Barry's 2001 B5 S4 Build Thread

[q20v]

Such nice work on the powder coating! I really wanted to do the same when I had my car ripped apart but everything else took way longer than I’d think.

I was surprised how well the subframes came out. They are mint!

Not a whole lot of progress this week except getting organized for this weekend. I put in another decent FCP order for misc hardware and gaskets. Adds up fast but is well worth it.

The 17z and 4-Piston Touareg rear calipers came in this week and I ordered new seals all around. I'll record the rebuild / powder coat process and make another YouTube video of that.

I have tomorrow off work and Sat / Sun no-kids, so those 3 days are dedicated to making progress on the project!

I made a quick video showing the Maxspeeding Rod balancing results. Overall they weren't too bad out of the box but the big end weights were ~43g lighter than stock rods. I had the crank balanced at a machine shop to account for this, and also had them polish the journals.

My first goal for this weekend is to re-assemble the bottom end and strip down the old engine to start transferring parts.

[AudiAR01]

This is such a great detailed build thread. Sub frames look awesome. I was gonna shell out the coin for verkline subframes. But I think I'm gonna media blast and powder coat them. I'm turning out old oven into a powder coating oven. I took it over to our garage last Sunday. I appreciate the PC info you gave me. I'm gonna be powder coating a ton of stuff now. Knowing I can do it in a regular household oven now.

2003 A6 2.7T 6spd Stage 1+ (motor pulled for stage 3+ upgrades)

2001 Allroad TIP Stage 1
2006 A3 2.0T 6spd Stage 1

[q20v]

Hey no problem! Glad to hear you're enjoying the build. And thanks for calling out the MS rod balance. I would have been gutted to have it come up after the car was running and realize I should have taken these extra steps. Love the community for this!

The subframe blasting / powder coating was $475 all in (Canadian) at a place here in Ottawa. I was anticipating months of wait time and $1k but it took them a week and was less than half $ wise.

Let me know if you need any more specifics on the powder coating setup. I've since installed a 'curtain' over the opening to help reduce the overspray on my shelves in the room.

[Silverex]

How did you make out on weight matching with the pistons? I had 18 to choice from and had a hard time getting them closer than a couple grams of each other on my build. The pins I was able to get close tho.
Edit: just watched your video and crazy how far off my piston/pin weights were off from each other compared to yours. Shocked your pins were dead nuts on. Although I was working with multiple incomplete sets of slugs but none were exactly the same like yours....my luck always sucks. Lol.


If you didn’t yet once you figure out which pistons are going on which rods I’d measure the pin clearance since the stock pins vary in size. I had to get 2 of my rods resized on the small ends.

[AudiAR01]

How did you make out on weight matching with the pistons? I had 18 to choice from and had a hard time getting them closer than a couple grams of each other on my build. The pins I was able to get close tho.
Edit: just watched your video and crazy how far off my piston/pin weights were off from each other compared to yours. Shocked your pins were dead nuts on. Although I was working with multiple incomplete sets of slugs but none were exactly the same like yours....my luck always sucks. Lol.


If you didn’t yet once you figure out which pistons are going on which rods I’d measure the pin clearance since the stock pins vary in size. I had to get 2 of my rods resized on the small ends.

I couldn't believe how close his rods weights were. Mine were way way out. That's the only reason I suggested it to him in the first place. Honestly his weren't out really far enough to cause problems more than likely. Especially having the entire rotating assembly balanced in the end. But doing what he did absolutely didn't hurt. And will in the long help the rod bearings in the long run. I didn't do piston weights. Now that I seen he did. And you mentioning it. I may do it on this build. Just to have one extra step of peace of mind. But I'm still a few hours out on mounting the engine to a stand to flip it over and remove the oil pans. I'll measure all mine and post them in my thread. Compare them to his to see how they are across the whole platform weight Wise OEM.

2003 A6 2.7T 6spd Stage 1+ (motor pulled for stage 3+ upgrades)

2001 Allroad TIP Stage 1
2006 A3 2.0T 6spd Stage 1

[q20v]

I was surprised at the piston pins too TBH. They are all from the same set / engine so that likely helps.

Thanks for the heads up on the piston pin diameter, I'll bust out the micrometer and check those before assembling.

[Silverex]

I was surprised at the piston pins too TBH. They are all from the same set / engine so that likely helps.

Thanks for the heads up on the piston pin diameter, I'll bust out the micrometer and check those before assembling.

You’ll need a dial bore gauge also. IMO that’s the tool that’s worth spending money on since you can have cheap mics, measure pin, zero bore gauge out to the mic measurement, and Whatever you get on small end is your clearance

[AudiAR01]

You’ll need a dial bore gauge also. IMO that’s the tool that’s worth spending money on since you can have cheap mics, measure pin, zero bore gauge out to the mic measurement, and Whatever you get on small end is your clearance

I agree with this 1000%

2003 A6 2.7T 6spd Stage 1+ (motor pulled for stage 3+ upgrades)

2001 Allroad TIP Stage 1
2006 A3 2.0T 6spd Stage 1

[q20v]

As usual thanks for the comments guys. I measured the wrist pins before assembling everything and they all measured the same. I didn't measure anything else as I read your messages too late in the process... and I'm not taking it apart for a third time
I'm comfortable with this for these reasons: The wrist pins / pistons are all from the same set and assembled beautifully. The Wrist Pins and rods (small ends) assembled the same, they felt great. I've done a lot of machining over the past 10 years and I can't see any reason to open up the small end bores. Obviously this is a subjective assessment but one that I won't lose sleep over.

Made some huge progress over the past 3 days.

- Removed all the fuel tank heat shields and straps, off to powder coat they go. Same with all the coolant hard pipes from the old engine. I was going to do some of these myself but the effort to strip the old paint / rust is not worth it, considering I have to bring in 2-3 big heat shields anyway, the cost to include a few more parts is a marginal increase.
- Washed the entire underside of the car as best I could (not a pleasant job haha).
- Touched up another pile of tiny surface rust spots under the car.
- Striped the old engine and cleaned most of those parts.
- Powder coated a pile of brackets (engine mount, PS pump, AC Comp, crankcase breather thing in the valley)
- Cleaned the heads.
- Put together the bottom end of the new engine.
- Put in another order for parts from FCP.
- Installed the new power steering lines and engine bay heat shields.
- 3D printed all the brake line clips that are on the rear subframe.

I'll post up some pics in the next day or two.

[AudiAR01]

Are you talking about the hard pipes and crossover pipe under the IM? I just bought new ones as apposed to powder coating them due the price. I got a new crossover coolant line and the coolant line that goes across and down in front of the driver's head for 110 bucks shipped.

2003 A6 2.7T 6spd Stage 1+ (motor pulled for stage 3+ upgrades)

2001 Allroad TIP Stage 1
2006 A3 2.0T 6spd Stage 1

[q20v]

Well, all of them haha
I think there's about 5 hard pipes in total that I brought in. It's one of those things where it costs like $80 to powder coat one part or $120 for 10 parts. I had to bring other stuff (fuel tank shields) in anyway so it'll be way cheaper than buying new pipes. Where did you find the new parts anyway??

[AudiAR01]

Well, all of them haha
I think there's about 5 hard pipes in total that I brought in. It's one of those things where it costs like $80 to powder coat one part or $120 for 10 parts. I had to bring other stuff (fuel tank shields) in anyway so it'll be way cheaper than buying new pipes. Where did you find the new parts anyway??

Between eBay and FCP

2003 A6 2.7T 6spd Stage 1+ (motor pulled for stage 3+ upgrades)

2001 Allroad TIP Stage 1
2006 A3 2.0T 6spd Stage 1

[q20v]

Got the crankcase breather assembly sorted out last night.

OEM Check Valve, oil transfer tube o-rings, hardware and Elring gasket. The cover cleaned up nice

[ShelbyM3]

Got the crankcase breather assembly sorted out last night.

OEM Check Valve, oil transfer tube o-rings, hardware and Elring gasket. The cover cleaned up nice

Any chance you can share the removal and install process for the oil transfer tube? I posted about disassembling this and got responses of “don’t touch it unless you’re rebuilding the bottom end”. Do you need a bare block to get it out?
Also, do you part numbers for the o-rings on the oil transfer tube? And, are there not crush washers on those banjo bolts?

Thanks! Love watching your progress. I admire your working style a lot. And, I’ve learned a lot from your threads and videos.


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[q20v]

Also picked up a NOS trunk badge. Decided on the old style.

[q20v]

Hey Shelby,

I shot a quick vid for ya this morning covering this area of the rebuild, check it out and let me know if you have any specific questions!

[ShelbyM3]

Barry, you didn’t need to go through all that trouble man. I can’t thank you enough. It’s all the little details, you’re a legend.


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[q20v]

It was no trouble at all! It got me thinking about recording a bunch of other 2.7t related videos as I reassemble this engine. I’m always looking for new ideas!

[AudiAR01]

Almost got my PC setup finished. I appreciate the info on basic oven use for powder coating.

2003 A6 2.7T 6spd Stage 1+ (motor pulled for stage 3+ upgrades)

2001 Allroad TIP Stage 1
2006 A3 2.0T 6spd Stage 1

[q20v]

No problem, post up how your first part goes and what your setup is like. I’m about to make a video on completely refinishing a set of 17z front calipers and 4 piston rears, hope to have it out in the next week or two.

[q20v]

Managed to powder coat a few more parts this weekend.. Used Platinum Silver from Prismatic Powders. I think I only have a small handful of really small things and the Intake Manifold remaining now. It's been a lot of work and it seems like no end to the cleaning but it's getting there!

Lower oil pan




Crank seal housing









Pics of the upper oil pan coming soon :)

[ShelbyM3]

You should definitely make a video on the assembly of all these things and the oil pump.


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[q20v]

Absolutely plan to do so!

[euro4sho]

they honestly look New from factory. great work

[q20v]

Thanks! I'm happy I finally made the powder coating investment.

Finished the upper pan. The largest and most complex part so far and it came out fantastic. Took forever to clean but it was worth it. Just gonna photobomb the results. I still have to pick out some old sealant from the threaded holes and get the gasket surfaces a bit cleaner.

[MCP]

Thanks! I'm happy I finally made the powder coating investment.

Finished the upper pan. The largest and most complex part so far and it came out fantastic. Took forever to clean but it was worth it. Just gonna photobomb the results. I still have to pick out some old sealant from the threaded holes and get the gasket surfaces a bit cleaner.

Wow that came out veryyy nice, great work!


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[ShelbyM3]

Those turned out really nice!


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[S4 John]

I'm drooling over the pc'd parts. Came out amazing!

[Silverex]

Upper pan looks awesome and I feel ya on how long it takes to clean.

What temp do you bake the parts at?...any worries about the aluminum parts warping?

[q20v]

Thanks guys, I'm super happy with the results as well. Can't wait to get them installed!

Silverex, yes, warping did cross my mind too. Baking temp is 400F so not too high. I was mostly concerned about the lower pan, considering it's quite thin and doesn't have tons of webbing compared to the upper pan. Considering I have a spare lower pan I figured I'd just try it, and it didn't warp, so all good there. The other parts are all fairly substantial in thickness.

Not a huge update but last night I removed all the old EM studs and chased all the threaded holes. No broken studs and they all came out using the 2 nuts jammed together method. Having the studs out and inspecting them a bit closer now, I probably could have just chased the studs threads and left them alone, but I had already bought replacements and this starts me off fresh.

This Friday I intend to assemble the oil pump / pans / RMS / front crank seal housing and video it all as a DIY. Stay tuned!

[q20v]

Thanks MCP!

I'm finnnnnally starting to put things together today and will record a PBGarage video to document it all. I have everything laid out and pretty much ready to go.

[q20v]

Managed to plow through quite a bit today.

- Oil Pump
- Upper / Lower oil pans
- Front crank flange
- Rear main seal
- A few brackets

Feels good to be assembling stuff for a change.

[AudiAR01]

That looks beautiful.

2003 A6 2.7T 6spd Stage 1+ (motor pulled for stage 3+ upgrades)

2001 Allroad TIP Stage 1
2006 A3 2.0T 6spd Stage 1

[q20v]

Thanks Seth!

I made a video showing the assembly of those parts, check it out:

[AudiAR01]

Thanks Seth!

I made a video showing the assembly of those parts, check it out:

Yup I watched it. I'm subscribed to your YouTube channel. That probably one of the cleanest 2.7s I've seen rebuilt in Audizine. Excellent job on the PC. I almost have my PC station setup. I got the oven in place and hooked up. Just waiting on some powder to get delivered. And the spray gun to get here. I appreciate all the info you gave me on powder coating. Bc I would've just used engine heat enamel if not. And powder coating is much cleaner and better looking. Lookn forward to watching you finish this. I'm a little jealous as I have C5 and not a B5 by body design. But the C5 just has more interior room. And a few more comfort features. But it just doesn't have that sport/track look like the S4 does. I'd love to find a nice rolling b5 shell. But out 8 I've looked at in person within reasonable driving distance to me. All have been complete shit boxes. Rusted through n through. I found one in Georgia that's in pretty immaculate condition. But he wants 3500 just for the rolling shell. But with no hood, trunk deck, fenders, or bumper covers. So it's way over priced. If it was a complete shell just drop motor in and go. I'd probably trailer it back home. But he's super firm on the price. So I'm going to keep looking. And again great work. And great detail on the videos and build. Your videos will help a lot New comers to Audi scene.

2003 A6 2.7T 6spd Stage 1+ (motor pulled for stage 3+ upgrades)

2001 Allroad TIP Stage 1
2006 A3 2.0T 6spd Stage 1

[Gosser]

Is that motor going into the display in the dining room?

Nice work.

[q20v]

Got a pile of parts back from a local powder coating place. Some of these were too big for my oven so I ended up just sending them a pile of stuff. All rusty steel parts that would take me forever to blast / sand for prep.



























No before pic of these, but:


Picked up this replacement from a forum member, thanks wpfahl! Going to put a fresh coat of paint on it.

[Gosser]

Nice fresh panels. Sooooo when we schedule the competition and it happens to be misty out... are you automatically dropping out?

[q20v]

Well if all these parts got dirty I'd have to get them all re-powder coated which is a lot of work, plus with covid and stuff.. maybe we can do a virtual race on Skype?

[S4James]

Well if all these parts got dirty I'd have to get them all re-powder coated which is a lot of work, plus with covid and stuff.. maybe we can do a virtual race on Skype?

Just add up all the HP numbers on your K&N and WingsWest boxes.