Badger5JMB Retrofits
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  1. #1
    evomaster3000's Avatar
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    Update on some engine work I've been doing: (1.9AFN)

    Well apart from tinkering with the install, since i'm now studying a motorsport degree, i now have more knowledge of engines and turbo's etc, so I've been intending to do a head re-build on the audi, so i set about it late last year.

    Started by stripping the turbo and manifolds off for a de-coke and clean out the vanes on the turbo.

    Then went on an removed the head and stripped it, replaced valve stem seals, cleaned all the carbon from the valves and re-lapped the valves, De-coked all the oil n **** from the ports! and there was a fair bit, loads on the inlet!

    Once all cleaned out set about giving it a clean and some colour!

    Head with valves re-fitted n re-lapped ready to be built back up:


    Complete head with turbo n cat, intake and EGR fitted:






    Now back to the car to clean the block for new head gasket:




    As you can see doing the head is a pig of a job on the A6 as the whole front end needs to be removed!


    New water pump fitted:

    May aswell get done as it cost 23 for a genuine new one and if it goes i'm not doin this job again so for 23 no point messing, get a new one even though the old one is fine.

    Head re-fitted and everything all piped back up. New Hydraulic lifters (some may have noticed my car sounding a little tappy - this should fix it!) Camshaft fitted and head all torqued up with new bolts.




    Thats how she sits at the moment, just need a mechanic to come and time her up properly and then fire her up!

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  3. #2
    dieselfitter251's Avatar
    Blow ma own trumpet?

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    DUde, hats off to you. My lump has now get 236k on her, I can't think of what crap has built up in there. It's all I can do flush at ever oil change, run some injector cleaner every now and then and treat her to some V-power.... Looking forward to how she runs!
    Ford Mondeo 2.0i Durtec Ghia X Estate
    Leather / Dog Hair.



    Dieselfitter 251
    A4 avant '97 1.9tdi q
    a.k.a. STINKY
    [B]250k!
    ..she's gooooonnnne!!!!

  4. #3
    APL TDi's Avatar
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    Good effort

    Whare are you doing your degree?
    2004 140 TDi sport 3dr (new turbo)

  5. #4
    evomaster3000's Avatar
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    Well I'm studying Oxford Brookes Road and race car tech course, i do 2 years at a college not too far away from me then final year @ oxford.

    The cleaning work i did an oil change wouldn't even touch! nor injector cleaner!

    The intake manifold was the worst! they say replacing it is easier than cleaning tho depends on the cost.

  6. #5
    devonmikeyboy's Avatar
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    Why waste money fitting a new CAT when you could/should have just removed it altogether along with removing the EGR system as well. It`s your EGR system that`s responsible for putting a lot of that crap in your pipework to start with.
    06 Audi 2.0 PD140 Sport TDI Quattro S-LINE.
    Old engine 330 bhp @ flywheel 263 bhp @ wheel 490 lb torque. Audidriver write up HERE
    Now stripped and playing with an uprated Cryo treated engine fitted with bigger turbo,water/methanol,uprated injectors etc etc.Wanting 400 bhp and 500 lb torque.

    Other car 500+ bhp MK4 Golf R32 turbo.

  7. #6
    dieselfitter251's Avatar
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    What are the chances of it passing the (PITA) emmisions test though? If you do remove the EGR, what do you do with the relevant pipes and vaccum hoses?
    Ford Mondeo 2.0i Durtec Ghia X Estate
    Leather / Dog Hair.



    Dieselfitter 251
    A4 avant '97 1.9tdi q
    a.k.a. STINKY
    [B]250k!
    ..she's gooooonnnne!!!!

  8. #7
    evomaster3000's Avatar
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    Quote Originally Posted by devonmikeyboy View Post
    Why waste money fitting a new CAT when you could/should have just removed it altogether along with removing the EGR system as well. It`s your EGR system that`s responsible for putting a lot of that crap in your pipework to start with.
    I agree, it's amazing what a bit of VHT paint does!

    I've read up about removing the cat and i plan to later but the EGR i'm not too sure, yeah it'll stop the crap build up but it's there for emmission reasons and along with a cat gone i'm not to sure my MOT tester will like me!

  9. #8
    devonmikeyboy's Avatar
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    Quote Originally Posted by evomaster3000 View Post
    I agree, it's amazing what a bit of VHT paint does!

    I've read up about removing the cat and i plan to later but the EGR i'm not too sure, yeah it'll stop the crap build up but it's there for emmission reasons and along with a cat gone i'm not to sure my MOT tester will like me!
    Removing the CAT and EGR has nothing to do with your MOT as you do not legally need to have one fitted. MOT`s only test for particle emissions which the EGR will make worse if anything due to recirculating exhaust gasses plus the crap it puts on the inside of the inlet pipes. The CAT removes/changes exhaust gases but has nothing to do with removing particles. People have been removing these things as long as when they where first fitted with no MOT problems.
    06 Audi 2.0 PD140 Sport TDI Quattro S-LINE.
    Old engine 330 bhp @ flywheel 263 bhp @ wheel 490 lb torque. Audidriver write up HERE
    Now stripped and playing with an uprated Cryo treated engine fitted with bigger turbo,water/methanol,uprated injectors etc etc.Wanting 400 bhp and 500 lb torque.

    Other car 500+ bhp MK4 Golf R32 turbo.

  10. #9
    evomaster3000's Avatar
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    Quote Originally Posted by devonmikeyboy View Post
    Removing the CAT and EGR has nothing to do with your MOT as you do not legally need to have one fitted. MOT`s only test for particle emissions which the EGR will make worse if anything due to recirculating exhaust gasses plus the crap it puts on the inside of the inlet pipes. The CAT removes/changes exhaust gases but has nothing to do with removing particles. People have been removing these things as long as when they where first fitted with no MOT problems.
    I've read up on your car before, very impressed!

    I was under the impression all cars from 1992 on must be fitted with a CAT?

    Is this not so? I plan to drop my emissions aswell with an addition of a hydrogen booster aswell to see the effects on mpg performance and emissions, although this is a very intested and widely disputed technology i want to try it myself to prove/disprove the theory.

    I am very tempted in removing the CAT and EGR as having seen the crap i've cleared out after 170k.

    Interested on your thoughts as you obviously know your stuff having done so much work on your car.

    Thanks Jack

  11. #10
    devonmikeyboy's Avatar
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    Quote Originally Posted by evomaster3000 View Post

    I was under the impression all cars from 1992 on must be fitted with a CAT?

    Is this not so?

    Thanks Jack
    Not in England you don`t. I haven`t had a CAT on any of my diesels in years and many friends of mine don`t run CAT`s and some don`t bother with backboxes just a straight pipe turbo back either even though i personally hate the sound.
    06 Audi 2.0 PD140 Sport TDI Quattro S-LINE.
    Old engine 330 bhp @ flywheel 263 bhp @ wheel 490 lb torque. Audidriver write up HERE
    Now stripped and playing with an uprated Cryo treated engine fitted with bigger turbo,water/methanol,uprated injectors etc etc.Wanting 400 bhp and 500 lb torque.

    Other car 500+ bhp MK4 Golf R32 turbo.

 

 

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