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My UrS6 Avant

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  • My UrS6 Avant

    Since I have some leave from work and some more time, I thought I'd put up the details of my car as well.

    The Purchase
    I started getting really bored with FWD after the last few hard winters, so I set out looking for a car.
    Gathering experience from my previous car ownership, I understood some features that I wanted in the car.

    So, I narrowed down the list of features that I had to have:
    1) All wheel drive
    2) At least 200 bhp on tap
    3) Automatic climate control
    4) Electric seats with memory function

    Now, there were not a lot of cars fitting the bill.
    In the end, I got to two - Audi Urs6 and Infiniti FX35.
    Very different cars on very different ends on the spectrum, but let me explain.

    I could either buy the Audi with cash, or I could lease the FX35. Being more confident in my driving skills, I decided against being a slave of the bank, and chose the Audi, saving on the insurance as well.
    I then started doing lots of research - and understood, that for best resale value I need to get a car with the 2.2 Liter turbo engine and a manual gearbox. Little did I know what ride I was going to be in for.

    The choice was not very large, and most cars I looked at were in very bad condition. I finally found one for 4000 euros.
    The previous owner had also written about the car on the Estonian Audi Club forum.
    The car was originally imported from Italy, and it was obvious there was a front collision. Although all airbags are in tact, the front paintwork is pretty shoddy, and the bumper does not sit perfectly.

    Quite a bit of work was done by the previous owner (I also got a ton of receipts passed on from the owner before, but I won't detail those):
    * Zimmerman ventilated brake discs front and rear
    * Gearbox and rear differential oil change
    * New brake bomb (sp?)
    * New clutch kit (luk)
    * 1.8T coilpack conversion
    * New ignition lock
    * Engine mounts
    * Afterrun pump
    * Timing belt, water pump
    * Viscous fan
    * New windshield and rear glass as well
    * New Hall sensor
    * New engine coolant temp sensor
    * Steering wheel and gear knob re-upholstered
    * Decat

    I drove the car, and it drove nicely. In fact, I did not notice anything off except a couple rattles.
    So I got it checked out by an Audi specialist.

    The results were actually pretty good. Here is a list:
    * Nearly all the bushings in the suspension needed replacing
    * Brake lines have cracks
    * All bushings of the rear differential and the main pad (sp?) need changing
    * Valve cover leaking slightly
    * Power steering pump leaking
    * IAC valve not working properly

    We agreed with the owner, that I will buy the car, but we will split all those repairs 50/50.
    Here are some pictures of the car from the original sale ad:




    Initial restoration
    What I found out later, is that the Audi workshop did not find all the little issues and niggles, and I'd have to fix quite a bit more. But such is life with these cars.

    Here are some pics of removing the faults that were found by the workshop:





















    http://tuner.ee - http://www.facebook.com/tuner.ee

  • #2
    Further ownership
    Here are some pics from my (then) two cars:






    Very soon, my car left me stranded. Fortunately in my own driveway
    The issue was with physical pieces inside the ignition lock being bent.
    So those got fixed.

    Since then, I have done the following:
    237042 - Fixing the ignition lock
    237072 - Oil change, 5w40
    237452 - Tyre change + balancing
    237682 - Alternator belt tensioner, lights inside, boost leak
    238522 - Handbrake cable, rear window wiper motor, air out of the clutch, more boost leaks, lights level in cabin, replaced all vaccuum hoses.
    238565 - Full rebalance of the suspension
    238789 - Injector cleaning on a special stand with high pressure and ultrasound. New O rings for the injectors
    239172 - New MAF (RS2)


    239806 - New drivers side mirror, it got stolen while the car was parked outside the house at night
    240000 - Front right wheel bearing - SKF
    240700 - New clutch pedal (I broke it... don't ask), new clutch master cylinder
    241300 - Straightening of one alloy wheel.

    Engine rebuild
    At this point, I had driven into a pretty secluded place in the country, and because there are really long straight roads with absolutely no one in sight, the car got plenty of thrashing.
    After I got back home (it was about 2000km road trip), I heard some ticking from my engine. I checked the oil level and realized that I had burned a liter in 2500 km.
    The turbo was fine, so the choice was to make an engine rebuild.

    So at 242600, it was time.
    * New rod bearings
    * New piston rings
    * All gaskets - head gasket, intake, exhaust, turbo etc
    * Spark plugs - Bosch FR5DP
    * Valve guides
    * Some more O rings
    * Head polishing & repair
    * Crankshaft got slightly polished as well
    * RS2 Replica exhaust manifold







    Engine bay before rebuild:



    When the engine was opened, the sight was not very pretty - O-rings being stuck, etc.
    I sadly do not have pics of the rebuild, as I was not always present at the workshop during the time, and I did not take pics.
    One particular thing is, that I needed two gaskets for the turbo, because the exhaust manifold otherwise did not seal properly. I guess such is the life with replicas.

    After I finally got my car back, I decided to celebrate it:


    More history, until today
    243106 - Cabin air filter. It had about four different layers of decomposing stuff inside. No idea if it had EVER been changed.
    243860 - Metal MAF->Turbo hose, Silicone+Metal Turbo->IC hose.
    243900 - Because cleaning was not giving the desired effect anymore - new IAC valve.
    244060 - Changed the fuel filter
    244430 - Changed the fuel pump for a Denso pump, similar to specs with 255 LPH Walbro.
    245100 - Changed the Intercooler entry hose, it literally burst under boost.

    Currently I have a leak-free car that does not eat oil and happily runs 1.6 bar boost all day without any new leaks developing. Also installed an SLC DIY WBO2 kit:




    TODO list
    * Fix rear window heating
    * Fix left mirror heating
    * Change heater matrix
    * Change climate control fan
    * Find out what is stuck and why the climate control does not want to blow warm air towards passengers legs
    * Go to dyno and fine-tune ignition timing cell-by-cell.

    I intentionally left out all the info and history on how I started working on Motronic.
    That is a story for another time
    Last edited by prj; 13 January 2011, 01:49.
    http://tuner.ee - http://www.facebook.com/tuner.ee

    Comment


    • #3
      Reserved #2
      http://tuner.ee - http://www.facebook.com/tuner.ee

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      • #4
        Prj,

        Can I ask how long have you owned it?

        and what were your previous cars?

        The reason being you seem to be very familiar with the 20vt engine from your posts over the last while.

        Kind regards.

        Comment


        • #5
          The car looks fresh. Nice interior.

          Audi UrS4 Avant 2.5 20vt - twincharged - Project
          Audi 80q B4 Sedan 2.2 20vt - Daily user
          BMW 320d Touring e91 M-Sport - Daily user
          BMW 740iA e38 - Project

          Comment


          • #6
            Originally posted by David in Dublin View Post
            Can I ask how long have you owned it?

            and what were your previous cars?

            The reason being you seem to be very familiar with the 20vt engine from your posts over the last while.

            Kind regards.
            Not very long - about a year.
            I have a lot to learn still, but all ICE's are similar to some extent.

            But no, I have not owned an Audi before this one, so all the stuff about turbocharging was very new to me at start.
            Only had N/A before. Fortunately there are good books and other resources to learn from

            Originally posted by Thuppu View Post
            The car looks fresh. Nice interior.
            Indeed. That played a large part of why I bought it. The seats are not worn out and it has been looked after well on the inside, but outside I need to re-spray the front bumper and hood, since it was not painted very well. The colours match, but the paint is cracking.
            http://tuner.ee - http://www.facebook.com/tuner.ee

            Comment


            • #7
              Holy smoke, now I catch the credit card. Thats nice!

              Audi UrS4 Avant 2.5 20vt - twincharged - Project
              Audi 80q B4 Sedan 2.2 20vt - Daily user
              BMW 320d Touring e91 M-Sport - Daily user
              BMW 740iA e38 - Project

              Comment


              • #8
                Originally posted by Thuppu View Post
                Holy smoke, now I catch the credit card. Thats nice!
                Thanks
                http://tuner.ee - http://www.facebook.com/tuner.ee

                Comment


                • #9
                  Prj,

                  I know you'll say I don't need it, but I was just wondering if the RS2 MAF was installed by itself, and if so do you feel it made any noticeable improvement ?

                  I'm assuming you'll say, no it didn't but as I needed a new ANN one I might as well get an ADU one?

                  What I had in mind was seeing if it is possible to get the two black plastic grilles from either end of the RS2 one and put them on my std S2 MAF ?

                  Will post a separate thread about this for greater exposure for the query.

                  At your rate of progress with your car, it will be interesting to see how it is in 12 months time.

                  Comment


                  • #10
                    Originally posted by David in Dublin View Post
                    I know you'll say I don't need it, but I was just wondering if the RS2 MAF was installed by itself, and if so do you feel it made any noticeable improvement ?

                    I'm assuming you'll say, no it didn't but as I needed a new ANN one I might as well get an ADU one?
                    The ADU one is 25% cheaper. That's the only reason I got it (and obviously because my old MAF stopped working).
                    They are exactly the same, I have taken my friend's AAN MAF, swapped it around, done a datalog in third gear WOT, put my ADU MAF back, did the datalog and the AFR was exactly the same. Not even 0.1 difference.
                    So - if your AAN maf works fine, no need to change it.
                    What I had in mind was seeing if it is possible to get the two black plastic grilles from either end of the RS2 one and put them on my std S2 MAF ?
                    Not sure.
                    Here is some photo material:







                    At your rate of progress with your car, it will be interesting to see how it is in 12 months time.
                    Hehe, I can literally just get a bigger turbo and injectors right now, and get 350hp or so. Perhaps the K24-7400 route would be interesting.

                    But first I want to fix everything that is wrong, including the little bits.
                    http://tuner.ee - http://www.facebook.com/tuner.ee

                    Comment


                    • #11
                      Great looking car in Silver. You didn't half get stuck into that suspension etc. Good luck with the machine.
                      Last edited by s2_wot; 4 August 2011, 22:48.
                      Shane

                      Comment


                      • #12
                        Originally posted by prj View Post
                        We agreed with the owner, that I will buy the car, but we will split all those repairs 50/50.
                        I wish I'd have thought of a deal like that. Great car Dmitri, delighted to see you have all of the maintenance taken care of. I'd be very keen to see where you end up with this one.

                        One question, in this photo there is a cover over the electrical connections that are mounted on the bulkhead (the black plastic under the strut brace). Is that an audi part, I'd like to have one on my car it would tidy up that place a lot..

                        Shane

                        Comment


                        • #13
                          Originally posted by s2_wot View Post
                          One question, in this photo there is a cover over the electrical connections that are mounted on the bulkhead (the black plastic under the strut brace). Is that an audi part, I'd like to have one on my car it would tidy up that place a lot..
                          UrS4/S6 cover cap - satin black

                          LHD - 4A0972807 01C
                          RHD - 4A2972807 01C

                          Locking hook - 4A0972619 (x2)
                          Clip - 4A0972621 (x2)

                          Audi UrS4 Avant 2.5 20vt - twincharged - Project
                          Audi 80q B4 Sedan 2.2 20vt - Daily user
                          BMW 320d Touring e91 M-Sport - Daily user
                          BMW 740iA e38 - Project

                          Comment


                          • #14
                            That should be an OEM part, basically a heatshield for POS's.

                            Prj, the K24-7400, is a good idea, iv'e been thinking about the same turbo in my car. Probably, after I get my gearbox and whatever-else-pops-up sorted... Next summer maybe

                            PS: This car is the first reason why I started thinking towards getting my slushbox out and replacing it with manual.

                            Comment


                            • #15
                              Ok, so fitted K26/K27 and mapped the car to about 400hp.
                              Then the bearing spun on the 2nd cyl when letting off gas.
                              Inside the engine is like new everywhere. All bearings, head, valves, pistons, rods, everything perfect except for the 2nd cyl. There of course the crank is damaged, the bearings are waste and so is the rod.
                              The conclusion: the crankshaft had marks on the 2nd cyl before, and it was put together like that, so this is likely what caused the failure, because the rest of the engine looks perfect.

                              So...
                              I got a "new" used crank, getting that measured as well...
                              New bearings, all new gaskets, etc.
                              Soon the engine will be out of the car and getting rebuilt.
                              I also lent my 2.5TFSI coilpacks to my good friend, who's car I mapped with GT30R, so will need to work something out there.


                              Meanwhile I got me one of these for 1000 euros:


                              Fixed a bunch of things on it, and now using it as daily driver until my S6 is fixed. 2.5 TD BMW engine, auto gearbox
                              http://tuner.ee - http://www.facebook.com/tuner.ee

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