B4 Avant - 2.0E to 2.2T

[K Simmonds]

The difficult nut on the back of the down pipe can be reached either by butchering a spanner or removing the starter motor and using a 3/8" drive socket/short extension. I've used both methods with success.

[NiTeC]

yeah I thought that was the relay but it sure doesn't look like one...

simmonds: I`ll try through the starter today...I still have to undo the driveshafts so perhaps it will be easier to reach it from the bottom...

[Audicted]

Hey Emil: Just popped in to say I'll be sure to track your progress on this forum.

Mario

[NiTeC]

Mario what's up buddy!

sigh....I was dead set on taking the AAN out today so it was a frustrating afternoon....

I couldn't get ahold of the downpipe bolt at first...a seized driveshaft bolt made it impossible to reach back without getting the downpipe out so I decided to take the head off (thinking the exhaust will follow)...If I only thought this through I'd see that the driver side downpipe would never squeeze through there...In the end when I lifted the head up I managed to get a wrench around the last downpipe bolt and got the exhaust out of there...

Mid afternoon:



and after a very good fight with this donkey I managed to pull it out...



its unbelievable how huge the tranny actually is...I'm pretty sure my B5 tranny is a lot smaller...I should put them together for some comparison pics...

and of course I had to play with my old R32 bumper

[NiTeC]

Parts list time (taken from 034's website)

Pistons: JE Forged (stock crank) - 949$
Rods: Scat Forged (20mm pin) - 595$
Studs: APR - 180$
Exhaust manifold: External WG/T3 flange - 295$
Turbo: GT3071R - 1395$
WG: Tial 38mm - 400$
Chip: GT3071R - 1049$
IC: S2/RS2 fit - 690$
Clutch/flywheel: ?? (not sure what to get for the 1.8T tranny) anyone?

It looks like I'll stop at the bottom end and turbo for now and just rebuild the head...the head will get more attention down the road...am I missing anything major?

Any comments on the parts list? According to 034 this hardware should put me around 340bhp, which should be plenty fun with a FWD...

[Acidburn]

Parts list time (taken from 034's website)

Pistons: JE Forged (stock crank) - 949$
Rods: Scat Forged (20mm pin) - 595$
Studs: APR - 180$
Exhaust manifold: External WG/T3 flange - 295$
Turbo: GT3071R - 1395$
WG: Tial 38mm - 400$
Chip: GT3071R - 1049$
IC: S2/RS2 fit - 690$
Clutch/flywheel: ?? (not sure what to get for the 1.8T tranny) anyone?

It looks like I'll stop at the bottom end and turbo for now and just rebuild the head...the head will get more attention down the road...am I missing anything major?

Any comments on the parts list? According to 034 this hardware should put me around 340bhp, which should be plenty fun with a FWD...

For what its worth, just get the following:

rs2 turbo
rs2 manifold
rs2 downpipe
rs2 injectors
bigger intercooler
chip

and you'd be doing around 380bhp for less depending what clutch you end up using.

Check threads by other forum members and save yourself some money.

[NiTeC]

what a pleasure it was to talk to 034 Motorsport today...no hesitation just straight service... :thanks:

on the order:

JE 81.5mm pistons
Scat rods
Main/connecting bearings
APR head studs

Also after a quick discussion with Dan (I think) we changed the turbo selection to the Garrett GT2871RS for a more linear power curve...he was worried the 3071 I had chosen would be way too much for the curves I'm about to tackle...the best thing is the turbo will be direct bolt-on to the stock manifold and I can use my original WG...here's some specs on their chip:

Specifications:

-26psi overboost, 22psi to redline, 7200rpm rev limiter
-Air/Fuel ratio 11.5-11.8 under boost, 14.7 under light load and idle conditions. Recommended for 91-93 octane fuel.
-330 wheel HP (to the wheels), estimated 400-425 crank HP.
-Injector duty cycle 85-90% max. under full load at peak rpm of 7200rpm.



very very very exciting stuff!

[NiTeC]

hah...I know...I'm equally scared and excited to see the final result...got some more work done today - tackled the wiring and damn what a task that was...

got in there:


had to take out the stupid heater because you can't pull out the wires without it...that thing is as big as the engine...



and after a couple of hours of solid and very uncomfortable fight:




then I got started on the head:


ok - what the heck is the secret to taking the intake manifold and the coolant crack pipe off? there are two bolts on the coolant line that are inaccessible from the top and without taking that off you can't get the manifold...there's gotta be a trick of some kind...

and the first of the parts started coming in...


hahaha - yeah I know the gaskets should be arriving last but at least it makes it look like it will actually be done one day

[Jamo]

Your crazy IMO a 2871 is a surge monster on the i5 and needs some very careful real time mapping
I would search the forum about 034 ecu chips, speak to Jade!

[Acidburn]

Your crazy IMO a 2871 is a surge monster on the i5 and needs some very careful real time mapping
I would search the forum about 034 ecu chips, speak to Jade!

agree with that

[NiTeC]

this is the word from 034...they suggested the 2871 vs the 28RS for the smoothness of the torque curve...what other turbo would you recommend then?

[Jamo]

You can use the 2871 but you are going to find the setup disappointing as the 034 tuning is going to be so safe the car is going to feel lifeless. The 28rs is too small for the I5 it's a non starter

What size hotside did they spec you? I'm hoping it's not the .63 and it's the .82

You could have run a RS2 or K26/K27 at least the generic chips for that setup are more advance if real time tuning is an issue.

I would consider ditching that and going http://www.s2forum.com/forum/showthread.php?t=42267 giving this http://www.s2forum.com/forum/showthread.php?t=4484


The 2871 is a good turbo Repo has tuned it to 458 bhp with vems but requires such precise tuning it's not one I would like without some proper chips, of course the alternative is buy the turbo ditch the 034 chips and speak to s2central, he did a 2871r on diesel des car was about 400 bhp I think they are ready for consumption.

[NiTeC]

the turbo is not finalized yet - i`ll talk with 034 again before I place the order...

very productive weekend this was....

Started off with:


and finished with:


then ripped the S4 legs off..



and dropped it like it's hot!

(on 3" wheels that is )

and as the S4 drove away on a flatbed the B4 rolled into the garage...

started cleaning up the cage:







From the front:


From the back:


and after some proper scrubbing and a first coat of paint it cleaned up pretty good:






The interior needs another coat or two and then everything goes back in...the pistons and rods should be in this week and the engine and head are off to the shop...

free pistons anybody?

[NiTeC]

We're live boys!

[NiTeC]

productivity is my middle name

touched the cage up a little bit


went from dirty:


to clean:


decided to play with the bumper:



R32? Why the heck not



a bit of trimming and a fresh coat:



and hmmm...what could this be?




:thanks: 034!!!


the interior is going in tomorrow and I'll try to get the bumper setup...the seat belts are the last thing I need to start driving around...still 2.0E but I'll get some seat time which is priceless...