Some back story:
I purchased the car back in February of 2014 from North Carolina. It was a well sorted 2001 B5 S4 Avant in Laser Red with a 6-speed manual transmission. Despite being an east coast car for pretty much its entire life, it was very clean, with minimal rust. Most importantly, ALL (and I mean ALL) maintenance was up to date, and it was a fairly freshly built car. It had a freshly rebuilt transmission, brand new BW K04s, and an OTS AWE fueling kit and tune (along with all supporting mods). It sat on a Bilstein/H&R cup kit and had Brembo/Porsche 18z calipers up front with the ECS rear brake upgrade. A very well sorted car, I had intended to drive it as it was. But as we all know, a car guy (and especially a B5 S4 owner) cannot stay away from touching or fiddling with the car. The car wouldn't stay like this for long.
Here's how the car looked like when I first picked her up. I was younger, and completely clueless to the adventure that was to come. I knew how to work on cars (I was only 16 at the time (not my first car)) but never something as complex or complicated as an Audi. I had prior experience on my dad's boosted E36 M3 and his 911, but it was very limited).
Brought her all the back to California from North Carolina. Unfortunately, I was too busy at the time so I just had the car shipped over.
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[/IMG]In the next year, I added a JHM SS and SSAC Twin1 Catback (Car came with AWE Downpipes). Nothing much, but everything was DIY'd (as I can only make so much money with a high school job lol) and started to prepare me for what was to come.
In the winter of 2014, I decided that it was time for more power. I upgraded to Bosch EV14 550cc injectors, an 85mm MAF, and got into contact with Aaron Walizer (aka STUKLR) for tuning. He dialed in the car and it ripped pretty hard (at least for 91). Eventually, I added methanol injection and tuned for it as well.
I also threw on a set of Bilstein PSS9 Coilovers to help sharpen the handling as well.
That's pretty much the end of the backstory. For almost the past year, the car has basically sat like this. The final setup was as follows:
- OEM BorgWarner K04 Turbochargers
- Bosch EV14 550cc Injectors
- Custom STUKLR Tuned on 91+Methanol
- 01E Transmission built by AA
- B5 RS4 LUK Clutch assembly with AWE LWFW
- Walbro 450 Fuel Pump
- Bilstein PSS9 Coilovers
- RS4 engine mounts
- Brembo/Porsche 18z front brakes with ECS rear brake upgrade
- 22mm Rear Sway bar
- AWE SMIC
- AEM W/M Injection system with Aquamist nozzles
- Misc. Mods such as Bi-xenon retrofit, tints, radar detector, etc.
- Basically all supporting mods that go along
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Fast forward to now, I just finished my first year of college. I'm also a somewhat more mature (lol!) 18-year old adult with responsibilities. With the combination of studying, working, and saving up and not touching the car modwise for the past several months, I suddenly had some extra cash saved up. I've always wanted to do an RS6/Big turbo style setup, but never actually thought I'd have the opportunity to do something like this. It'll also keep me nice and busy during the summer lol. I love how quickly K03/K04 turbos spooled (minimal lag) but always wished they didn't die off at higher RPMs. In addition, the car was due for some major maintenance (timing belt, coolant fresh, etc) so I decided to use that as an excuse to do a build. I bought a fast car, improved on what I could....NOW IT WAS TIME FOR ME TO BUILD A BEAST.
Over the past 6-8 months, I've done my research, enlisted the help of several close friends, and jumped on deals whenever they popped up on the classifieds. I have decided the following to be my final new setup:
- SRM K24/RS6 Hybrid Turbochargers
- RPM Rods
- Bosch FID 1000cc Injectors
- Walbro 450 Fuel pump
- 2.8 Cams
- Custom Tuning by STUKLR on 91, 91/meth, and E85
- AWE SMIC
- White Dog Racing Custom BiPipe
- AEM Water/Methanol Injection
- Southbend Stage IV Extreme Clutch with AWE LWFW
- Stern Motor and Transmission Mounts
- JHM Trio Shifter Package
- Gates/ECS Timing Belt Kit
- R8/2.0T Coil Conversion
- Modified Catless AWE Downpipes (changing flanges to RS6) and SSAC Twin1 Exhaust
- ALL Maintenance Done (rod bearings, gaskets, seals, etc)
- FCP Euro Front Control Arms
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I chose the SRM K24/RS6 hybrids because I wanted to lose as little of the spool that K04s are famous for. With the fact that I'm doing rods, limiting torque shouldn't be as big of an issue as stock block builds. I've seen E85 Stock Block K24 cars rip, so I can't wait to see what I can achieve. I will be doing ALL work (except machine shop work) by myself and with friends. This is the first time I've attempted something like this, so this will be interesting.
Mileage at the time of teardown was 136XXX. Car ran flawlessly up until teardown. My dad thinks I'm crazy for taking apart a perfectly running car I have spent so much time and love working on it. Oh well, you only live once.
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Last I finally pulled the engine and trans. Had some friends come over and we got it out. Honestly, it was super fun and wasn't too difficult at all
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[/IMG] Engine out!
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[/IMG]Obligatory group photo. I'm in the purple shirt. For 4 out of the 5 of us (only four of us are in the picture, one of my friends had to leave right before this) this was the first time we've ever pulled a motor on a car of any type. My friend laying on the floor has had 6 B5s and has pulled the motor several times prior. Can't thank Randy enough...
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This past week, I've been working slowly on the car. I'm out of class for the summer, so other than working and taking some summer classes, I've just been slowly working on the car.
Turbos were absolutely spotless. ZERO shaft play and ZERO dents on the fins. (The coolant on the driver's side turbo was from an exploded coolant hose haha). Once they are cleaned up, they could be mistaken for a pair of brand new turbos. I ran the car on a 22psi tune, changed oil every 5-7k using Mobil1 0w-40, and ensured proper warm up and cool down. They will be for sale soon.
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[/IMG]I wasn't too crazy about warm up/cool down either. I would cold start the car in the morning, let the revs settle, say under 3k/out of boost until the coolant was up to temp, and then tried to stay under 5psi (or out of boost whenever possible) until the oil registered 175 degrees. For cool down, I just took the last miles easy. I also pretty much hit redline/full boost almost every time I drove. This car was never babied, and never will be. What's the point of building a fast car if you're never going to use it?
Got the engine on the stand
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[/IMG]Valve Covers off. Looks pristine inside.
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[/IMG]Removed intake manifold
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[/IMG]Obligatory "I think I know what I'm doing" selfie
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[/IMG]Got the heads off. Minimal carbon buildup, and the factory hone/cross-hatching is still visible on the cylinder walls. The factory printing is still visible on the tops of the pistons as well. Basically looks brand new inside. Water/meth injection really helps keep things clean. The heads/valves are in great shape as well.
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[/IMG]As of today (6/18/16) (and writing of the thread) I have removed both heads, lower and upper oil pan, oil pump, timing belt, and a lot of random crap. Never realized how small the block actually is. It's hard to believe this motor made such a great sound and was the source of so many good memories over the past two years.
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[/IMG]Tomorrow is father's day, so I'll probably take a break and spend some time with my dad. I suggest you all do the same as well. Though he does enjoy this kind of stuff. I guess I get it from him.
I'm waiting on my turbos from Sean, but other than that everything seems to be going smoothly. Heads are going off to the machine shop next week; I'm still debating on whether or not I should do new valve seals (mine are flawless, and I know they can last a while). But then again, I might as well do them while the heads are off. Thoughts?
In the entire time I've had this car, I never had any major issues with it. I wouldn't hesitate to drive it cross-country on a moment's notice. After this build, I hope to keep it the same way. It just goes to show that if you keep these cars well maintained, they can go a long way.
I also will have a lot of "Stage 3" parts for sale, if you're interested feel free to inquire. I will be creating ads for the parts in a couple of weeks. If you're in need of something, I probably have it lol.
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Originally Posted by y3ti
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