My 170K SRM K04 Stage 3 Build

[big_jerm]

My car has been stage 2 for about 1 year now and about 2 months ago my boost levels dropped off like crazy. I had no power and made about ~3psi. Then randomly my exhaust note completely changed. The car became raspy and crazy loud, it sounded horrible. So i had a feeling the cats had started to clog and fall apart. So i bought some SSAC downpipes and last Saturday I began the process of swapping them. After 5 hours, i got the drivers side downpipe out. I reached up and felt very little shaft play (yay). Then I found my boost problem. My drivers side wastegate was wide open. I looked to the side of the turbo and sure enough the linkage to the valve was snapped in the middle. Dont ask me how i managed that but i did. So after staring at the problem for awhile and trying to decide what I was going to do i decided the only way to get enough room was to pull the motor. And theres no way i was going to pull the motor and not do the turbos. So my stage three build began.

[big_jerm]

Saturday night I took a trip to my aunts house, my late uncle was a little bit of a collector *cough* hoarder. And of coarse she had a harbor freight shop crane still in the box. Snagged that from her and set it up Saturday night.



Then sunday morning I got to work. had to run to a hardware store for some bolts to pull the motor. (Got to ride my GSXR 750 ) Then I began the process. I followed this thread Here
It was extremely helpful. And honestly the process of removing the engine wasnt bad at all. Probably the most relaxed ive ever been working on a car. The motor came out after ~8 hours. Which i think is pretty good considering this was my first time ever pulling a motor and i did it by myself except for some help from dad when i was actually pulling the motor out. I was so surprised when i got to the heater core and the hoses almost fell off when i took the clamps off. I was fully prepared to fight with them until the core broke. Thankfully that wasnt the case. The biggest problem i ran into was the passenger motor mount. When i put a wrench on it the bolt just spun. What a surprise the mounts broken..

But after some clever drill work I freed the mount in about 5 minuets. And that was about the only snag. oh except forgetting the second shifter linkage. opps. "why isnt the motor moving at all.. ohhh, opps." Thankfully nothing broke.

Here was some photos from the pull.

















And heres the problem that started all this..

[Bordom]

Coulda welded that biotch back together. Interested on seeing more

Everything graciously mispelled by Android

[getslideways]

Do you already have the SRM turbos in hand? If not, hope the car is comfortable sitting on jackstands for a long while lol

Glad you are enjoying your stage three build, and thanks for sharing it with us

After this, you will likely be able to pull a 2.7t out in under 2 hours

[big_jerm]

Coulda welded that biotch back together. Interested on seeing more

Everything graciously mispelled by Android

with where the linkage was it would have been impossible to weld in the motor. and once that motor was coming out I wasn't putting those baby k03s back in. they will soon become a nice lamp

[big_jerm]

Do you already have the SRM turbos in hand? If not, hope the car is comfortable sitting on jackstands for a long while lol

Glad you are enjoying your stage three build, and thanks for sharing it with us

After this, you will likely be able to pull a 2.7t out in under 2 hours

I don't have them yet but I talked to Sean at SRM and he told me they would ship in like 2-5 days. but it doesn't matter either way I wasn't going to put it back together with a broken wastegate. and I already had so much stuff taken off that would have had to come off for the motor pull anyway. hopefully it doesn't take too long for them to show up! I'm already getting antsy to drive it!

hopefully I don't have to pull my 2.7 again for a while haha

[Bordom]

Yeah, SRM is infamous for the "it'll ship in a few days" excuse, and people wait close to 3 or so months for their products

Everything graciously mispelled by Android

[Wagonholic]

Nice to see another build! Good luck! Always a nice feeling to have more power.

I ordered several items from Sean/SRM back in early May. Turbos showed up at the end of June, as for my injectors....well I'm still waiting for them. "They'll be shipped in 2-5 days" really means "I'll ship them in 2-5 weeks (if you're lucky) after you constantly ask me if they've been shipped or not." Hopefully all the increased power makes it worthwhile ;)

I'll be following this build!

[big_jerm]

haha dang, hopefully I have better luck with them. it was either f21s or the srm k04s and I went with srm but hopefully that was the right choice. I'll hafta bug them till they are shipped.


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[f4m0u5]

Very nice! Good luck with evrything! I waited 5 weeks for m5 f21s to ship, but should be worth the wait!

Flyboy has some tte550s for sale.(a little more pricey tho) Maybe you can bug him for the f21 mixed flows he has lol

[big_jerm]

Downpipes are here!



The guac was good!



So late last night I pulled the transmission off! To my surprise all the bolts were marked with red sharpie and the clutch and flywheel looked to be in good shape. I start examining the flywheel and realize it is not stock and looks to be a lightweight one. I havent been able to figure out what brand it is but i believe its NGP or AWE.



Any ideas?


Photo of my daily



Then this afternoon I got the turbos off. They had much more shaft play then i first thought. Although i have never felt a turbo before so i have nothing to compare it too.




You can see the fins have a few marks. Turbos ate something small maybe? Anyway.



Both of those greasy things are out. Time now to focus on cleaning up the engine and bay. Tomorrow the clutch and valve cover gaskets come in so ill start on the valve covers at some point this weekend!

Dirty motor. Was leaking coolant and oil. VC gaskets were done about 3 years ago but im gonna redo all the seals. No point in not doing it.



Oh and here were my motor mounts... seen better days!

[getslideways]

I ordered several items from Sean/SRM back in early May. Turbos showed up at the end of June, as for my injectors....well I'm still waiting for them. "They'll be shipped in 2-5 days" really means "I'll ship them in 2-5 weeks (if you're lucky) after you constantly ask me if they've been shipped or not."

That is the exact reason I asked the OP if he already had the SRM items in hand, and if not, to ensure the car was comfy on the jackstands for a good long while

I'll hafta bug them till they are shipped.

Unfortunately you probably will have to

[Wagonholic]

That's an AWE flywheel. Looks exactly like mine.

If you email them they can get you a new friction surface and flywheel bolts (TTY, must be replaced)

[big_jerm]

yeah, I'm really hoping I get them in a non ridiculous amount of time! have other stuff to work on in the mean time!


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[big_jerm]

That's an AWE flywheel. Looks exactly like mine.

If you email them they can get you a new friction surface and flywheel bolts (TTY, must be replaced)

I thought it might be awe. did yours have any markings anywhere? and I'll have to email them about that cause I defiantly want to replace that surface!

thanks!


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[Wagonholic]

I thought it might be awe. did yours have any markings anywhere? and I'll have to email them about that cause I defiantly want to replace that surface!

thanks!


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Mine did have an AWE logo stamped on it, but it's the exact same thing as an AASCO flywheel, which would probably have no logo. In fact, if you order the replacement surface friction disk, it gets drop shipped from AASCO.


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[Wagonholic]

Also, what type of clutch kit are you planning to go with?


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[big_jerm]

Also, what type of clutch kit are you planning to go with?


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Rs4. I actually just got my clutch kit from ecs this morning.


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[Wagonholic]

Rs4. I actually just got my clutch kit from ecs this morning.


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Excellent choice. I ran a plain old LUK B5 RS4 clutch kit (with the standard disk) on my K04 setup (with meth). Never slipped, hooked up on every single launch/NLS, and was super easy to drive. When I removed it it was in excellent shape still, and it's actually going to be used in another car now because of its condition :).

People underestimate the RS4 kit; truth is, it's still one of the best options up there up to K04 power.


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[big_jerm]

Excellent choice. I ran a plain old LUK B5 RS4 clutch kit (with the standard disk) on my K04 setup (with meth). Never slipped, hooked up on every single launch/NLS, and was super easy to drive. When I removed it it was in excellent shape still, and it's actually going to be used in another car now because of its condition :).

People underestimate the RS4 kit; truth is, it's still one of the best options up there up to K04 power.


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thank you! I actually had a buddy convince me to get it. he has done way more research for a stage 3 build. I honestly didn't start looking into this until last weekend. saw my motor had to come out and made the decision. so in talking to him he told me that they are way underrated and that it would be a great choice. and now that I have my rs4 one I'm starting to think that the clutch that was in the car was an rs4 one already. it's in very good condition and looks almost identical. need to compare the part numbers and check! either way I'm putting the new one in but maybe I can sell the used one and remake some money if it's still in decent shape! it would kinda surprise me for the previous owner to have spent the money to replace the flywheel with an aftermarket lightweight one but not upgrade the clutch.


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[big_jerm]

the piles of parts is getting bigger!!


kinda bummed, throw out bearing was broken in the box




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[Tjtalan]

Cant tell from that photo but if that is a plastic bearing I would get a metal one. I used a plastic on a stage lll build and it disintegrated after 3K haha.

[Wagonholic]

RS4 and S4 clutch use the same organic disk, the only difference is the pressure plate. RS4 has higher clamping force. Compare part numbers.

Don't forget to set the SAC before install.

Bummer on the TOB, probably should contact ECS about that. That TOB works fine on an RS4 pressure plate; only when going to the aftermarket non-SAC plates is an extended/metal TOB necessary. My standard TOB was perfectly fine when I pulled the clutch.

[big_jerm]

Didnt get as much accomplished this weekend as I wanted to but it was so hot I decided to ride my GSXR instead. But I got started on cleaning the engine bay and wow was it dirty. Used a whole bottle of de-greaser and had to use some steel wool to really clean up some areas.

Before:



After: (Not quite finished, but its a start)



Then i pulled the wiring off the engine. Up until this point i have been super comfortable with everything, However removing the whole wire harness and then all the vacuum hoses makes me a little nervous. It seems like it should go back together pretty easily but it still makes me a little nervous.

I wish i had the money to get the valve covers powder coated but ive already spent too much money ha. So im gonna rattle can them. I know it wont be as durable but hey for $9 if it lasts a month ill be happy. But i think I want to go with a burnt copper look for the y pipe and the valve covers and then black for the intake manifold. Here is a can I found at autozone today that I think im going to go with!

[getslideways]

/\ prep prep prep

The more prep work you do to the valve covers and pipe, the better your chances of it sticking around for a while

[CJ_]

I used the VHT wrinkle paint and VHT header paint for the valve covers and manifolds. Both you need to cure in the oven, but they are both very durable and have no chips or anything after 5-6 months

[christianb5s4]

All in the prep, make sure you clean the crap out of whatever you're spraying. I used Duplicolor Ford gray engine enamel and it turned out great and still looks awesome over a year later, just needed to make sure the part was clean first.

[big_jerm]

I used the VHT wrinkle paint and VHT header paint for the valve covers and manifolds. Both you need to cure in the oven, but they are both very durable and have no chips or anything after 5-6 months

All in the prep, make sure you clean the crap out of whatever you're spraying. I used Duplicolor Ford gray engine enamel and it turned out great and still looks awesome over a year later, just needed to make sure the part was clean first.

I'm glad to hear everyone else is having good results with spray painting them! I'm certainly going to take my time with it. make sure it's nice and clean.

Ordered my MAF housing, accordion hose replacement, and the 040 drop in fuel pump kit from 034 last night! Free shipping weekend for the win!


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[big_jerm]

Finally removed the intake manifold and fuel injectors and fuel rail. Manifold and under it was nasty. Worked on cleaning up the engine A LOT!



I removed the bottom opening of the manifold and now im struggling to find the gasket online. If anyone knows what part number or where i can get it that would be great. Its the square opening on the bottom.

Its pretty nasty inside and out:





Heres the right side of the top of the oil pan, not cleaned yet...



Heres the left side after 25 minuets of cleaning...




Still have a lot of work to do on cleaning. And now i need to find that gasket!

[big_jerm]

Injectors ordered tonight as well!

[big_jerm]

Did some more cleaning, pulled the valve covers. everything looks good under the covers. now is there anything I can use to clean under there? like brake parts cleaner? I plan on flushing the motor with my old stashes of oil since I'm supposed to used a different kind with the srm turbos. but is there anything I can use to spray down the whole area and rinse the old oil and any debris that fell in when I pulled the covers?


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[Robsa6]

Excellent choice. I ran a plain old LUK B5 RS4 clutch kit (with the standard disk) on my K04 setup (with meth). Never slipped, hooked up on every single launch/NLS, and was super easy to drive. When I removed it it was in excellent shape still, and it's actually going to be used in another car now because of its condition :).

People underestimate the RS4 kit; truth is, it's still one of the best options up there up to K04 power.


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Shout out to Wagonholic for the quick shipping and good price on said RS4 clutch! it is getting ready to go in my stage 3 A6! Good luck with the build

[big_jerm]

more parts in!



still waiting on SRM for the turbos. getting kinda pissed off that I haven't heard back or seen the order yet. starting to seem like what everyone else was saying is true. probably going to have to cancel that order and buy f21s if I don't get a response soon. Need to get this thing back together.


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[f4m0u5]

more parts in!



still waiting on SRM for the turbos. getting kinda pissed off that I haven't heard back or seen the order yet. starting to seem like what everyone else was saying is true. probably going to have to cancel that order and buy f21s if I don't get a response soon. Need to get this thing back together.


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F21s were about a month to ship to me but they are worth the wait.i was in sme exact perdiciment as u but a month ago lol. 1 turbo died pulled motor and ended up waiting s month and am in the middle of finishing up the motor install. If ur looking to do somthing asap id go buy the used turbos from flyboy i talked about before. They are def a little more pricey but suposed to be superior quality

[getslideways]

still waiting on SRM for the turbos. getting kinda pissed off that I haven't heard back or seen the order yet. starting to seem like what everyone else was saying is true. probably going to have to cancel that order and buy f21s if I don't get a response soon. Need to get this thing back together.

Sorry to hear, this seems to be yet another unfortunate example of the direction SRM is going sadly

[Zba]

more parts in!

still waiting on SRM for the turbos. getting kinda pissed off that I haven't heard back or seen the order yet. starting to seem like what everyone else was saying is true. probably going to have to cancel that order and buy f21s if I don't get a response soon. Need to get this thing back together.


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Call or send an email. The squeaky wheel gets the grease

[big_jerm]

I talked to them yesterday and Sean was on vacation for a couple days so he said he would ship them today which they did! so I'm glad SRM shipped them out sooner than I was thinking they would! can't wait to get them and see what they can do! ecs received my clutch and they are going to be hopefully shipping my replacement soon!


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[big_jerm]

So this weekend I painted all my covers and intake manifold. and dam did they come out good.





Then I went ahead and did the vc gaskets and reinstalled everything! was pretty annoyed cause I kept forgetting stuff and I put the intake manifold on and off 3 times haha. but after I got everything on I there I threw the y pipe on as well to get a nice look!






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[zatch_303]

love the color! nice progress so far.

[big_jerm]

love the color! nice progress so far.

thanks! I feel like the photos make it look more gold then it really is. but regardless I love the color!


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