One of those days....

[aragorn]

Decided i'd finally get round to tackling a job on the car thats been needing done for a while.

Theres an exhaust blow when cold, and under load theres a nasty farting sound. I suspected the gasket between the manifold and head, or the manifold and turbo, so i ordered up some new bits and decided i'd get them changed.

After some preliminary steps, i had this:

I hate touching turbos, as the bolts always snap, and sure enough, one did (probably not helped by me using some random crappy bolts from the spare bolt box, rather than genuine audi ones when i fitted the turbo last year):

Not a huge deal, i was half expecting it, and i figured i just pop the turbo off and get the bolt removed.

Continued on, removing the manifold bolts, then noticed one was missing. At first i thaught perfect, i've found the cause, i'll just chuck a new stud in there and we're sorted.

As i worked at removing the rest of the bolts, a realisation hit me.... thats not fallen out, its snapped

Sure enough got the manifold off and it was snapped, about 5mm inside the head flange.

Rage ensued, due to its position its inaccessible with a drill, and even if it was, drilling something like that is bound to end in tears. After some thought, i decided to remove the head, and take the head into the local engine shop to have them sort it.

Wont get it back until monday or tuesday, and i'm now waiting on bolts and gaskets and various other bits too.

Car looks sad:

 

[Bradderz_1988]

I hate a simple job that turns out to be a nightmare.

 

[ScottD3]

Gutted mate.
I hate it when jobs go like that.

At least its a good oputunity to bolt in new and better bits like ermmmmmmmmmm......................yeah.
Good luck.

 

[Bradderz_1988]

Hhhhg hhmmm ... RODS !!

exactly what i was thinking scott lol

 

[aragorn]

Hhhhg hhmmm ... RODS !!

exactly what i was thinking scott lol

Its already got rods in it, fitted them when I rebuilt it last year

 

[Bradderz_1988]

Its already got rods in it, fitted them when I rebuilt it last year

What rods you running ? You got pistons or standard ??

Is this shed ??

Im confused as you do have 3 B5's lol

Im toying with buying a used block and getting it rebored and fitting a 2.0 crank just need to look in to it a bit more as not to sure if they use differant rods/pistons ive been looking at some gt turbos ive found one that tickles my fancy but its off a diesel i think but its internally wastegated and looks similar to some gt30's and will need a custom built manifold and downpipe. Just wana build my own motor really lol

 

[aragorn]

Yeh this is shed. Annoyingly i've got more similar fun to be had on the avant when its new turbo comes, probably in the next week or so

Brute rods from PagParts in the states, stock pistons/block/crank.

If you go for a 2.0 crank you need different pistons. You use the same rods as normal, but the combination of the longer crank and standard length rods would make the pistons stick out the top of the block. So the stroker pistons have the pin mounted closer to the top of the piston, so it doesnt stick up.

On an AJL, you also need to modify the block itself for clearance at the sides, and i believe you need to alter the drive gear for the oil pump, or it catches on one of the rods.

 

[Bradderz_1988]

Right looking at this turbo would you say its ok for a custom build ??

Turbocharger Garrett GT3576 ISUZU 6HK1 XS w/ Gasket | eBay

 

[aragorn]

Its MASSIVE, GT35's probably a 5-600hp turbo. Which means lagtasticness.

Its also probably not a genuine garett, although i have heard good things about kinugawa in the past. While they make copy turbos, they seem to do a good job of making copy turbos.

If you wanted to go down that route, Kinugawa do some TD05 and TD06 turbos which could fit the bill, Welly is using an FP-Green, which is a hybrid based around a TD06 and has had pretty good results (444hp). He also ran a TD05 of some description previously and managed good figures from that too (~380 iirc).

 

[Bradderz_1988]

Nice to know well it will be a on going thing if i do go ahead and do it just really like to build my own motor and do a custom setup thats a bit differant.

Is this what your on about

Kinugawa Turbo Turbocharger TD05H-18G AR 8cm w/ 3" cover T25 Flange 370 HP | eBay

 

[aragorn]

yeh something like that

 

[aragorn]

Finally got it sorted yesterday!

All went back together fairly smoothly once i got all the parts. I did at one point have an "oh ****" moment when i realised i'd sent the head to the machine shop with the inlet valves on cylinder 1 sat fully open, and the head had been sat down on them.

Luckily they were fine, though i did make starting the car somewhat nervewracking

After a test drive it seemed my missfire had got worse, so i swapped a couple of the coils out and it went away Another issue easily fixed.


When i had it apart i also replaced the N75 valve, to see if that would cure my weird boost-lag after gearchanges. The valve i removed was dated 11-96, which means it came off my old FWD A4 having done 195k. Not entirely surprising that it might be a bit worn out! New valve fitted, and it now seems much smoother and finally, no more lag