My first AR

[ShelbyM3]

Well f$&k, boys! This weekend has felt like an extra gravity day that never ends. I found a major crack in the upper oil pan today. Explains why my subframe is sooo coated with oil, aside from all the other leaks that initiated this voyage to hell. Haha.

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Oil pickup has little eels hiding back in its depths

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Oil pump

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Looks like I get to convince my wife that I may as well rebuild the bottom end at this point. I mean, it’s what rod bolts once the upper pan is off? Ugh!


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[ShelbyM3]

Crisis adverted! Apparently I should wear my glasses more and that is casting flash. Sure feels like a crack and looked like there was an impact knick, but I’m relieved it’s not. It’s nice having a community to settle you down sometimes, haha.


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[rah253]

Any updates, progress or lack of it? ( i know family and babies have priority)Took a hiatus from the forums for a while but wanted to check how the battle was going.

[ShelbyM3]

Thanks for asking Rah! You never really think people pay a ton of attention, haha.

I definitely have taken a hiatus. I lost motivation due to lack of funds and feeling secure financially at the time, my demanding healthcare job with the pandemic, and then my son taking all of my attention. My wife also work healthcare and we more or less single parent as ships passing in the night because of schedules and my on call schedule. That said, I’ve not given up. I’ve been slowly accumulating more parts over time.

I got my downpipes in, a couple other miscellaneous things, and most recently my TTV single mass flywheel with B7 RS4 clutch kit in. I’m slowly feeling reinvigorated. Hopefully in the near future I’ll get the blessing to submit my FCP order for my turbos, and all the other little things that nickel and dime an almost 20 year old car, and get this show back on the road!

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[rah253]

Thanks for asking Rah! You never really think people pay a ton of attention, haha.

I definitely have taken a hiatus. I lost motivation due to lack of funds and feeling secure financially at the time, my demanding healthcare job with the pandemic, and then my son taking all of my attention. My wife also work healthcare and we more or less single parent as ships passing in the night because of schedules and my on call schedule. That said, I’ve not given up. I’ve been slowly accumulating more parts over time.

I got my downpipes in, a couple other miscellaneous things, and most recently my TTV single mass flywheel with B7 RS4 clutch kit in. I’m slowly feeling reinvigorated. Hopefully in the near future I’ll get the blessing to submit my FCP order for my turbos, and all the other little things that nickel and dime an almost 20 year old car, and get this show back on the road!

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Hey that is nice to see you are still going with it! it takes time and with both of you being in Healthcare, this Covid era and the baby it makes sense to put it on the back burner, as well as the financial aspect without a doubt. We are gluttons for punishment with those C5 (i have two of them...). I still remember this car in Puyallup when i was looking for one! i ended up going to California to pick my 6 speed manual one. Your clutch set up is what i will be doing on mine once it decides that it is time for it, and since the trans will be out, no better time for down pipes and stage 2 at that point! Keep the updates coming, i enjoy it!

[jbain2]

Thanks for asking Rah! You never really think people pay a ton of attention, haha.

I definitely have taken a hiatus. I lost motivation due to lack of funds and feeling secure financially at the time, my demanding healthcare job with the pandemic, and then my son taking all of my attention. My wife also work healthcare and we more or less single parent as ships passing in the night because of schedules and my on call schedule. That said, I’ve not given up. I’ve been slowly accumulating more parts over time.

I got my downpipes in, a couple other miscellaneous things, and most recently my TTV single mass flywheel with B7 RS4 clutch kit in. I’m slowly feeling reinvigorated. Hopefully in the near future I’ll get the blessing to submit my FCP order for my turbos, and all the other little things that nickel and dime an almost 20 year old car, and get this show back on the road!

IMG_4403.jpg
IMG_4402.jpg


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Hey that is nice to see you are still going with it! it takes time and with both of you being in Healthcare, this Covid era and the baby it makes sense to put it on the back burner, as well as the financial aspect without a doubt. We are gluttons for punishment with those C5 (i have two of them...). I still remember this car in Puyallup when i was looking for one! i ended up going to California to pick my 6 speed manual one. Your clutch set up is what i will be doing on mine once it decides that it is time for it, and since the trans will be out, no better time for down pipes and stage 2 at that point! Keep the updates coming, i enjoy it!

I’ve run this same clutch flywheel setup on a couple cars. My old C5 allroad and my current 2.7swapped B7. It’s perfect for KO4 framed and smaller. OE feel and drive ability with reliability.

Keep it going OP!


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[Bloomquist]

I’ve run this same clutch flywheel setup on a couple cars. My old C5 allroad and my current 2.7swapped B7. It’s perfect for KO4 framed and smaller. OE feel and drive ability with reliability.

Jbain erase your PMs ;)

[C_lebAR03]

This build thread is a massive kick in the butt to start playing with my AR, my fiancé has now stopped dailying it and now back in my possession haha


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[rah253]

I’ve run this same clutch flywheel setup on a couple cars. My old C5 allroad and my current 2.7swapped B7. It’s perfect for KO4 framed and smaller. OE feel and drive ability with reliability.

Keep it going OP!


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Nice to know, i will be in the process to add another tune and down pipes this winter and most likely that setup. I do daily drive it unless i am on the bike so i do need that daily reliability.

[ShelbyM3]

Hey that is nice to see you are still going with it! it takes time and with both of you being in Healthcare, this Covid era and the baby it makes sense to put it on the back burner, as well as the financial aspect without a doubt. We are gluttons for punishment with those C5 (i have two of them...). I still remember this car in Puyallup when i was looking for one! i ended up going to California to pick my 6 speed manual one. Your clutch set up is what i will be doing on mine once it decides that it is time for it, and since the trans will be out, no better time for down pipes and stage 2 at that point! Keep the updates coming, i enjoy it!

Great minds think alike!That was part of the delay for myself, I may as well “while I’m in there” and that bill racked up quickly.


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[ShelbyM3]

I’ve run this same clutch flywheel setup on a couple cars. My old C5 allroad and my current 2.7swapped B7. It’s perfect for KO4 framed and smaller. OE feel and drive ability with reliability.

Keep it going OP!


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I’ve read nothing but good things about this setup. Thanks for the feedback and confirmation. I’m excited to feel the difference. Also, you can’t really beat the price of a LUK B7 RS4 clutch for future replacements.


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[ShelbyM3]

This build thread is a massive kick in the butt to start playing with my AR, my fiancé has now stopped dailying it and now back in my possession haha


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Thanks so much! I appreciate the kind words. And that sounds a lot like how my Allroad started. Wife’s 540i wagon got totaled and the AR became her daily and I started tinkering with it. We then got an Alltrack for her and my AR went under the knife which is when I found my damaged journal bearing and the saga began. Haha.


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[ShelbyM3]

Well there’s not a ton of info out there, but I’ve had a couple guys say it’s possible. I pulled the trigger on billet subframe bushes. I’m not sure if I’m going to remove the locating pin from the spacers or drill a hole in the bushes, but I’m giving it a shot. I also kind of forgot I got the VAG tool for subframe bushing removals.


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[ShelbyM3]

Labor Day sale at FCP Euro. Pulled the trigger on 90% of my wishlist. Now I can hardly wait! I better get to cleaning and getting my ducks in a row.


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[nubiannupe]

Labor Day sale at FCP Euro. Pulled the trigger on 90% of my wishlist. Now I can hardly wait! I better get to cleaning and getting my ducks in a row.


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Hey... are you going to PWL this month? I've been following your thread for some time now, and wouldn't mind seeing your baby up close!

[ShelbyM3]

Hey... are you going to PWL this month? I've been following your thread for some time now, and wouldn't mind seeing your baby up close!

Thanks! I was just talking with my better half about this. She works and I’m on call so I don’t think we’ll be making an appearance this year. Allroad is still in pieces, too, if that’s the baby you’re referring to, haha.


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[ShelbyM3]

FYI, oil pump chain tensioner is No Longer Available. I’ve had 2 orders canceled recently. With help from another member I ordered one from Latvia off Ebay…I hope it’s legit haha.


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[rah253]

FYI, oil pump chain tensioner is No Longer Available. I’ve had 2 orders canceled recently. With help from another member I ordered one from Latvia off Ebay…I hope it’s legit haha.


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NLA is the trend lately when it comes to our dear C5's i swear. My A/C has not work on my RS6 due to 3 actuating motors/ air recirculation flap positioning motors and out of 3, 2 are NLA... The love for these cars is going to ruin me. I started parts bins for both lol, the just in case it breaks method! Thank you ebay and other countries for keeping some stuff alive.

[ShelbyM3]

NLA is the trend lately when it comes to our dear C5's i swear. My A/C has not work on my RS6 due to 3 actuating motors/ air recirculation flap positioning motors and out of 3, 2 are NLA... The love for these cars is going to ruin me. I started parts bins for both lol, the just in case it breaks method! Thank you ebay and other countries for keeping some stuff alive.

It’s brutal. Over the last year I’ve been compiling parts and saving funds and just slowly watched as parts become NLA. A small piece of me died every time, haha.


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[ShelbyM3]

I was actually able to find one in Tucson with the help of an Audi parts guy here in town. I ordered it up just to be safe. I may end up having an extra once the EBay one arrives at the end of October, haha. If anyone else is looking Brunswick Volkswagen in Ohio has one, but that may be the last in the states.


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[rah253]

It’s brutal. Over the last year I’ve been compiling parts and saving funds and just slowly watched as parts become NLA. A small piece of me died every time, haha.


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I hear that. The latest one the RS6 did was to get a wear hole from a bracket in the radiator. Found the last warm weather package radiator available at a Audi dealership in New Jersey for it, $1800... i took it, and i also kept the old one, i am looking into how to fix it so that bill does not happen again!

- - - Updated - - -

I was actually able to find one in Tucson with the help of an Audi parts guy here in town. I ordered it up just to be safe. I may end up having an extra once the EBay one arrives at the end of October, haha. If anyone else is looking Brunswick Volkswagen in Ohio has one, but that may be the last in the states.


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extra is better then NLA!

[ShelbyM3]

Welp, life is fun sometimes. I love being a dad. It’s fantastic. I miss my wrench time greatly, but it’s here when I can get to it. Some things can wait. In other news, my wife is 5 months pregnant………..this will be finished in 2026…

Offered to do a friend a favor and cleaned up some old light fixtures in the US Cleaner so I decided I’d seize the cleaning solution opportunity and clean my fuel injectors and oil pan. Turned out nicely. Nice sunny Sunday. It felt good.

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[rah253]

Welp, life is fun sometimes. I love being a dad. It’s fantastic. I miss my wrench time greatly, but it’s here when I can get to it. Some things can wait. In other news, my wife is 5 months pregnant………..this will be finished in 2026…

Offered to do a friend a favor and cleaned up some old light fixtures in the US Cleaner so I decided I’d seize the cleaning solution opportunity and clean my fuel injectors and oil pan. Turned out nicely. Nice sunny Sunday. It felt good.

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Congratulations on the new baby, pretty awesome to be a dad. Mine are all grown now but i would not trade those days for anything. now we just work on cars together, amazing the amount of extra time you receive when they leave the nest lol. They are never too far as they always come by and work on their own cars in my shop!

Nice work on the cleanup btw, and regardless of the time frame, progress is progress! it will be amazing once completed. You make me want to get an injector tester now haha. hope all is well!

[ShelbyM3]

Nice work on the cleanup btw, and regardless of the time frame, progress is progress! it will be amazing once completed. You make me want to get an injector tester now haha. hope all is well!

Thanks on the congratulations! I never knew being a parent would be as rewarding as it has been. This late in my life I thought that ship had sailed.

Injector tester is awesome! Definitely consider it. Relatively cheap off Amazon, came with adapters for break cleaner flush and actually fit the injector, and worked wonderfully. I also sourced a pigtail to have a solid connection with the injector. After a 15 minute US bath I ran some break clean through them for about 30 seconds on unlimited pulse mode and the spray pattern is good as factory, (that's what my bucket was for I was spraying into it.)

[ShelbyM3]

Tis’ the season, for nesting. Got a new job when I got a second boy. Life is way different. I have some time again. I did some things.

Wastegate lines. I have no idea…I just went for it. It’ll work for now. Not much I could find on this that wasn’t overkill for what I’m doing.

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Next I replaced the shoes on my cam chain tensioners, cleaned the tensioners out really well, and put in some assembly lube.

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I think I dodged a bullet on that last shoe. It was about to lose a tip.


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[ShelbyM3]

Found out half my lifter buckets were frozen. Womp. Today I did the pain staking process of tearing apart the hydraulic lifters and cleaning them out then reassembling them. First time for that. It was fun, but my thumbs are still sore.

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Other project with my teenager. He’ll be 17 soon. VAG family.
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[ShelbyM3]

I stayed up late and knocked out the cam install. The passenger side jumped on me as I set the cams. Looks like it’s still in time.

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[rah253]

Found out half my lifter buckets were frozen. Womp. Today I did the pain staking process of tearing apart the hydraulic lifters and cleaning them out then reassembling them. First time for that. It was fun, but my thumbs are still sore.

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Other project with my teenager. He’ll be 17 soon. VAG family.
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Wow great work on all, that is such a time consuming and tedious job but the end result and self satisfaction cannot be beat. I honestly gave up on big jobs like that, not sure if it's my age bracket, time or patience lol. i still enjoy taking apart the old bug, but they are so simple to play with! Your teenager looks to have a great project at hand, keeping it VAG! 2.0 or 1.8T?

[ShelbyM3]

Wow great work on all, that is such a time consuming and tedious job but the end result and self satisfaction cannot be beat. I honestly gave up on big jobs like that, not sure if it's my age bracket, time or patience lol. i still enjoy taking apart the old bug, but they are so simple to play with! Your teenager looks to have a great project at hand, keeping it VAG! 2.0 or 1.8T?

Thanks! This was never planned, it started as a weekend valve cover gasket job and ended with a cracked intake cam journal and an engine pull. Then the “while I’m in there” bit me and here I am. Haha!

The Jetta is actually a 1.9 TDI. It’s been a great project for him to get a taste of wrenching and rewards after hard work.


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[C5S6]

Other project with my teenager. He’ll be 17 soon. VAG family.

Awesome! I've been doing the same with our daughter...also 17 soon, but she's already into fixer-upper / flip#3.

[rah253]

Thanks! This was never planned, it started as a weekend valve cover gasket job and ended with a cracked intake cam journal and an engine pull. Then the “while I’m in there” bit me and here I am. Haha!

The Jetta is actually a 1.9 TDI. It’s been a great project for him to get a taste of wrenching and rewards after hard work.


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It's always how it starts lol, I did a few of those and the last one I ended up giving up on my big bumper MK2 GTI 16V, and regret it to this day! Nice on the Jetta great engine, pretty much bullet proof if you keep it maintained, great way for him to learn and earn. I did the same with my kids.

[ShelbyM3]

Got the bottom end torn down, off the stand, and ready to replace the rear main and front crank seals.
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Wow! Look at those grooves on the oil pump tensioner shoe! It’s down to the bubbles in the plastic from the mold! Definitely needed replacing. Glad I sourced TWO!
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[ShelbyM3]

Rear main is off. Snug fit!
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This explains the coolant mess. Pressure build up in the block’s coolant passages from a sand box! Holy crap! This also explains why I had to poke the drain with a pick to get it to drain when I was pulling the engine and trans.
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Go do a coolant flush! That is all for now.


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[ShelbyM3]

Spring cleaning. I’m so sick of cleaning. I killed a big patch of grass in the yard. I’m in trouble. On a better note, Cougar Chemical makes an awesome wheel cleaner. Just my opinion. I used this stuff to clean off my B8 S4 wheels I’ve neglected and years of dirt, oil, and grease build up off Allroad engine parts. Check it out.
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Cleaned:

Need to source new fittings and repair swaybar mounts.
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Before a US bath
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After-light skim of oil on parts
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I love that thing!

Some of the things
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Gross
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Pretty stoked on these!
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I found the hidden compartment to my throw out bearing…
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[ShelbyM3]

Transmission
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After
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Almost all of my turbo piping was siliconed together. Please don’t do this. Buy o-rings or replace the proper coupler. Thanks.
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[ShelbyM3]

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I didn’t get a ton of pics of everything, but here’s the upper pan. Good, but not great.
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[ShelbyM3]

Block prep- FML I’m over cleaning!

Rear main and oil distribution block in for positive progress vibes…
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Anyone know where to find this afterun coolant pump check valve or have a good solution for replacing it? #078122351A. Mine works about 90% based off garden hose pressure. I cleaned a bunch of chunks out of it and my entire crossover piping.

I’m not paying $250 for the valve with the 2 hoses attached. #078122349A. I want to relocate the afterun pump, but I’m not there yet. Links would be appreciated, I have done a little research based on S4 stuff a while ago.

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[ShelbyM3]

Sunday was a failure. Frustratingly, I carved out time during naps and feedings to seal up the bottom end. 3 steps in and I roll the crankshaft seal. Womp.

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Front flange came back off and sure enough…thank goodness for that lifetime warranty.
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[ShelbyM3]

Front crank seal installed. Glad I went with PTFE after doing more reading. I’m pretty sure I had one originally.
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Upper oil pan, new tensioner, pump and bits, and some odds done!
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I also did a thing. I totally botched it, but they are what they are. First time wrinkling. I’m not going to stress over them.
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[ShelbyM3]

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Time to flip it!


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