B5 S4, operation money pit. Forever evolving, never ending.

[Exodus_2pt0]

Got the bore mic in and did some work on it tonight. Tons of meat left in the cylinders. Did a proper hone and remeasured afterwards. Gotta do the other side and then start fitting the rings.

[Exodus_2pt0]

Well after a lot of back and forth, I decided to gap the rings and throw it together. Taking out the ridge ended up with a bit of taper, but all above where the top ring will ride. From that point down I only have about .001" of taper, which I'm OK with. Worst case scenario I tear it down in 20,000 miles and punch it out to a 2.8.

Gapped the rings at .021, and finally got to do some more work. Got one bank done and installed tonight.





I need to order some more tools, crank lock pin so I can change the front main. Cam lock tool for timing belt install, cam gear puller for the seals. Then a new timing belt/pulleys.

Still a long way to go, need to clean the engine bay, rebuild the trans, and order turbos. Found my 4:1 center diff kit though, so that should be a fun bit when it gets running again.

Also, found a great alternative to burning pallets. These things run $2.50 a pack and I am able to get a night's worth of heat out of one. Load the stove and it burns around 600* for hours on end. With the pallets I was loading every 30 minutes.

[Exodus_2pt0]

Aggravated right now. Installed the 4th piston and noticed that it was much harder to turn over. These engines have a offset rod journal on the crank where journals are shared by opposing banks.

There's no thrust play for the rods once both are installed, and they rub pretty good. IMO it's shit, feels like shit, and would be an enemy to horsepower.

Waiting to hear back from some guys with 2.7T experience to either confirm or deny my concerns. I'm hoping that by some chance they are designed to wear in to each other.

[Exodus_2pt0]

Had some bad info on rod orientation. I was told that the bearing tangs should be towards the exhaust side of each bank. Removed and flipped the rods to the intake side, and magically everything is just how it should be.

Moving on....



Now to order a few more odds and ends and I can assemble the engine. Then it's on to the trans.

In turbo news, these new ball bearing turbos I've been told have authentic Garret gt28rs CHRA's and have put down 675whp so far.

It kind of makes a single not worth the extra effort.

[Exodus_2pt0]

Off topic, long after my Daughter gets bored playing in the garage and heads to the house, this guy is glad to keep me company.



Probably just because of the fire, but I'll take it.

[Clintoxx]

I had a noggy. I miss that car.

[Exodus_2pt0]

I had a noggy. I miss that car.

I can imagine. I don't see myself parting with this car any time soon.

Got the heads bolted down, front and rear mains changed. Had to put together a small order list with ECS for misalaneous items before I can finish assembling the engine. (Crank bolt, random o-rings, crank breather gasket, and some other random bits and pieces that nobody thinks about until needed.)

[Exodus_2pt0]

Woo boost!

Gt28rs hybrids are ordered. Should be good for up to 36psi and near 700awhp. I'm still shooting for 600whp now, and down the road maybe a little more.

Almost there, still need to order random bits and pieces to complete the engine, downpipes, and injectors.

Decided to do some painting, which I didn't intend to do and will surely regret. Since I didn't involve a machine shop or even remove the crank I didn't bother to clean anything other than gasket mating surfaces (don't want to wash oil out of bearings by spraying chemicals everywhere). Once everything is back together I'll tape off the open ports and give it a thorough bath.

[Julien]

How many people have left this thread for a craigslist s4? lol - keep up the posts, it's great

[Northern]

Yeah once or twice. I would go for an avant.

[HennaE30]

How many people have left this thread for a craigslist s4? lol - keep up the posts, it's great

More times than I can count. Exodus, you'll regret painting it black at least. It makes it a pain to see oil leaks.

Sent from my HTC One A9 using Tapatalk

[stonea]

How many people have left this thread for a craigslist s4? lol - keep up the posts, it's great

God knows I have. I really want one now, but at the same time I also want a e39 M5.

[Exodus_2pt0]

More times than I can count. Exodus, you'll regret painting it black at least. It makes it a pain to see oil leaks.

Sent from my HTC One A9 using Tapatalk

Oh I know it. Considering going red on the valve covers, but we shall see what happens.

Ordered most of my miscellaneous shit for the engine. Need to swing by a Audi dealer for a crank bolt that nobody seems to have in stock online.

Found some new Bosch unmodified injectors that flow 1100cc @ 4 bar, and 3" downpipes. Last parts on my list to order!

Getting excited, still a bit of labor ahead but at least I'll have everything on hand so I won't be waiting around.

[Exodus_2pt0]

Injectors and 3" downpipes on the way. Only thing left at this point is the crank bolt, and I need to pickup a press for the trans overhaul.

Getting there!

Oh, and this.

[Exodus_2pt0]

Injectors and downpipes have been delivered, as well as all the engine odds and ends! Still waiting on a crank bolt though, so there's always something...