Tom's urS4 motor swap "mini-project"

[saltinot]

I thought about calling it "RS2 America distraction project", but I digress.

A week before Christmas my faithful 1994 S4 decided to loose compression in cylinder no.5. It was warm here and I had the windows open enjoying the lovely whine of my RS2 turbo and was sort of showing off a little with my co-workers in the car. I decide to stick the car in 2nd gear under boost threshhold and stomp it......letting the turbo spool up and make maximum noise in the process. Well, right as the boost was coming up something let go, I immediately pushed the clutch in. She's making an aweful ticking noise now.

I called for a ride and came back later to trailer the car home. It did a compression check last week which told the real story.......no.5 only had 100psi. So luckily I bought a salvage S4 with low miles in the Fall. So there is my motor.

So the plan is to pull the motor, not to mention break the remainder of the car for parts, and move my RS2 stuff to the replacement motor. During this process I'll disassemble, clean, replace gaskets, replace a few hoses and sensors and then put things back together.

This is is going to move at a much quicker pace than my RS2 project I can assure you. Pics to follow.

[iain1067]

Well good luck with, i believe my old urs6 suffered a failure on cylinder 5 too, hmmm wonder if it's trend in these engines developing with higher miles and higher boost than stock.


Iain

[saltinot]

Cheers.

That is interesting. How many miles did you car have when no.5 gave you trouble?

I cannot complain at all as the motor was original with 238k miles on the clock and it has been running 26lbs of boost for over 140k of those.

[iain1067]

oh er you got me on the mileage i think it was a mere baby at around 120k

[saltinot]

Starting off I pulled the engine from the donor car. There goes another S4...but it is for a good cause.




On the engine stand it goes and outside for a degreasing and general clean up. A little aluminum foil to cover the openings and electrical connectors.

[saltinot]

Fresh from the its bath, but still more scrubbing to do.

[saltinot]

Off comes the turbo....Wow....no cracks here?



....and the exhaust manifold.



Now to the intake side continuing to disassemble things. Started with this.



Inlet manifold with the throttle body and aux water pump/pump bracket removed. I've already gotten the itch to bead blast the water manifold and left motor mount bracket. Those have been placed back on the engine.

[saltinot]

Studs removed and one new stud test fitted. Right side motor mount bracket and front stub mount removed, blasted and returned to their place on the block.



Removed the viscous fan, fan pulley, and bearing. Media cleaned the alu fan bracket. Removed the cast iron hydraulic pump bracket, media blasted it, repainted it with Rustoleum Satin Black. Both are mounted in this picture. Serp belt tensioner get a new pulley and has been polished to a shine with a little jeweler's rouge and remounted.





I've ordered a bunch of gaskets, seals, etc. that should be arriving to tomorrow so I have to wait until those to arrive before I can continue. Just when I was starting to have fun.

[URQguy]

Nice. I want to do that with my s6 bad. It is my Daily right now, but my URQ got some new shoes, so maybe I will take on that project soon.

Hank

[saltinot]

I had a few hours over the past weekend to do some more work. All my gaskets arrived too so I made time.

I've been struggling with myself on this project. One part of me wants to tear the entire engine apart and start from the ground up, but the practical side of me says "just do a little cleanup with few new gasket and hoses and put it in the car".

Anyway, I cleaned up the inlet and valve cover and attached with new gaskets. The old injector inserts just fell apart when I attempted to remove them. I ended up heating the area around the inserts with MAPP gas until the plastic began to bubble a little. They were no trouble after that. I was glad for that!







Reattached the viscous fan with a new bearing.



The cast iron hydraulic pump bracket was beginning to turn rusty in a few spots toward the top, as they all do, so a short stint in the blast cabinet followed by a shot of new black paint and........

[saltinot]

more cleaning, blasting, etc. A new oil pressure switch is on the way. We all know how much fun those are to change so I thought I'd replace it while it was easy to reach.



Installed the throttle body, ISV, and all the brackets on the inlet manifold. The throttle body was filthy..........it had to soak in cleaner to break up the dirt/grease. Lookin' good now



This one is a just for fun comparo picture. Left is the stock S4 K24 turbo, the middle is RS2, and the Garrett on the right is the stock turbo from my 1997 Ford F250 7.3L turbo diesel pickup truck. You know everyone in the US has a pickup, right??
Is it just my eyes or is the Garrett is double the size if the K24?

[UrS4boy]

Tom: Make sure you do the hose from the water manifold to the hard pipe that goes to the turbo. They like to die at the most inopertune times.

You should announce the availability of pearl body parts on Audifans.com and AudiWorld (with a link to an Audifans marketplace ad).

[saltinot]

Thanks Dave. I've done two of those on my S4 in the car. Oh what a pain. I've already replaced that hose and the hose connects the T-stat with the black hard line the runs along the block.

I was waiting on a good snow storm to blow through the north before I posted my front bumper for sale. The only damage to this car was a bent quarter, deck lid(boot), and two taillights. It looks like an SUV hit it high in the back as the rear bumper wasn't even touched. I do have a bunch of spares to rid myself of at this point. This is the third S4 I've parted in four years so I should probably have a sale.

If anyone is looking for something just shout via PM.

[Nace20]

Thanks Dave. I've done two of those on my S4 in the car. Oh what a pain. I've already replaced that hose and the hose connects the T-stat with the black hard line the runs along the block.

whitch hose is that?

[saltinot]

The small water hose from the water manifold to the turbo. It can be seen in this picture running parallel and to the underside of the water manifold.