watching him walk around and point out everything that was missing or not OEM lol.

Justin did my PJK04 build just over a year ago. I helped out as much as I could. He does awesome work, knows these cars inside and out, and you can learn a hell of a lot from him just by being there.

Congrats on the build! I agree, I've done the vast majority of the work on this car but I know my mechanical limits and he's an encyclopedia of B5 S4 knowledge.

Congrats on finally taking the plunge into crazy land.

It sounds like you've done plenty of research and parts gathering beforehand, which will help eliminate many of the unforeseen headaches that pop up. Probably the highest miles yet I've heard of someone going stage 3. 5 or 6 years ago when I converted mine over about 110k miles on the car I remember some people telling me it wouldn't last. All these years later and constantly driving the car hard, it still performs flawlessly and beats up on cars it shouldn't. Your build will be a testament to the b5s4 chassis.

Thanks Peter, glad you chimed in especially because I love your car and videos especially since your car is a benchmark for reliable fast stage 3 builds IMO. These cars are very well built, if their weak points are addressed mechanically there is no reason these cars can't make it to very high miles. Mine is certainly no garage queen, unfortunately years of neglect for a lot of these cars (including mine) means lots of preventative maintenance will be required before even thinking about doing a build.

Heck, I've spent thousands on just OEM replacement parts alone but this car has yet to breakdown in the 2 years I've daily driven it or even have a single light on the dash over a year. B5 S4s have a very specific (read: addictive) character and charm to them that's hard to place a finger on, but it's certainly there.

[bmoreS4]

Thanks for the link, I remember your thread but must have missed it when I searched. So awesome, did you end up using the silicone couplers and cutting the inlets or just running them as is?

Thanks. ended up doing all new silicone.

[christianb5s4]

I am officially starting to feel guilty how many packages I'm having delivered at my parent's house now. Weeks of relentless car part deliveries.

[christianb5s4]

Injectors arrived today, so excited to start the build tomorrow. Does anyone see anything I'm missing on the parts list by chance?

[MikeyB3]

FINALLY. I cant wait to see this thing all finished. Beers afterwards.

[eagano]

Injectors arrived today, so excited to start the build tomorrow. Does anyone see anything I'm missing on the parts list by chance?

I was going to say fuel pump. But then I saw 044 from your first post:

Done during my ownership:

- New fuel level sender installed, confirmed Bosch 044 pump installed

Seems like a very solid build, can't wait to see how it turns out! Who's tuning it?

[02nms4]

Subscribed looking forward to seeing this done. Looks like a solid setup, just finished a ko4 build for my buddy a couple months ago, he dailys it without any problems and is hard on it with 224k and he couldnt be happier. Im hoping to have my stage3 build on the road by the end of the month as well. Also saw on another one of your threads your planning on going to wuste, I'm going to be in Vegas that weekend so I'm hoping to check it out if time allows good luck!

Sent from my SM-G925V using Tapatalk

[getslideways]

this is an example of how to step into the stage 3 arena correctly

[christianb5s4]

I was going to say fuel pump. But then I saw 044 from your first post:

Seems like a very solid build, can't wait to see how it turns out! Who's tuning it?

Thanks man! Blake over at Etspec (him and Daz worked together) is doing the tunes, going to have an E85 and 91 tune done but will start with 91 for now just to get the car broken in and sorted.

Subscribed looking forward to seeing this done. Looks like a solid setup, just finished a ko4 build for my buddy a couple months ago, he dailys it without any problems and is hard on it with 224k and he couldnt be happier. Im hoping to have my stage3 build on the road by the end of the month as well. Also saw on another one of your threads your planning on going to wuste, I'm going to be in Vegas that weekend so I'm hoping to check it out if time allows good luck!

Sent from my SM-G925V using Tapatalk

You should definitely stop by Wuste if you can, there are going to be a whole bunch of B5 S4s in our group coming out from Socal. Fingers crossed everything goes smoothly! Mileage is not a big deal with these cars if taken care of, one of the benefits of a well engineered chassis and drivetrain (not without its weaknesses I know).

this is an example of how to step into the stage 3 arena correctly

Doing my best, I've learned a lot on here and credit AZ and many helpful and knowledgeable B5 guys for helping me get to where I am today. Community is key here.

[christianb5s4]

So update, car is officially at Justin's. Got all the parts needed except for the injectors (thanks stupid USPS) and am ordered a few odds and ends along with Cinesnow's wastegate lines today as well. Going to be working on the car with Justin this weekend but he'll tear the car down this week so I can order anything needed prior to the weekend.