RMode's S4 Journey

[Silverex]

How much of a voltage drop are you seeing?
What’s the amp rating on the 3.0 alternator?

[RMode]

- - - Updated - - -

How much of a voltage drop are you seeing?
What’s the amp rating on the 3.0 alternator?

Drops to around 12.3v at wot in the upper rpm's. But it really seems tied in directly to heat as well.

Alternator is 150amp

No issues with starting, even after sitting for days, everything works, nothing flickers. Just something I happened to notice a couple weeks ago.

[RMode]

So while the grounds measured perfectly fine when checked last weekend, I am hoping this coming week to check the positive cable from battery to alternator.

This morning it was noticeably cooler - only about 60F when I left the house. Voltage was in the 13.9-14.1 range when I first set out, and after a 35 minute drive, was at 13.5. Didn't use the a/c today at all since it was so nice out.

[Silverex]

Heat will definitely have an affect and I’ve also been dealing with some drop but not quite that low. Today it was 97F and with my EFK on high, AC, headlights, etc it was around 13.0v and would goto 12.7-12.8 at higher RPMs. I redid my grounds and no change. Been thinking the same about the power to alternator wire might be the issue but haven't had a chance to investigate further. Definitely curious if your findings.

[RMode]

Heat will definitely have an affect and I’ve also been dealing with some drop but not quite that low. Today it was 97F and with my EFK on high, AC, headlights, etc it was around 13.0v and would goto 12.7-12.8 at higher RPMs. I redid my grounds and no change. Been thinking the same about the power to alternator wire might be the issue but haven't had a chance to investigate further. Definitely curious if your findings.

At no time has it tossed the alternator light or a code either. Perhaps I am just on the edge of what level alternator I need, idk. I would like to inspect/measure resistance on the power wire like you said. Might have to wait until the new motor goes in this winter though

In the meantime, did new plugs over the weekend (just regular BKR7E, since it was the only set immediately available locally), and THETuner coils. In doing so, I had the battery on my trickle charger from Thursday evening into Friday. By Friday around 11am, it was showing fully charged (at least per the green light on my battery tender). Didn't use the car again till today. No changes from what I had previously seen, so wondering if this is just how it is or what.

Also trimmed up the new engine cover. Have a bit of edge finishing to do tonight once things cool off outside a bit. Below is pre-final trimming and smoothing. My prior, rarer cover went to a good friend for his build.

[travis_w]

What car is that cover off of?

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[RMode]

What car is that cover off of?

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A 3 liter C5 A6, and a lot of trimming


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[travis_w]

Been trying to find one for a while. Been around every junk yard close to me.

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[RMode]

Been trying to find one for a while. Been around every junk yard close to me.

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I’ve received the last batches I brought in from Europe. It’s a very uncommon car here. Awaiting more but they are all spoken for.


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[RMode]

Sadly, but fortuitously, some coolant left the chat yesterday. I was running some errands near home (maybe a mile). All was normal. Around 88F outside, so a/c was of course on (I’m forever warm). Smelled a bit of coolant. Temps were all normal. Drive maybe 1/8 mile, to the next traffic light, and now I see a bit of burnt coolant smoke coming though the a/c vents. Turned a/c off, rolled the windows down, and now notice the smoke coming from the front section of the hood.

Pulled off to a parking lot, and it’s giving a little whistle, not quite “tea is ready”, more model-train. I watched the expansion tank volume go from just under low, to gone in short order. Removed the engine covers, and there’s droplets but nothing obvious as far as a source. Most of my coolant hoses, from hard lines to soft, have been replaced over the last few years. Turbo lines, crossovers front and back, etc. Etc. Most.

Anyway, since I was so close to home and temps weren’t shooting up, I continued with my errands - 2 stops even closer to my house than I was (another 2 mins total driving time). Got home, left her in the street to bleed. Now I have the distinct pleasure of spending my Saturday working on it, instead of enjoying my new deck extension built for my outdoor smoker smh. Problem is, at this moment while typing, my motivation is zero and so are my energy levels. It was a week….




Fingers crossed that it’s a rubber hose that 1. I have in stock, or, that I can cut as needed temporarily and 2. Is easily accessible.

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[RMode]

All fixed

It was the hose from the rear crossover to the expansion tank T. Jesse called it correctly. As usual :)


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[CELison]

You can take the man out of the b5, but you can’t take the b5 out of the man. I’m still lurking on all the b5 happenings.

[travis_w]

My wife is questioning getting rid of the car because of the headache from the previous builder, but I can't stop, won't stop.

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[Silverex]

At no time has it tossed the alternator light or a code either. Perhaps I am just on the edge of what level alternator I need, idk. I would like to inspect/measure resistance on the power wire like you said. Might have to wait until the new motor goes in this winter though]

After some more thought if you are running a factory length accessory belt like myself, maybe the tensioner is outside of its normal working range and causing the slight drop at higher RPMs?

[RMode]

I’d tend to doubt it, since there would be signs of slippage. The serpentine was replaced when this alternator was done last year. It had ~20k on it when timing was five this year. While I had a fresh belt ready to go, it looked nearly perfectly so we reused it without issue. I’m also on a Fluidampr crank pulley but those aren’t said to be a different size vs stock. My best guess is the regulator. When the new engine goes in, I’ll do a fresh higher output alternator


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[RMode]

If the motivation is there, I think I will be tackling the updated trunk install :) It's been sitting for far too long

[travis_w]

What is the updated trunk? The euro lid?

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[RMode]

What is the updated trunk? The euro lid?

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Yep, a facelift euro trunk to replace my pfl one. Didn’t get around to it last weekend. I really urgency with it, but it’s painted and ready to go


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[RMode]

Revisiting the To Do list.

Redoing the headliner, b pillars and c pillars. Mine are fine, but I want it to be perfect. Only way to get there after you do the headliner, is by doing pillars to match. Going with the OEM material. DONE, need to arrange shipping it back to me (yay smh) and a time to install

Recover and install black rear parcel shelf. DONE, same as headliner etc



Wrapping up the engine cover project - Abandoned

Fuel tank straps, fuel tank shield, fuel filter - I think at this point, I'll do it with the new engine

Paint/install new rear spoiler Done, but haven't had the motivation to install the new trunk

Fire extinguisher setup - not sure how I want to do this yet. TBD

Finish getting the headlight levelers working again. Front motor/link is new, need to do the rear when I do the fuel tank stuff. Will be back to this soon, as I think I am going to use one of my Euro switches and do the plug and play harness for level adjustment from in the car

Next List - by end of Q1

1. Pick up engine from Jesse, get it to my machinist for a once over and discuss any further upgrades he feels are worthwhile

2. New Wheels - yep, it's time again. I love these, but have decided I want a different look overall that stands out a touch more. I have them picked out, but need to measure the brakes now that those are bigger to ensure I get things exactly correct out of the gate.

3. New Coilovers - I know exactly what I'm going with this time. Very much looking forward to these.

4. Pick New Turbos - I think I know what I am going to go with next - a set of THETuner's new RS3 based units. I will further upgrade the inlets, and fuel pump, and likely intercoolers too. Undecided yet if I am going to do a new intake manifold/throttle body setup or not.

5. Verkline front subframe - likely going to be installed just to make future work much easier

As of now, that's all I got! Car has been continuing to run well and serve daily duty use. In the longer term future, I am going to retrieve the B7 from PA and start using that again this winter, and then grab the B9 in the spring and likely sell it or trade it for something new for my wife, as her car is starting to see the near side of 100k. I very well may then end up taking her car as my own new daily, and set the B7 aside for my nephew

[CELison]

It's been hanging out. I'm excited to see it in a car again, all of my larger/more expensive b5 parts have gone to good homes.

[RMode]

It's been hanging out. I'm excited to see it in a car again, all of my larger/more expensive b5 parts have gone to good homes.

I can’t wait! It will continue on in a loving environment


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[RMode]

Thanks to the help and patience from my friend Chris (fellow S4 owner), the rear trunk is sort of on. Not without its hiccups.

Firstly the brand new lock assembly I got from tradition wouldn’t turn with either key they supplied, after the first turn. Ended up needing to rebuild the lock. But it took months before I enlisted help/had an opportunity to really dive into it. With that working, we go to getting the trunk fitted.

Had to make a modification to the plastic end that the rod from the lock to latch connects to. From there, it’s taken a bunch of adjustments to get the trunk to latch correctly. Same latch worked in my previous trunk for years. So who knows.

I still need to play with the alignment and keep fiddling with the latch itself, connect the soft touch switch buttons, and get my hands on the correct license plate lenses (the ones I got weren’t correct). But it’s on and the lock works. It’s a subtle change but now that it’s fitted, I love it. Especially with the bumper

Debating if I want emblems back on. Leaning towards what I had with my last trunk: OG S4 emblem, and no rings). We will see.

Spoiler is next in the coming days. Wish I’d have done this earlier when the weather was warm since doing this on a garage, even heated, it less than ideal.

Next up will be the new suspension toys and getting the new wheels ordered.




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[LJS]

Nice--looks real good!
Anxious to see your new wheels!
FWIW- I think the Audi RINGS would look great on the trunk....

[RMode]

Nice--looks real good!
Anxious to see your new wheels!
FWIW- I think the Audi RINGS would look great on the trunk....

Thanks!

I’ve got new rings logo in stock and a classic S4 emblem too, but I want to keep it badgeless for a bit and see how I like it

My wife voted for rings and the emblem. She thought no emblems didn’t “honor the heritage”.


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[RMode]

Installed the wing last night. Will sort out emblems tonight. After looking at it in day and night hours, it’s too naked as is.





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[RMode]

Emblems installed.

Next I’ll do the wiring for the switches, and get the liner back in there.

Hard part wise, next is fuel filter, the stainless fuel tank supports I offer and a fresh fuel tank shield. Then beyond that will be the new coil overs. Wheels will wait till spring as far as install but I will see them before the year is done. Then December will start the engine side of things :)





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[LJS]

looks real good!
always liked the "original" S4 badge....Did you replace the one in the front grill...
FWIW-
I made the error of de-badging my S4 early on but was able to restore it with your help....

[RMode]

looks real good!
always liked the "original" S4 badge....Did you replace the one in the front grill...
FWIW-
I made the error of de-badging my S4 early on but was able to restore it with your help....

Nope, I’ve never run a front grille emblem at all


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[RMode]

Winter has set in here in New England - cold temps day and night.

Still continuing to use the car daily, and the miles keep piling on. Now sits at 239,600. That means we are on the cusp of 100k miles since July 2019 when I got this car.

Of course, that also means more work lol. I’d been having odd boost performance of late where it would hit target, then it felt like the throttle plate closed and then opened again. Had a friend take a look as work for me has been madness lately.
Dropped the car off last Friday and picked it up yesterday. Also addressed a few other things - some planned, some not.

Turns out, the passenger side wastegate line off the turbo tore. Do yourself a favor if and when you upgrade turbos. Don’t use the Paragon lines. Others have said it before, but they are bulky, they don’t route nicely as a result, and they’ve been on and off problematic since they were installed. Now, granted, it took 4 years and many miles for this to let go. But, the original ones I removed to fit these when I did the turbos went 20 years and 141k miles and were still fine. Lesson learned. The rubber hose had torn, causing the boost issues. These will go in the trash when this engine comes out and I’ll make my own, correctly, like I’ve done for the upper halves. The upper halves mind you were also Paragon and they began leaking about 7 months aggressor install. Never again.




Also got rid of the old pb5 fan controller/probe and moved over to a simple temp switch, in-line to an upper coolant hose, and run via a relay. Fan comes on at 190F, off at 165F. Just much simpler. We will see how things do when it’s hot out again.





From there, there was a very small fuel weep from the feed fitting. Easy fix.

Also, replaced serpentine belt and tensioner - which was the main thing along with boost that I wanted looked at. I’d ordered a new alternator harness but it didn’t arrive in time. Will do that when the new engine goes in.

Then, when giving things a once over, he found that the upper inner control arm bushings in the 2Bennett arms were torn, causing a lot of inner camber wear. One was worse than the other and both tires were separating. Car still had felt fine but obviously this was dangerous and sketchy. I didn’t want to get deeper into the cycle of changing tires 2 at a time, as I’ve been there the last couple years and it’s annoying. So I grabbed a full set of DWS06+. Now we have fresh tires all around. I’ve used the older version many many times. These have way better street manners than the Pilot AS4. Much more comfortable! A big plus. Also great to be able to just pick up from the Tire Rack warehouse in CT.






Then last thing was replaced a damaged MAF connector with a fresh genuine one. This was an original connector and we all know how brittle all the plastic in the engine bay gets over time. Glad to have this fresh and new.




Doing a couple map revisions now that the wg line is solved. Going to upload the new map today and take it out later on.

Next up: install the new fuel tank straps and fuel tank shield, new fuel filter and bracket, and replace those upper bushings (currently en route from 2B).

After that, need to pick the engine up from Jesse and get it to my machinist and continue accumulating the new parts for the new setup. Still need to decide IC’s and a few odds and ends but I think I’ve got the new setup pretty much mapped out.


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[Ryes7]

Winter has set in here in New England - cold temps day and night.

Still continuing to use the car daily, and the miles keep piling on. Now sits at 239,600. That means we are on the cusp of 100k miles since July 2019.

Of course, that also means more work lol. I’d been having an odd boost performance of late where it would hit target, then it felt like the throttle plate closed and then opened again. Had a friend take a look as work for me has been madness lately.
Dropped the car off last Friday and picked it up yesterday.

Turns out, the passenger side wastegate line off the turbos. Do yourself a favor if and when you upgrade turbos. Don’t use the Paragon lines. Others have said it before, but they are bulky, they don’t route nicely as a result, and they’ve been on and off problematic since they were installed. The rubber hose had torn, causing the boost issues. These will go in the trash when this engine comes out and I’ll make my own, correctly, like I’ve done for the upper halves.




Also got rid of the old pb5 fan controller/probe and moved over to a simple temp switch, in-line to an upper coolant hose, and run via a relay. Fan comes on at 190F, off at 165F.





From there, there was a very small fuel weep from the feed fitting. Easy fix.

Also, replaced serpentine belt and tensioner - which was the main thing along with boost that I wanted looked at. I’d ordered a new alternator harness but it didn’t arrive in time. Will do that when the new engine goes in.

Then, when giving things a once over, he found that the upper inner control arm bushings in the 2Bennett arms were torn, causing a lot of inner camber wear. One was worse than the other and both tires were separating. Car still had felt fine but obviously this was dangerous and sketchy. I didn’t want to get deeper into the cycle of changing tires 2 at a time, as I’ve been there the last couple years and it’s annoying. So I grabbed a full set of DWS06+. Now we have fresh tires all around. I’ve used the older version many many times. These have way better street manners than the Pilot AS4. Much more comfortable! A big plus. Also great to be able to just pick up from the Tire Rack warehouse in CT.



k


Then last thing was replaced a damaged MAF connect with a fresh genuine housing. This was an original connector and we all know how brittle all the plastic in the engine bay gets over time. Glad to have this fresh and new.




Doing a couple map revisions now that the wg line is solved. Going to upload the new map today and take it out later on.

Next up: install the new fuel tank straps and fuel tank shield, new fuel filter and bracket, and replace those upper bushings (currently en route from 2B).

After that, need to pick the engine up from Jesse and get it to my machinist and continue accumulating the new parts for the new setup. Still need to decide IC’s and a few odds and ends but I think I’ve got the new setup pretty much mapped out.


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This is fantastic to see real world maintenance updates on a higher mileage B5. Much appreciation.

[LJS]

FWIW-The AWE intercoolers work good on our platform....they fit well and require minor trimming on the driver side core support and fender wing along with a minor adjustment to the horn bracket
I used a Dremel Tool with a Dremel reinforced 1-1/2” cut-off wheel-VERY easy job
Also the OE hoses fit correctly with the passenger side lower hose needing 1/8" removed to fit perfectly.
They work well for a side mounted solution
I've had them on my S4 since 2018 with NO issues

[RMode]

FWIW-The AWE intercoolers work good on our platform....they fit well and require minor trimming on the driver side core support and fender wing along with a minor adjustment to the horn bracket
I used a Dremel Tool with a Dremel reinforced 1-1/2” cut-off wheel-VERY easy job
Also the OE hoses fit correctly with the passenger side lower hose needing 1/8" removed to fit perfectly.
They work well for a side mounted solution
I've had them on my S4 since 2018 with NO issues

They are no where near enough for the new engine/turbo’s going in. I’ve been on the Wagner S4 ones since doing the turbos in 2021. These too are also much too small, so will be upgrading further. Just needs further cutting to make it work :) (and. $$$)


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[LJS]

Got ya....
Look'n forward to your new build!

[RMode]

Got ya....
Look'n forward to your new build!

Same :)


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[CELison]

Well you can't pick this motor up now. I pushed the engine stand handle through my garage wall like an idiot. So when that engine goes I'll have to fix the wall.

[RMode]

Well you can't pick this motor up now. I pushed the engine stand handle through my garage wall like an idiot. So when that engine goes I'll have to fix the wall.

Easy solution

https://www.youtube.com/watch?v=h99r2Xmp-Xg


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[CELison]

Easy solution

https://www.youtube.com/watch?v=h99r2Xmp-Xg


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Ok, you can have it then. It's the last bit of my b5 at the house lol.

[RMode]

A few odds and ends done over the last couple of days

Finally got around to fitting my own replacement fuel tank guard. Mine was rusting away - actually the only real rust on the car. Very happy it’s now gone. Also did the fuel filter. I last replaced it tbh, too long ago - 2020. It was gross (which, to an extent, it always will be with age). But, I recently scored a dozen of the original Audi ones, so I’ll be doing this more frequently now. I know there’s nothing wrong with the Bosch or Hengst or whatever. I just like factory original things for some items.

While there, also did a fresh set of original fuel tank straps and all the hardware. Unfortunately the stainless ones I get made are in between production runs, otherwise I’d have used those. But since I would have done cerakote anyway, rhese originals are a welcome addition. Now it’s all nice and tidy underneath. I think I’ll be doing the dry ice cleaning at some point this spring or summer.





Idk why that adapter, which appears to be for coolant lines, is in there. I didn’t put it there. Back in 2020, I had the fuel filter changed at regular garage near where I now live in MA. I was up here at the time during Covid. I can only guess they, for some reason, put it on. It’s gone now.

A few months ago, I was able to get my hands on a dozen genuine, new old stock fuel filters. So one of those is now in the car.




Fresh oil change with an original filter and DT40. Mileage wise, we are now at 243,284 as I type this. That means I crossed the 100k mile mark since buying it in July 2019. Still its original engine, trans, and rear. I’d have to look back to get exact figures but that’s about 80k miles on the K04 setup. Still daily driven. Once the new engine is in, it won’t be daily’d, but it will still get a good bit of use.

Finally had the upper bushings replaced in the 2Bennett arms. These had started to tear, which was causing some odd noises from time to time, as well as some light shaking under heavy braking. All gone now. Couple other odds and ends done, nothing sexy this time though. Many thanks to my buddy Joe at Northeast Euro. His shop is about an hour from my house but only about 30 minutes from my office. So I dropped it off Thursday, grabbed a rental car, and picked it up yesterday. All without my wife lamenting “why do you use a shop so far away”, as I’ve heard her mutter before. New house is on the agenda for hopefully 2026, so that I can finally build out the dream garage I’ve concocted in my head. My current one at this house just doesn’t lend itself to lots of car stuff, as it’s just too narrow. I really want a singular space so all my cars can be in one spot, a dedicated area for cleaning them with drainage, and, ideally, a loft area for my own parts inventory as well as the restoration and performance stuff I offer for these cars.

Next up is finally retrieving Jesse’s engine from PA, finishing selection of turbos and IC’s. I’ve gathered most of the ancillary stuff at this point - RS4 intake manifold and TB, THE-Tuner fuel rail. I’ll reuse my current injectors just send them out for a cleaning. I parted ways with the sole used RS4 bumper I had, which I’d been keeping for myself. I’d still like to do one, so need to track one down.

I recently was involved in an ongoing project with Andy of Gepfeffert. He’s doing a full widebody, carbon panel conversion with built engine, etc etc. I surprised him with a set of the mats I offer. You can see it on his YouTube channel, the episode was a couple weeks ago. I’ll be fitting a set of his KW V3 Clubsports in the coming months. Also got word something else I’ve been working on has shipped, I’ll announce that on arrival, assuming it all meets what I hope it will.

The car desperately needs a thorough bath. With all the snow and then rain we had, it was pretty gross. I used a quick touch less last night on my way home, but I’ll be having a thorough one done tomorrow or Tuesday. A clean car is a happier car.


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[RMode]

Gathering things for the new build




Also inbound Set of Torque Factory 2.5 inch lower inlets coming too. I’ll have some matching uppers made (they don’t make them unfortunately)

And a set of THE-Tuner exhaust manifolds with the heat shielding




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[CELison]

Guess I'll get a section of drywall cut out then.