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After two years of planning began a week of more than full time work in my garage for two people.
The daily driver is now back on the road and producing good power.
Installed new K04's, ceramic coated stock exhaust mani's, resealed upper and lower engine oil pans, ECS Ultimate TB kit, AWE Intercoolers with custom stainless mounting, both forward O2 sensors, 034 street density engine mounts, RS4 trans mounts, replaced front outer CV boots, fuel filter, front rotors and pads, modded stock downpipes with relocated rear O2s, Vibrant 3" cat back exhaust, all new engine fluids and a bucket full of new seals, nuts and bolts.
Contrary to the "easy install" adverts, the AWE Intercoolers don't mount very nicely and rub on everything in the vicinity cause they're really big. Took extra time to fab custom stainless steel brackets to secure them properly so they are good and solid now.
Phenolic spacers are going in whenever I have to pull the intake.
Vogtlands are on the shelf and going in next spring.
Getting some bits together with more inbound at the time of this pic

ECS Timing Belt Kit done

The fun begins

Room to Party

Hoisted

Upper pan had an oil leak so reseal pans



Old K03's out and replaced before passenger side popped. Slight detectable end to end shaft play on driver side turbo. Passenger side turbo whistled under boost and had excessive end to end shaft play. Also noted Passenger turbo sluggish to spin by hand compared to driver turbo.


New K04 and ceramic coated stock exhaust manifold. Intake castings are quite rough so smoothed both K04 intake pipes

Replace a few damaged mani studs and cleanup threads on the rest

K04 Install Time



Drivetrain going back in


Downpipes with original rear O2 bungs capped and new bungs installed behind main cats. Did a few DP test fits to determine best angle of bung orientations before welding bungs in place. Re-dressed stock rear O2 wire harnesses with no extensions needed.



Ran engine with open DPs to blow out any remnant bits, then install 3" Cat Back






New front outer CV Boots


Fiddling the AWE Intercoolers





Bumper went back on to get to work the next day so no more pics. Bumper comes off again next weekend to tweak the intercooler mountings to perfection.
For those that dream of K04's... it's worth it


AWE Intercooler Install Update
http://forums.fourtitude.com/zerothread?id=3572795



Modified by GLS-S4 at 3:49 PM 12/3/2007
 

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Re: K04s and more... (GLS-S4)

Looks great http://****************.com/smile/emthup.gif do you have plans to upgrade the fueling soon?
 

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Re: K04s and more... (BeitzDUB)

hey any points u can give for what to look for or any tips on pulling motor during this job whats a bitch and how u did it. Im getting ready to do mine soon. What chip are u running are u running any fuel for the turbos and do u just have piggie pipes on there.
Thanks
Dan
 

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Re: K04s and more... (chaos2984)

Thats the hotness!
 

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Re: K04s and more... (chaos2984)

f*** it, get it all done at once! nice pics man! http://****************.com/smile/emthup.gif
 

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Re: K04s and more... (paranoia)

Looks very neat...Succes !! http://****************.com/smile/emthup.gif
 

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Re: K04s and more... (BeitzDUB)

Thanks for the feeback guys http://****************.com/smile/emthup.gif
Quote, originally posted by BeitzDUB »
Looks great http://****************.com/smile/emthup.gif do you have plans to upgrade the fueling soon?

I'm considering fueling for the future. Car has very good power right now for a daily driver and I'm liking it

I VAG Logged a ton of info before the upgrades and am now in process of VAG Logging all over again to determine new baselines. I'll compare the logs and go from there. I'm watching for any lean fueling conditions under higher RPM boost and no issue yet.

Quote, originally posted by chaos2984 »
hey any points u can give for what to look for or any tips on pulling motor during this job whats a bitch and how u did it. Im getting ready to do mine soon. What chip are u running are u running any fuel for the turbos and do u just have piggie pipes on there.

After the week was over I felt like I ran a marathon. It had it's moments of
but overall it sure was fun!!
I would strongly recommend ceramic coating the exhaust mani's to anyone who is replacing turbo's. There is a dramatic reduction in engine bay temps which means IAT's go down and components last longer.
I researched the motor pull for many months. Several write ups and tools listed under "Engine Pull - Turbo swap" at:
http://homepage.mac.com/edyjun1/S4/index.htm
No additional fueling yet but I replaced fuel filter to ensure good flow for now.
I'm running APR with 4 Slot enabled Flip Switch and EMCS support, primarily 91 Perf Code. In process of determining whether to reprogram or not... likely will next Spring when better injectors go in.
Piggies are home made for $15 of plug & bung pairs and are done up as per VAST specs. It's a bit of work so VAST's price is justifiable if you don't have the time or a welder.
http://vastperformance.com/sho...id=65

Quote, originally posted by EUROTEKS4 »
what website did you get the exhaust ?

Vibrant 3" Cat Back Exhaust was from an AudiWorld 10 person Group Buy last winter. This exhaust was from the Audi Accessory Catalog as an optional upgrade and dealer retailing for $1K. GB was half that. Fit and finish is perfect but I'm going to replace the 3" clamp with a better one. This exhaust sure sings a sweet song under boost.
http://vibrantperformance.com/...9367f
Startup Racing carries the Vibrant exhaust and it's on sale right now for $595
http://www.startupracing.com
 

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Nice Job!
It took me about a week to do mine also, then I was sore for another week.

Here's a picture from when I did mine, my garge isn't as nice as yours ahah


Heres how my K03's looked
 

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Re: (vwkid23)

What software are you going to run?
I got a sweet file that is faster than AWE and EPL. Waaay cheaper too.
 

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Discussion Starter #14
Re: (paranoia)

Car has 51K Miles and 2 PO's.
I'd like to learn more of the sweet file http://****************.com/smile/emthup.gif
The Vibrant is good. Build quality, fit and finish is spot on. I find it slightly droney in low RPMs, settles out nicely passing up thru 2K RPM under light accel, sounds awesome under boost. This vid is with a mostly stock car but gives a good reference:
http://video.google.com/videop...59083
 

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Re: (GLS-S4)

Quote, originally posted by GLS-S4 »

I'd like to learn more of the sweet file http://****************.com/smile/emthup.gif

me too http://****************.com/smile/emthup.gif
 

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Re: (GLS-S4)

nice work man! and your lift rocks http://****************.com/smile/emthup.gif

edit just realized your in canada, if your in my part of the country, you feel like doing another one sometime
http://****************.com/smile/emthup.gif


Modified by dubsix at 3:30 PM 11-9-2007
 

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Discussion Starter #17
Re: (dubsix)

If your up for the 1K drive http://****************.com/smile/emthup.gif
The Bendpak Lift is the best tool in the shop! Used mid height posts to access driveshaft and exhaust.
It has more than paid for itself over time

http://www.bendpak.com/cart_pr...id=49
 

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Re: (GLS-S4)

yeah that is a bit of a drive! who knows, maybe we'll talk before I am ready too jump into it, still parts collecting, we have alot of the same stuff, did you get your coils from Startup? those are the ones I am running, I really like them.
thanks for the link on the lift, man that looks like the perfect lift, although i would probably still have to drive up on boards to clear it as my car looks like it would be too low to drive over it.
 

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Discussion Starter #19
Re: (dubsix)

There is one high spot on the lift's mechanical lock that will rub so I drive up on a pair of 2x8's to clear, then proceed to lift.
Vogtland Coilovers and Intercoolers are from Mike at Purems http://****************.com/smile/emthup.gif
 

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Re: (GLS-S4)

that will change once you put the vogtlands in

Good tip on the AWE intercoolers, mine are on the way and here I thought it would be straight forward... at least I won't be putting them in thinking I am the only one that they don't go in easy for.
 
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