Fun fun fun (Audi s4 k04 turbo upgrade)

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Fun fun fun (Audi s4 k04 turbo upgrade)

Post by Aesgarth @ Sat Sep 12, 2009 6:32 pm

My S4 is fcuked. Given the quote of £1000 for labour alone to fix it i decided to do it myself. This will save money if it works and result in a massive Ebay parts sale if it dosent.

The problems i currently know of are:
>fcuked turbos
>fcuked dump valves
>fcuked front hub

The turbos at the very least have failed oil seals. I know this because there is engine oil in my dump valves and in the intake, the dump valves are open almost all of the time meaning i have no boost, and as a result no power and the front hub has an issue with the ABS sensor which i partially understand but not entirely.

on to the pics: i will attempt to document my trial and error process in this thread, it will be a slow process.
In the garage:
Image

Bumper off:
Image

The Fox trying out a bit of cross-dressing
Image

Headlights out:
Image

Engine oil out:
Image
niiiiice

As it currently stands:
Image

Image

So far:
Bumper off, bumper bracket off, headlights disconnected and out, air filter and most of the intake out and one of the dump valves out. engine oil out.

next task: drain coolant and remove radiator. dont expect to get much done before next tuesday though as i'm mountain biking tomorrow and putting an engine back into a Mustang on monday/tuesday. :(
Last edited by Aesgarth on Thu Apr 08, 2010 7:26 pm, edited 1 time in total.
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Re: Fun fun fun

Post by Me. @ Sat Sep 12, 2009 6:51 pm

Cars hey...don't you just love 'em?

I just had a customers car fail it's MOT, he was stunned as 'it passed last time!'. It's a 20 year old E30 316i. :banghead:
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Re: Fun fun fun

Post by Gizmo @ Sat Sep 12, 2009 7:22 pm

Best of luck. I never have the space, nor the tools, never mind any idea where to start with this kind of thing.

However, I'm thinking of replacing the suspension on my MX5 soon, an enterprise which will no doubt be constructed largely of skinned knuckles and swearing.
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Re: Fun fun fun

Post by Aesgarth @ Sat Sep 12, 2009 7:27 pm

Don't get the impression that just because i appear to have the tools i have any clue what i'm doing. Chances are this will end in disaster. So far i have avoided skinned knuckles (barely when i snapped the head off my t-45 torx key) but there has already been lots of swearing. I'm buying tools as i discover i need them or when i break my old ones.
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Re: Fun fun fun

Post by Me. @ Sat Sep 12, 2009 7:38 pm

Take pics as you dissassemble, otherwise you will end up with a box of spares when you reassemble it.
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Re: Fun fun fun

Post by WD40 @ Sat Sep 12, 2009 7:42 pm

Gizmo wrote:Best of luck. I never have the space, nor the tools, never mind any idea where to start with this kind of thing.

However, I'm thinking of replacing the suspension on my MX5 soon, an enterprise which will no doubt be constructed largely of skinned knuckles and swearing.


...and result in a previously roadworthy & perfectly serviceable MX-5 languishing on a driveway sans suspension for a year or so awaiting the return of Giz' attention span? ;)
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Re: Fun fun fun

Post by Towie @ Sat Sep 12, 2009 7:50 pm

1. Silly point, but don`t forget to disconnect the battery. Best to remove it.
2. Don`t even think about disassembling the turbos, just remove them and give them to a specialist.
3. Remove and completely clean the intercooler and associated pipework. Remove all traces of the oil which will undoubtedly ne laguishing there. Failure to do this will very quickly fcuk your new turbos.
4. Before you emove the abs sensor, check the wiring is not frayed and that the connector plug in the loom has good contact.

Good Luck!
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Re: Fun fun fun

Post by nervy @ Sun Sep 13, 2009 12:23 pm

Gizmo wrote:However, I'm thinking of replacing the suspension on my MX5 soon, an enterprise which will no doubt be constructed largely of skinned knuckles and swearing.


me and muppet did his in less than 4 hours last week, and were both fuckwits.*

















* none taken.
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Re: Fun fun fun

Post by Gizmo @ Sun Sep 13, 2009 12:42 pm

nervy wrote:
Gizmo wrote:However, I'm thinking of replacing the suspension on my MX5 soon, an enterprise which will no doubt be constructed largely of skinned knuckles and swearing.


me and muppet did his in less than 4 hours last week, and were both fuckwits.*












* none taken.

Shouldn't take me less than a week then :)
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Re: Fun fun fun

Post by The Dragon Slayer @ Sun Sep 13, 2009 12:49 pm

Towie wrote:1. Silly point, but don`t forget to disconnect the battery. Best to remove it.
2. Don`t even think about disassembling the turbos, just remove them and give them to a specialist.
3. Remove and completely clean the intercooler and associated pipework. Remove all traces of the oil which will undoubtedly ne laguishing there. Failure to do this will very quickly fcuk your new turbos.
4. Before you emove the abs sensor, check the wiring is not frayed and that the connector plug in the loom has good contact.

Good Luck!


What this man said.
Don't even think about looking in/cocking about the turbos. You will almost certainly break them and need new ones, which won't be cheap. But would mean you could get bigger/better ones. :D Oh, the higher in the air you can get the car, the better. Nowt worse than having to dig around behind your head for that bolt/tool you just dropped, but can't quite see as you are unable to turn around fully.
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Re: Fun fun fun

Post by Aesgarth @ Sun Sep 13, 2009 2:09 pm

Mr Maz wrote:
Towie wrote:1. Silly point, but don`t forget to disconnect the battery. Best to remove it.
2. Don`t even think about disassembling the turbos, just remove them and give them to a specialist.
3. Remove and completely clean the intercooler and associated pipework. Remove all traces of the oil which will undoubtedly ne laguishing there. Failure to do this will very quickly fcuk your new turbos.
4. Before you emove the abs sensor, check the wiring is not frayed and that the connector plug in the loom has good contact.

Good Luck!


What this man said.
Don't even think about looking in/cocking about the turbos. You will almost certainly break them and need new ones, which won't be cheap. But would mean you could get bigger/better ones. :D Oh, the higher in the air you can get the car, the better. Nowt worse than having to dig around behind your head for that bolt/tool you just dropped, but can't quite see as you are unable to turn around fully.

Battery already disconnected. was the second thing i did after opening the bonnet. The only thing i intend to do with the turbos is wipe any crap off and put them in a box to be posted. I dont see how failing to clean my intercooler will in any way affect the new turbos, the air goes from the turbo into the intercooler then into the engine - thats how the oil got there in the first place. i will however be thouroughly cleaning any bits i don't replace anyway. Not going to worry about the ABS yet, not until after the engine is out at any rate.

If i'm honest bigger turbos was always the plan. This is just the excuse i was looking for.
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Re: Fun fun fun

Post by Turntable @ Sun Sep 13, 2009 4:34 pm

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Re: Fun fun fun

Post by Aesgarth @ Sun Sep 13, 2009 6:50 pm

blindswelledrat wrote:Good luck with this. The very thought of this kind of thing terrifies me.

Me too. The thought of handing over £1000 to have someone else do it terrified me more though.

Radiator came off today, what a pain in the arse that job is. Got oil and coolant bloody everywhere.

Image
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Re: Fun fun fun

Post by NNK @ Sun Sep 13, 2009 7:19 pm

You are one brave man. The only way I could get a car to the stage in the last photo was if I was dismantling it forever.
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Re: Fun fun fun

Post by Aesgarth @ Mon Sep 14, 2009 12:21 am

Not now Kato wrote:You are one brave man. The only way I could get a car to the stage in the last photo was if I was dismantling it forever.

:rofl: It could well end up that dismantling it forever is the way it ends up. engine and transmission are to come out yet :hehe:
Permanent dismantlement is not the current plan but could well happen.
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Re: Fun fun fun

Post by Tokyo Sexwale @ Mon Sep 14, 2009 8:18 am

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Re: Fun fun fun

Post by Great Pretender @ Mon Sep 14, 2009 9:37 am

'kinnel,

Am I correct to assume that the engine needs to come out in order to replace the turbos?
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Re: Fun fun fun

Post by Aesgarth @ Wed Sep 16, 2009 5:58 pm

carrera2 wrote:You know you'll never be able to sell this to one of us now don't you? Regardless of whether you fix it or not - this is how your car will be remembered.

Really? not even with 415HP? (that being the target) I'm sure someone on here would want it. Just not for the amount of money i want for it. trouble is no matter where i try to sell it that would be the case, even without this.

Great Pretender wrote:'kinnel,

Am I correct to assume that the engine needs to come out in order to replace the turbos?

Yes. That would be correct.



Update coming shortly.
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Re: Fun fun fun

Post by Aesgarth @ Wed Sep 16, 2009 6:13 pm

OK, so far i have:
Removed the battery cover and bonnet seals
Disconnected the battery
Removed front grille and foglights
Disconnected headlamp washers and removed bumper
Removed belly pan
Drained oil
Removed headlamps
Detached bonnet release cable
Removed air filter and connecting ducts
Removed Y pipe from top of engine
Removed top half of airbox and associated electrical connections
Removed bumper supports
Detached front fan
Detached A/C condenser
Drained coolant and detached radiator hoses
Detached oil cooler hoses (forgot they were full of oil at the time)
Removed radiator and oil cooler
Removed intake pipes with intercooler hoses attached
Removed dump valves
Removed lower radiator mount
Removed hard coolant line from front of engine
Removed oild filter
Detached fuel lines
Removed serpentine belt
Detached A/C compressor.

As it currently stands:
Image

Pile of bits:
Image

Tomorrow if i'm lucky the driveshafts get disconnected, the rest of the wiring harness gets disconnected and the engine and gearbox come out.
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Re: Fun fun fun

Post by TheCaseAce @ Wed Sep 16, 2009 6:18 pm

Jesus. I am glad there are people in the world who will do things like this in exchange for money.
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Re: Fun fun fun

Post by Aesgarth @ Wed Sep 16, 2009 6:19 pm

TheCaseAce wrote:Jesus. I am glad there are people in the world who will do things like this in exchange for money.

Unfortunately for a job this big they charge almost the value of the car including parts and labour. A price i'm not able to justify.
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Re: Fun fun fun

Post by Towie @ Wed Sep 16, 2009 7:19 pm

Aesgarth wrote:Radiator came off today, what a pain in the arse that job is. Got oil and coolant bloody everywhere.


Well timed tip number 27.

Always drain the coolant before you have the car in the place you are going to work on it......
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Re: Fun fun fun

Post by TheCaseAce @ Wed Sep 16, 2009 7:58 pm

Aesgarth wrote:
TheCaseAce wrote:Jesus. I am glad there are people in the world who will do things like this in exchange for money.

Unfortunately for a job this big they charge almost the value of the car including parts and labour. A price i'm not able to justify.

Wow I thought that car would be worth £8-10k.
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Re: Fun fun fun

Post by Aesgarth @ Wed Sep 16, 2009 8:05 pm

Towie wrote:
Aesgarth wrote:Radiator came off today, what a pain in the arse that job is. Got oil and coolant bloody everywhere.


Well timed tip number 27.

Always drain the coolant before you have the car in the place you are going to work on it......

I drained most of it into a bucket, but it still got everywhere. and then more escaped when i actually took the radiator off, which made more mess than actually draining it.



TheCaseAce wrote:
Aesgarth wrote:
TheCaseAce wrote:Jesus. I am glad there are people in the world who will do things like this in exchange for money.

Unfortunately for a job this big they charge almost the value of the car including parts and labour. A price i'm not able to justify.

Wow I thought that car would be worth £8-10k.

More like 4-5 (very optimistic) in its current state, 5.5-7 when fixed. maybe a bit more if i go through with the upgrades i'm considering but not a great deal.

eta: more like 3-4 in current state on a good day:
http://www.pistonheads.com/sales/1146152.htm
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Re: Fun fun fun

Post by Pigeon @ Thu Sep 17, 2009 3:50 am

Aesgarth wrote:
Towie wrote:
Aesgarth wrote:Radiator came off today, what a pain in the arse that job is. Got oil and coolant bloody everywhere.


Well timed tip number 27.

Always drain the coolant before you have the car in the place you are going to work on it......


I drained most of it into a bucket, but it still got everywhere. and then more escaped when i actually took the radiator off, which made more mess than actually draining it.


There is always, no matter what you do, enough coolant remaining in the system to (a) make a sticky green puddle on the floor right where you need to lie to get at something and (b) to drip continuously on your head while you're under there.
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Re: Fun fun fun

Post by onomatopoeia @ Thu Sep 17, 2009 7:32 am

Gizmo wrote:Best of luck. I never have the space, nor the tools, never mind any idea where to start with this kind of thing.


Space = garage. Many houses have them.
Tools = Halfords, get a kit of spanners, sockets etc to get you going, add to it as you need to. Machine Mart for big stuff like engine hoists if you can't lift it yourself.
Idea = Haynes manual. The way many amateurs get started fixing their own car (including me).

A lot of car mechanicing is like playing with Lego, but with spanners.
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Re: Fun fun fun

Post by minimoog @ Thu Sep 17, 2009 7:56 am

onomatopoeia wrote:A lot of car mechanicing is like playing with Lego, but with spanners.


And blood. Don't forget the blood.
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Re: Fun fun fun

Post by 33JS @ Thu Sep 17, 2009 8:07 am

Aesgarth wrote: Not going to worry about the ABS yet, not until after the engine is out at any rate.


Chances are the ABS will be the easiest problem to solve on these. Always start at the sensors. Unless Audi changed their design, it's likely that it's just the splined part of the drive shaft being full of shite or rust.

buy plastic ABS sensor caps from VAG - about £1 each
Disconnect sensor cable
Undo allen screw and slide out sensor from strut
remove old plastic cap
clean splines on drive shaft
put new cap on sensor
slide sensor back in until resistance felt and 'o' ring pops into groove
turn drive shaft and listen for the little teeth on plastic cap breaking
repeat 3 more times
done.

Hopefully ABS now sorted.
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Re: Fun fun fun

Post by Shampoo Efficient @ Thu Sep 17, 2009 11:48 am

minimoog wrote:
onomatopoeia wrote:A lot of car mechanicing is like playing with Lego, but with spanners.


And blood. Don't forget the blood.


And rag-n-bone men coming along every day and asking if X or Y is for scrap. If it was scrap, I wouldn't have spent four hours carefully removing it from the car, would I?

Time to move everything into the shed or garage, methinks... and get some BIG padlocks.
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Re: Fun fun fun

Post by onomatopoeia @ Thu Sep 17, 2009 11:51 am

PeteG wrote:And rag-n-bone men coming along every day and asking if X or Y is for scrap. If it was scrap, I wouldn't have spent four hours carefully removing it from the car, would I?


Oh I get them. And when I point to the panels I cut off the old Imp with an angle grinder they get all huffy and say they take up a lot of room on the pickup and are only worth a couple of quid, haven't I got any engine blocks they could have?
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