2005 S4 Noggy 4.2 V8 (B6)........ The project commences

Well....... After two months of ownership, I get a smile on my face every time I go out (In the car.....LOL) just love that V8 Roar..... Goes with the registration plate.....

So far I've had the onset of corrosion sorted in the drivers side roof guttering by a specialist classic car body shop. I just couldn't be bothered going to Audi and haggling over what percent I would have to contribute to what should be totally down to them as my car is well within the body corrosion warranty period and has a full service history. So I decided to go to a specialist body shop who went the whole hog in an attempt to ensure that the corrosion was removed and did everything to prevent it returning. Micro blasted the channel back to bare metal, all bare metal treated with some type of rust inhibitant, sealed, primed, topcoat etc etc and the strip that seals the roof guttering had the rubbers replaced and the undersides treated with waxoil prior to being refitted. Whole roof resprayed, front bumper and front wings resprayed. Over the moon with the quality of their work (Mission Bodyshop - Gosport - Hampshire) total perfectionist.....

Here's the finished results - Perfect colour match, perfect finish match.













So pleased with it, I've decided to spend a little more on her, So I'll keep updating this on a weekly basis, first mod due to be completed this coming weekend.

Pics to follow :

Plan is : Wheels, Suspension, Exhaust System and full timing chain tensioner overhaul using "full" JH Motorsport kit, (I remove the engine, take it to a specialist to do the technical bits) & Replace Clutch as I have a full service history from new and all the receipts, but no record of the clutch being replaced, so silly not to do it while the engine's out.

JHM Timing Chain Service Kit (JHM-OEM) for B6-B7 S4 - FULL PLUS - JH Motorsports Inc. - -- JHM.

All this will be done this month, yep I know it's a huge outlay, but I recently sold one of my toys and feel it's worth it as the bodywork is unmarked and the underside is very similar (Already started cleaning the underside).

Goose : Wayne just delivered springs, the first item to arrive so far.

Lifting engine out this weekend, Wayne looked too smart to ask him to give me a hand ........ LOL.

I'll also have that ARB off you, I'd dropped you a PM.


Many Thanks Jim

Quick Update - Just before we were about to start pulling the engine, these arrived. I just had to fit one side and take a few pics. H&R springs not fitted at this stage.







Sorry for crappy pictures (IPhone).

I haven't deserted you, just waiting for a few parts that I want to replace prior to putting the engine back in.

Photo's up soon.

Jim

Well.............. Having got the engine out I decided to spend a little time tidying up the engine bay and replacing a few items while I have an empty engine bay.

A few delays due to waiting for a few parts in addition to all of the timing chain/tensioners/guides/inlet cam adjusters etc etc etc which I have had for some time.

I decided that while the engine was out, I may as well replace the two non return valves and the oil jet after removing the inlet manifold, so had a week lost waiting for these.... but at least it will set my mind at rest knowing that I'm replacing every possible component to give me another 100k miles with minimal issues.





I purchased my H&R Springs from Goose, and these are on the car now but until the engine & box is back in place it's not worth putting up pics.

The 19" BBS CH wheels were the first thing to arrive and look great, but they'll look even better once the car is no longer on the lift, and she's sat on the ground...... LOL.

So I'm holding fire on those pics too......



Milltek Exhaust System (Non Resonated) is presently sat in my garage waiting to be taken to my buddy at Moorland Motors who are refitting the engine, but he's asked if I can hang onto it until mid week, as space is limited in his workshop, but at least I now have it in my dirty little hands, as this too delayed a few things as Milltek must be doing really well at the moment as they are now only building to order and it took them four weeks to produce. Very pleased with the quality of their work though and worth the wait.









The pictures below were taken about two weeks ago when I first started removing the engine........ More To Follow.







Ending up replacing a lot of seeping gaskets (Sump, Rocker Covers, Crankshaft end seals, front pulley oil seals....... the list goes on) and of course the engine has now been thoroughly cleaned.

Hoping to have it back on the road for the end of this coming week, so expect lots of pics....LOL.

Will post up pics of the engine work once I get the photo's from my buddy.

Well, after a few delays and me being a bit anal about cleaning parts as they were taken out and in some cases cleaning parts before they were taken off to prevent and debris falling into the engine, things are finally on the move. A few additional parts that I hadn't budgeted for have had to be bought as it would be stupid not to fit them now while the engine and gearbox are out. Those parts include a new flywheel, Clutch and Pressure Plate and taking the sump off to cure a few seeping areas, along with a few unexpected gaskets, but when your doing this much work it's not worth scrimping. I'm just dreading adding up what it'll have cost at the end, but this is a long term project and this is just making sure the mechanics of the car are perfect before I go even further.

I won't bore you with what a pain it is to remove the engine and box and how many components you have to move out of the way first, but just to say it's not for the faint hearted, but if your mechanically minded and have access to some decent facilities it is possible.

So now I'll just add the pics of a sorry looking car, that will be perfect once I've finished.

Here goes :













And lo and behold, I found the reason for committing to doing a total rebuild of the timing gear, every item is being replaced as recommended by JHMotorsports, and just as they state, most of the engines that come in for a timing gear rebuild, they almost always find one particular tensioner has failed........... Which is exactly what I found, luckily mine had only cracked and not broken up and fallen into any other moving components. Guess I was lucky, or my timing was perfect in doing this mammoth job. As you will see, the timing chain tensioner (The guide actually) had cracked in two, but was still in place.







Having checked all of the remaining guides/tensioners, everything else appeared in good condition, but showing signs of wear, this is an 81k miles car, so not a sky high mileage one. Just goes to show.















Well, I hope that's enough pics to keep you guys happy for a couple of days, the next pics will be when everything has been replaced.

And for anyone who's going to ask how much this is costing ........... DON'T.