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Thread: my DTM 'build' - story so far, hybrid K04 - custom FMIC

  1. #81
    olethalb's Avatar
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    haha thanks bud

    well popped to the garage last night, jumped in the car to leave and it took a few cranks to start which was odd, as i pulled off there was no power what so ever, felt like it was in limp. pulled over popped the bonnet and had a browse, everything seemed in order. turned off and restarted - still no good, so i nursed it home ~ 1 mile

    got up this morning and decided i'd check the HPFP first, popped the pump off and pullet the tappet out and was greeted with this....

    the middle one came out of the car and was brand new rom Audi 5k miles ago, the one on the right was in the car when i got it and was distorted and cracked, the one on the left was removed from car running stock pump and covered 11k



    i inspected the camshaft pump lobe, seems a little worn but it's not scored



    while i was in the bay i made up a stainless bracket and mounted my catch can





    took it around the block and all seems to be running well again, i'll order another tapped and keep one spare and check at 3k intervals.

    i think i'll invest in an S3 intake camshaft in the next couple of months to ease my mind a little

    also hoping my ally welder will be back to work after the christmas / new year break so i can get my pipework sorted

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  3. #82
    olethalb's Avatar
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    Just confirmed with Audi Camberley £254.90 for S3 inlet camshaft - 06F 109 101 G but none in the country so need to go down and pay before they'll order it from ze motherland

  4. #83
    Golfedd's Avatar
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    OUCH only 5k man! that's bad!... what the main difference between the camshafts to make the S3 one better?

    Have you thought or tried a TPS branch, they normally will knock a few ££'s off if you chat them up might make it £230 instead... just a thought. That Catch Can doesn't look like the fancy Saikoimichi Type 951 or is it the custom Bora one?

    Phantom A4 Build Thread

  5. #84
    olethalb's Avatar
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    oh yea, didn't even consider TPS

    alot of people say they are different profile, alot of others say they are the same - as far as i can work out the s3 cam pump lobe has and extra lifter, i think stock lobe is 3 point and s3 is 4?

    either way they both come up at the same price so it's a no brainer really.

    oh catch can is a 42 draft stainless jobby

  6. #85
    olethalb's Avatar
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    reading further into it the S3 cam is still Tri lobe but 'apparently' has a little extra lift and if i get the latest revision 06F 109 101 H the fuel pump lobe has a coating or is treated to reduce wear.

  7. #86

  8. #87
    olethalb's Avatar
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    thanks Chets - seen these, currently got an uprated intank pump on order from FR&R

    just concerened about added wear to the pump lobe from hardened follower. also think i'll get a pump stud kit so swapping followers is easier

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    Hi Olethalb.How easy is it to check the fuel pump follower? I am reasonably confident mechanically but unsure how to de-pressurize the fuel system,also I have no means to cancel any fault codes that might crop up in doing thisIs it worth doing? the mileage on my car is 45,000 it,s a 2ltr Bul engine...Cheers Paul...

  10. #89
    olethalb's Avatar
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    well the new stainless arrived



    so made a new template



    and decided to use the non polished side




    also got the boss welded on my boost pipe so i could fit the water meth injector



    fitted



    got my DV hard pipe back from the welders too




    now the heatshield was redone, had the DV pipe and my new slightly smaller Air filter i could have another crack at the intake.

    i decided i'd make a little more room for the filter so dropped the condenser 30mm



    and reshaped the pipes to give more room





    now there was a little more room i could mock up a new intake path








    once the pipe was mocked up, i now had to make a boss for the MAF sensor probe






    i'll try and get it down to the welders this week
    Craig Cull likes this.

  11. #90
    olethalb's Avatar
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    Paul - do you have early full hard piping to the pump?

  12. #91
    Golfedd's Avatar
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    That intake solution looks much better man! thought about having it coated too just to be even 'cooler' also second attempt on the heat shield was a gooooood shout!

    Phantom A4 Build Thread

  13. #92
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    Hi olethalb. I,m not sure what you mean as to the full hard piping to the pump..The car is a 2006 model with the 220bhp engine.Does this help you identify it???? All I want to know is do I need to de-presureize the fuel system to remove the pump? Cheers mate..Paul

  14. #93
    KemiksiZ's Avatar
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    Very taste mods

    A suggestion if you dont mind; get some bi-xenons.. The halogens show the car some kinda old fashioned!
    Golfedd likes this.


    '' Wanna Trade Your Pre-facelift BRUSHED ALU interior trim with my Piano Black ones? '' PM me..

  15. #94
    olethalb's Avatar
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    well got a call from the welder.....lovely.....






    also threw some paint on my DV return pipe


  16. #95
    olethalb's Avatar
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    got a couple of days off, so got up this morning and test fitted the intake




    once happy with the fit i sanded it back and layed some paint on it




    while that was hardening i made a blanking plate for the Turbo intake pipe



    fitted the maf to the intake



    now that was done i popped the filter on and fitted it to the car




    also took some pics of my complete delete of all oil breathers into the inlet tract - intake mani / turbo intake pipe

    BSH bullet proof PCV fix



    silicon blank on intake mani



    silicon blank on cam cover



    ally blanking plate on turbo intake



    breathers are no routed to catch can that vents to atmosphere as the TFSI suffers badly with build up on the valves. with this and the wmi should eventually have some cleaner valves.

  17. #96
    jjmurphy21187's Avatar
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    Excellent workmanship! Personally I would've left the intake pipe silver but it looks great as it is

    Car: 2007 A4 3.0TDI Quattro S-Line Cabriolet
    Mods: Pipercross Panel Filter, Smarttop, LED Plate Bulbs, LED Interior Bulbs, Blue LED Needles, Remap, EGR Delete, Custom Stainless Exhaust (4" Slash Tips), Cupra-R Splitter, Embossed Number Plates, 19" BBS CH Reps & Vredestein Ultra Sessanta's, 12mm TPI Spacers, -30m H&R Springs, MTEC Black Edition Brakes (Dimpled & Grooved), Mintex Pads, RS4 RARB, Vibe Square Subwoofer in Ski-pass & Alpine MRP-350 Amp

    VCDS - PM for details (East Midlands)

  18. #97
    olethalb's Avatar
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    Fastmonkey - the DV return pipe was done in Halfords satin black, the Turbo intake pipe was done in Car Plan satin black, i prefer the Carplan finish TBH
    Spurred on by my intake being finished i popped down to Audi and ordered the 4 'extra' engine bay / scuttle covers. i couldn't belive it when they said the had 2 of them in stock.
    i ordered
    A/C pipe cover / intake cover
    ABS / Fluids cover
    Scuttle cover
    battery cover
    fitting components

    battery cover

    scuttle cover

    as it comes, small pollen filter cover on the passenger side


    new scuttle and battery cover fitted

    found a vauxhall brake res cap in the shed


    then cut a bit of carbon sheet to size and put good old fabric tape around the edge to keep it frm rubbing


    fitted

    now that was done i gave it a wipe over


    and inside



    oh and my cigar lighter 'mod' from a B6 A4


  19. #98
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    Looks gorgeous! Where abouts you located? You said you go to Camberley Audi for your parts. Go to Guildford TPS instead. Used to work there, it's much cheaper than Audi themselves, and you don't pay anything upfront, and you can return parts (not like Audi). You are meant to be trade (Trade Parts Specialists), but I'm sure they will sort you out.
    2011 Audi-Sport.net Fantasy Formula 1 Champion

    2005 Audi A6 3.2FSI S-Line Quattro Stratos Blue
    19x9 S6 / Half Leather Interior / Memory Seats / Black Headlining / S6 Paddle Wheel / S6 Exhaust
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    Double Glazing / Auto Dimming Interior & Exterior Folding Mirrors / Storage Pack / Lighting Pack

  20. #99
    olethalb's Avatar
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    Chris - i'm from Bracknell way bud, i have friends who get a good discount at TPS but i'm too impatient haha

    well Audi text me this morning to say my parts are ready....
    rs4 side cover

    A/C pipe cover from TDI

    fittings

    abs / fluids side

    spacer and grommet fitted

    cover fitted


    A/C pipe cover will need modifications to work with my set up

  21. #100
    ASC
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    Very, very, very nice mate.. Grand job!
    2006 Sprint Blue S4 Avant - 2.5" catless DP's - Miltek Non Res cat back - BMC panel filter - JHM remap - H&R springs - EBC TG discs - Yellow stuff pads - Matt/Polished RS4's

  22. #101
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    I'm sure I saw you a few months ago when I was over in Bracknell I'm from Aldershot

    Audi takes longer to get parts than TPS. Most stuff is in next day at TPS, with only bits coming from Germany taking a week or so. But I suppose Camberleys a lot closer than Guildford.

    Makes me wish I still had my DTM (albeit a replica!)
    2011 Audi-Sport.net Fantasy Formula 1 Champion

    2005 Audi A6 3.2FSI S-Line Quattro Stratos Blue
    19x9 S6 / Half Leather Interior / Memory Seats / Black Headlining / S6 Paddle Wheel / S6 Exhaust
    Front & Rear Parking Sensors / TPMS / Adaptive Xenons / Actuated Boot Lid / Bose / Sat Nav / Bluetooth / Sunroof
    Double Glazing / Auto Dimming Interior & Exterior Folding Mirrors / Storage Pack / Lighting Pack

  23. #102
    Golfedd's Avatar
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    oh dam! I want your centre console with the flip up ciggy lighter! damn it!

    Looking good bolllywood!

    Phantom A4 Build Thread

  24. #103
    ANDYTQ's Avatar
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    Just need r8 oil cap and porsche header tank cap now to finish it off ,plus some red coil packs.Very nice work dude.
    06 A4 AVANT QUATTRO 2.0T S-LINE SE,GARNET RED, RS4 REAR ARB,SPACERS ALLROUND,H & R SPRINGS,B5 PERCHES,A6 V8 RIMS.PORSCHE CAYENNE TURBO S SIX POTS .REVO ST2 MAP ,MILLTEK CATBACK EXHAUST,PANEL FILTER,034 INTAKE PIPE.

  25. #104
    olethalb's Avatar
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    well cam day today

    as it started



    loom pulled back, intake off



    metal coolant pipe pulled back to access HPFP



    HPFP union undone



    unbolted



    removed



    fuel pump follower



    withdrawn with finger



    500 mile wear on existing cam



    cam cover off



    vacuum pump off



    cam chain cover removed







    HPFP cam lobe





    cam marks and pointers







    cam box and cam out





    cam lobe - heavily worn



    comparison







    valve lobe lift comparison





    new cam in



    new follower



    all back together and cam cover painted satin black



    my cam was the A version

  26. #105
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    Love this build thread.

  27. #106
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    Good info keep up the good work

  28. #107
    olethalb's Avatar
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    thanks for all the comments

    in other news i think i've just bought a new 2.0T FSI engine, i've decided mine's getting a little long in the tooth if i'm trying to crack the 400bhp mark.....

    hopefully the deal goes through, i'll get delivery of a complete 20k mile K04 engine from seat leon with all ancillaries / box / turbo the lot, obviosly i'll just use bare block and head and flog the rest to claw some wedge back

  29. #108
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    Where on earth did you learn all this... XD great workmanship saves yourself ££££'s in the process.

  30. #109
    olethalb's Avatar
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    Jay - i used to work in the trade a good few years ago but was full of people trying to make a quick 'earner' by ripping people off so i got out of working for other people.

    well a couple of updates from the past week.....

    new lump was delivered

    wasted no time in pulling it apart, so i can get it ready for the swap and i can build my parts onto it.








  31. #110
    olethalb's Avatar
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    set about moving the parts off a spare A4 TFSI intake onto the new transverse one as they are a slightly different layoutfuel lines are routed differently

    [IMG]http://i276.photobucket.com/albums/kk32/ollethalb/dtm/4D5BE467-DB9F-4865-9770-33487B708542-3762-
    00000515A7B8AE80.jpg[/IMG]



    also the one way valve on part of the carbon canister / evap system can give out meaning you lose boost through it



    the line runs into to turbo intake via the cam cover but also into the intake mani, this is where the valve is subject to boost



    so i removed the pipework completely



    and removed the two ends i needed from the pipe



    now with some 3/8 air ride line i made a new line that goes direct to cam cover then to TIP, this is only under vacuum







    used heat to form the pipe to the shape i needed



    now that was done i was left with the intake mani outlet



    so used a blanking plug





    now that was done i could fit the fuel lines and give it a wipe over



    while i was at it i thought i'd strip out my spare Throttle Body and give it a once over





    bit of etch primer and satin black





    re assembled


  32. #111
    Golfedd's Avatar
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    oh the look of shiny new parts - new engine looks like a winner bollywood! hope to see north of the infamous 400bhp soon :-)

    Will the rev limiter be lifted? if so what you think it will take with balls to the walls? 9k? leaning out?

    Phantom A4 Build Thread

  33. #112
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    Superb build thread, some quality work put in there

  34. #113
    olethalb's Avatar
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    well been quiet a while, saved some pennies for an 034 SMF and southbend stage 2 endurance clutch kit - didn't get much change from £1k []

    also bought a couple of bits so i'm ready for the install, coolant, heatwrap for my DP and lambda boss to relocate my 'post cat' lambda. also bought 20L of oil as i'm getting ready for a few changes if i'm going to be testing this new turbo...



    when the clutch arrives [O] i'll be ready to drop the new lump in [funky]

  35. #114
    olethalb's Avatar
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    well as you can see not a lot happened for a while, first i was waiting for clutch then knee op. so i've been mainly sat in bed resting the leg and doing some internet purchasing - mainly ebay :D


    well the lads at Dubtech Customs sorted me out with the clutch and even hand delivered it to me

    034 billet SMF and southbend stage 2 endurance kit with all bolts, thrust bearing and pilot bearing





    then ebayed an RS4 intank pump controller



    se b7 grill



    rs6 grill



    carbon fibre bumper strip







    another centre console - without phone holder cut outs





    TT flat bottom wheel



    then changed my mind and went RS4



    and RS4 gearknob



    also ordered larger FMIC and some steel pipe to replace the crash bar to get maximum exposure

    looking forward to get the new bits all on and up together

  36. #115
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    Where did you get your Carbon fibre boot trim from dude? I got mine from a company on eBay and it is just a tad too short

  37. #116
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    same place i guess bud - Argon Creative, i was going to buy another one. thought i just got a bad one but if you have a short on too i'll mail them and complain.

  38. #117
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    Yea that's them. First they didn't send me any bonding agent to attach it then when they did and I tried fit it it was too short. The only way I could get around it was to paint the edges of the chrome trim black to disguise it. They were selling some cf pillar bits too but after the rear trim I can't trust.

  39. #118
    olethalb's Avatar
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    they sent me a couple of packs of some sort of glue which was no where near enough so i got a tube of windscreen bond. i sanded down the silver bit so it couldn't be seen but wasn't impressed with the fit to be honest.

    i'll pop them an email.

    i was going to buy the pillars too but to be honest if this is how 'good' the stuff is i'll just get some stock pillars skinned for half the price.

  40. #119
    craichouse's Avatar
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    “If everything seems under control, you're just not going fast enough."

  41. #120
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    Shame that argon's stuff didn't measure up well for either of you guys. I saw they had a facebook page might be worth a mention on there if they don't resolve it properly.

    Olly - looks good with the new additions for sure :-)

    Phantom A4 Build Thread

 

 
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