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  1. #1
    Established Member Two Rings
    Join Date
    Aug 29 2017
    AZ Member #
    405950
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    PWN

    Intro and build thread in one

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    Hello all Audi and B5 owners, I'm pleased to me a member of this masochistic group. I say this because for the love of anything holy, why would any SANE person LOVE working on these cars? LOL

    Small into about myself. I simply love cars and some of my friends say that I have too many of them yet I say that I don't have enough. All of my true car friends have Audis ranging from an allroad to a S2, I think (My BMW background is showing), so I decided to join the club. After looking at all the models and knowing how much I want to spend, I decided to get the B5 S4 (joke's on me right?!?!?! LOL).

    Now onto the main event, the car. After months of searching WA for a decently priced and looking B5 and not finding any, I decided to open the search to Oregon. I saw a few but most of them have body damage and that's a 100% no from me. Then it happened, I saw one that I can actually work with right here in WA. Silver ext., black int., but high miles, 196K. But honestly at this point, I did not care. So after some, very little haggling, the female seller and myself settled on a fair price due to sentimental value, which I do understand.

    Here she is (little do I know that I should have taken more pics of it as she'll NEVER be this virgin again):
    Outside Audi Pic 1.jpg

    I really like the car and it drove well, but it was SLOW!!!! I have an Acura Integra and this twin turbo Audi felt no different. Plus, during some pulls, my friend's Allroad ran away from me so fast, it looked as if I was in reverse. So after receiving enough azz wooping, I said enough is enough and decided to tune it.
    What a world of difference. The K03 woke up and the car came alive. This is what I was expecting from the start.

    But as they say, all good things comes to an embarrassing halt due to my stupidity. I changed all the fluids but didn't do the belts, serpentine or timing. Yes, shoot me now. What's funny is that the car even warned me in a way.

    When driving one day, the steering suddenly went stiff and I thought that the engine went out, but it was running, so I knew that it had to be the serpentine belt. I went to a friend's shop and this was the culprit:
    Broken aux belt tensioner.jpg

    Right then I should have done the timing belt, but no, the jedi stupidity force was strong and reigned supreme as I simply fixed the aux belt tensioner and continued to drive the car around. I even went as fast as buying a new exhaust.
    Then you guessed it, coming back from putting on the exhaust, the car DIED while cruising to a stop light and refused to start. With the stupidity force still with me, I tried to start it but it wouldn't even crank.

    So it was towed away and I have never driven it since. What was the culprit you ask? Why the belt tensioner pulley decided to become a donut, that's why:
    destroyed pulley.jpg

    So to every one out there, for the love of anything holy, don't procrastinate and change everything on a new to you car.

    The engine swap will be in the other posts. Thanks for reading.

    I'm working on the picture hosting issue.
    Last edited by SoundEfx; 06-11-2018 at 03:02 PM.

  2. #2
    Established Member Two Rings
    Join Date
    Aug 29 2017
    AZ Member #
    405950
    Location
    PWN

    So the build starts here. I miss driving the car so I decided to simply get the car running again. Unfortunately all of the local audi engines are in pieces but sold for really cheap, so I bought a spare block which I plan to completely build, but more on that later. WAY LATER....

    I found a few on the internet and decided on one before the searching drove me into 100% insanity. But as luck would have it, the engine they sent looked HORRIBLE with rust on almost everything. So I decided to use it as a learning tool. It's from an auto, so there were more wires and hosing than the manual counter part. But the dilemma of taking out the broken engine still loomed and I dreaded the day. It looked complicated with all those wires and hoses every where and even though every one kept saying that it's easy, I know that there are always the small things that would get you. More on that later.

    There are some of the pics of the 'new engine':
    Auto engine hoses galore.jpg

    Top of auto engine.jpg

    Auto engine compressor 1.jpg

    Auto engine front.jpg

    Because I'm learning as I go, I took my time, took quite a few pictures so I 'know' where everything goes. It took me a while but here is the progress I made:
    Auto engine total teardown.jpg

    Let me know what you all suggest I do with the engine.

    My next post will be about the engine pull. It was such an emotional ride.
    Last edited by SoundEfx; 06-13-2018 at 07:52 AM.

  3. #3
    Established Member Two Rings
    Join Date
    Aug 29 2017
    AZ Member #
    405950
    Location
    PWN

    On to the actual engine pull. I'll start off by saying that after taking out the engine, it is NOT difficult, but, IN MY OPINION, these things are necessary:
    1. The right tools. I had everything I needed and without one tool, it would be more of a headache.
    2. A second pair of hands and eyes to navigate the engine's destination.
    3. Be prepared to learn on your own as there is no 100% fool proof guide out there. There will ALWAYS be a ground wire, wire loom clip or something that is still attached which would have you stomped and cursing. Simply take your time and do this with no rush.

    So yesterday I decided to put my big boy pants on and was determined to get this damn engine out of the car. I followed the famous youtube guide and it got me really far, but as I said earlier, there is always something.
    1. The axles would not have cleared the stock down pipes, so I had to take them out. Which is a task by itself.
    2. The ground wire and wire loom that's on the bottom right of the cross member had me cursing for a few minutes because according to everything I can remember, I detached everything. I was wrong.

    So to some of you, this is a walk in the park, but to me, this was my first ever audi engine swap and I'm very particular about my cars. I HATE dents and the usual "Just do this, no one will see it because it's under that car" attitude.

    Final result of my Audi engine adventure:
    Old engine out.jpg

    I decided to leave the shifter on there because I didn't want to mess with aligning it later on.

    The next few posts will be of me pretending I know what I'm doing as I take out worn parts like the clutch and swap over known good parts from the bad engine.

    Wish me luck.
    Last edited by SoundEfx; 06-13-2018 at 07:56 AM.

  4. #4
    Established Member Two Rings
    Join Date
    Jun 07 2016
    AZ Member #
    374403
    Location
    San Diego

    Smart you left the shifter rod attached to the linkage ..

    Rookie mistake on my part, definitely disconnected it and spent another 10-15 minutes unnecessarily realigning it as I got it back into the car.
    2001.5 S4 6MT - F21s w/ some things - Build thread HERE
    2007 Honda Fit 5MT - Daily

  5. #5
    Established Member Two Rings
    Join Date
    Aug 29 2017
    AZ Member #
    405950
    Location
    PWN

    Quote Originally Posted by TylerT View Post
    Smart you left the shifter rod attached to the linkage ..

    Rookie mistake on my part, definitely disconnected it and spent another 10-15 minutes unnecessarily realigning it as I got it back into the car.
    Thanks for reading.

    I wouldn't call it a rookie mistake because if I remember correctly, the expert in the video also took out the shifter mechanism.
    Besides, the less I have to mess with on the car, the greater chance of it being driveable after I am done with it.

  6. #6
    Established Member Four Rings JustManson's Avatar
    Join Date
    Oct 11 2016
    AZ Member #
    382924
    Location
    Connecticut

    Intro and build thread in one

    Welcome SoundEfx!

    I too was in your position about 6 months ago except I blew both of my K04 turbos. Just turned 900 miles on my build.

    Engine removal was “easy” but it sure didn’t feel that way looking at it everyday... I know the feeling all too well.

    I ended up not removing the axles, I removed the down pipes and pushed the axles to the rear of the car, cleared.

    I also removed the entire linkage. It aligns very easy IMO and had it setup and shifting perfectly in minutes. The JHM video helped a lot and alignment with my IPhone on the level within the compass app worked great LOL.

    Looking forward to seeing your progress!




    Sent from my iPhone using Audizine

  7. #7
    Established Member Two Rings
    Join Date
    Aug 29 2017
    AZ Member #
    405950
    Location
    PWN

    Quote Originally Posted by JustManson View Post
    Welcome SoundEfx!

    I too was in your position about 6 months ago except I blew both of my K04 turbos. Just turned 900 miles on my build.

    Engine removal was “easy” but it sure didn’t feel that way looking at it everyday... I know the feeling all too well.

    I ended up not removing the axles, I removed the down pipes and pushed the axles to the rear of the car, cleared.

    I also removed the entire linkage. It aligns very easy IMO and had it setup and shifting perfectly in minutes. The JHM video helped a lot and alignment with my IPhone on the level within the compass app worked great LOL.

    Looking forward to seeing your progress!




    Sent from my iPhone using Audizine
    Thanks man. I remember your thread. I decided not to remove the down pipes because I was running out of time and when looking at it, looked like a more difficult task than the axles. But I might be wrong because now my axles are destroyed.

    My next step is to get all the new gaskets and start the engine refresh process.



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