2000 S4 Project

[Kaane]

I was browsing the local craigslist and saw a 2000 S4 with a blown motor. Was listed at $3200, but chassis looked pretty clean, zero rust, texas car entire time. Timing belt snapped and motor was taken apart, heads were off and the shortblock had rust from being open for a year. So needs new motor. Interior was very clean, paint was good with only one tiny dent on edge of hood that can probably be PDR'ed. Car has APR Bipipe, Milltek Sport Exhaust and Stage 2 Tune of some sort. Ended up buying it for $2400, so not too bad.

Found a a6 2.7T engine with fresh timing belt water pump and valve cover gaskets, tensioner gaskets, just redone. Going to pick it up Friday. Not sure for the goals on the car yet. I was kind of an impulse purchase. I already have a 2002 Allroad, will see how it drives with the new motor.

Here are some pics.

[verymickey]

good luck, that is going to be a pretty fun project.

[MarlinFoundNemo]

Of course theres an American flag on the back of a German car in Texas haha

[R490]

Good deal! And that interior does look minty fresh, that passenger seat hardly looks used at all.

Sub'd.

[S4tech2]

Merica. Sweet car though I feel like you got a good deal.

[xuandatou]

Sub'd ! And looking forward to see a nice and clean B5 back to live !

[Kaane]

In the garage, started taking it apart. What a mess. Everything is coated in oil gunk. Lots of cleaning ahead. Since the heads are off, I am wondering if it is better to yank out the old motor without removing the transmission or yank it together.

[MarlinFoundNemo]

Together for sure. Unbolting CV's, trans mounts, linkage, and driveshaft wont take long.

[88ninety9]

When I pulled mine, I jerked the motor/tranny/subframe all as one. Was super easy. Just make sure to jack er up high

[Kaane]

Motor is out. While taking it apart, found the following.

Car has H&R front swaybar, upgraded rear sway bar end links, not sure on the rear sway bar. Bilstein B6 shocks, some sort of lowering springs. Braided Stainless brake lines. AWE DTS.

The A6 motor I was looking at did not pan out, so looking for another motor.

[b5329]

Looks like previous owner cared for the car and put in the money to buy quality parts. I approve of everything you did btw!

[Kaane]

Bought a new house and finally had some time to work on the car.

Got a low mileage engine from a 2002 Allroad, but it was automatic. Engine has new timing belt, new water pump, new valve cover gaskets. It was still pretty filthy, took forever to clean the oil pan and turbos. 5 cans of brake cleaner. The oil pan is the devil when it comes to getting dirt out of the crevices.

This is how it looked when i got it.





Removed the SAI pump and got 034 block off plates.



Block of Plates installed. New rear Main seal installed as well.



Axles needed some work, they were trashed. Joints still good though, so just clean and repack.





All taken apart.



All clean and done!



Clean oil pan :)



New clutch setup. TTV Racing Billet steel flywheel and B7 RS4 clutchkit.

[christianb5s4]

Great progress, love all the work you're doing. Amazing how much clutter the nasty SAI system creates.

[b7_Andy]

@Kaane Your project looks sweet! I'm about to pull my buddy's Allroad motor to replace his turbos. Can an OEM B7 RS4 clutch be used on a 2.7 motor? I'm thinking about getting a very similar S4 project on Craigslist to rebuild and sell it but already have two cars that need transmission work and my friend's car so it'd be too much at that point haha. Good luck finishing the car, your progress looks really good!


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[gahigalaba]

TTV makes a flywheel that will bolt onto the 2.7t and accept a b7 RS4 clutch and flywheel

[b7_Andy]

TTV makes a flywheel that will bolt onto the 2.7t and accept a b7 RS4 clutch and flywheel

So the B7 RS4 clutch only works on the 2.7 if you have the TTV flywheel?

[derek2079]

Looking good Kaane.

[Kaane]

So the B7 RS4 clutch only works on the 2.7 if you have the TTV flywheel?

Yes or another custom flywheel.

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[mauromj]

Yes or another custom flywheel.

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Beware of the TTV and B7 pressure plate with anything other than the stock B7 disk... If you try to install a 6 puck disk, your bolt heads will likely hit. I am in the process of finding a machine shop to counter sink the bolt holes so I wont have this issue.

[XLR8 Craig]

Wow looks like quite the project you have going in to see how it goes!

If you need any help looking for parts let me know.

Thanks,

Alex

[Kaane]

While waiting for some parts started refinishing the headlights. They were beyond bad.

Here is the before.



Here is after some some work.

[Kaane]

Took a break from the car to finally get one of these. Should be installed tomorrow.

[Corradovolksb]

Man I need one of those in my garage.

[Kaane]

Lift installed :) Moved my garage opener to the side, so now I can raise it all the way.

[Kaane]

I think the wheel bearings are shot a bit. 3 out 4 are like this.

[Cysco abt S4]

Good work
She's going to be a killer ride

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[19birel]

Great progress!

What did you do to restore the headlights? Mine look similar to how yours did, but not quite as bad.

[Kaane]

Great progress!

What did you do to restore the headlights? Mine look similar to how yours did, but not quite as bad.

I used sand paper to get the bad haze off about 4 different grits and then coated them with Spar Urethane mixed with mineral spirits. Fastest method for me.

[Kaane]

Got a lot of work done. Replaced front wheel bearings. Replaced all front control arms using the FCP Kit. Dropped the engine in finally.

Got a new battery and oil and fired it up :)

Can't drive it yet, since I lost the snub mount bracket and waiting for it to arrive. Also the tires are shot and replacements are in the mail.

Engine runs good, ran it with no coolant for a few seconds. Injectors were leaking from the seals, 2 of them. Grabbed new seals and should be good to go.

[Kaane]

Got some new tires and took the car for a spin. Engine runs good, only 1 code for 1 bad egt sensor. I used nefmoto stage 1 tune and modified it for my Bosch maf and tuned out the egts.

Finished the front suspension. Installed all new control arms.





Rear suspension was making a ton of noise and was a mess. Car had 1 mismatched shock. It has 3 bilsteins and 1 old rusted factory shock. Makes no sense. Even the spring was rusted and the rest of the suspension has zero rust...



Got a new spring from a friend and ordered a matching B6 bilstein shock. Rear wheel bearings were shot completely. It had also super noisy aftermarket sway bar end links. Started to take it all apart and stripped the fricking axle bolt. Had to weld a socket to it to remove it.



Finally I got it all apart. Ordered new Meyle HD swaybar endlinks, New tie rods and new axle boots. Deciding if I want to replace all the bushings or not.



Pressed out the old bearing and got new ones installed. No more noise, nice and tight.

[b7_Andy]

How's the car doing? Running strong?


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[gotboost]

Very nice project. If you don't mind me asking, what did you pay for the A6 motor?