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

Discussion in 'Audi S4/A4/A4 Cab (B7 Chassis)' started by olethalb, Nov 16, 2012.

  1. olethalb

    olethalb Active Member

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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

    [​IMG]

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

    [​IMG]

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

    [​IMG]

    [​IMG]

    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. olethalb

    olethalb Active Member

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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. Golfedd

    Golfedd Active Member

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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?
     
  5. olethalb

    olethalb Active Member

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    oh yea, didn't even consider TPS :laugh:

    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. olethalb

    olethalb Active Member

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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. Chets

    Chets New Member
    VCDS Map User

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  8. olethalb

    olethalb Active Member

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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 :)
     
  9. pburv

    pburv Well-Known Member
    Team Glacier quattro Audi S3 saloon

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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 this:shrug:Is it worth doing? the mileage on my car is 45,000 it,s a 2ltr Bul engine...Cheers Paul...
     
  10. olethalb

    olethalb Active Member

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    well the new stainless arrived

    [​IMG]

    so made a new template

    [​IMG]

    and decided to use the non polished side

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    [​IMG]

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

    [​IMG]

    fitted

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    got my DV hard pipe back from the welders too

    [​IMG]
    [​IMG]

    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

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    and reshaped the pipes to give more room

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

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

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

    olethalb Active Member

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    Paul - do you have early full hard piping to the pump?
     
  12. Golfedd

    Golfedd Active Member

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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!
     
  13. pburv

    pburv Well-Known Member
    Team Glacier quattro Audi S3 saloon

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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:think:
     
  14. KemiksiZ

    KemiksiZ Active Member

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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.
  15. olethalb

    olethalb Active Member

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    well got a call from the welder.....lovely.....

    [​IMG]
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    also threw some paint on my DV return pipe

    [​IMG]
     
  16. olethalb

    olethalb Active Member

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    got a couple of days off, so got up this morning and test fitted the intake

    [​IMG]
    [​IMG]

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

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

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    fitted the maf to the intake

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

    [​IMG]
    [​IMG]

    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

    [​IMG]

    silicon blank on intake mani

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    silicon blank on cam cover

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    ally blanking plate on turbo intake

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    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.
     
    James.c likes this.
  17. Joe_Murphy21187

    Joe_Murphy21187 Tiptronic

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    Excellent workmanship! Personally I would've left the intake pipe silver but it looks great as it is
     
  18. olethalb

    olethalb Active Member

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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
    [​IMG]
    battery cover
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    scuttle cover
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    as it comes, small pollen filter cover on the passenger side
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    new scuttle and battery cover fitted
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    found a vauxhall brake res cap in the shed
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    then cut a bit of carbon sheet to size and put good old fabric tape around the edge to keep it frm rubbing
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    fitted
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    now that was done i gave it a wipe over
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    and inside
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    oh and my cigar lighter 'mod' from a B6 A4
    [​IMG]
    [​IMG]
     
  19. ChrisFurlong

    ChrisFurlong Avantageous

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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.
     
  20. olethalb

    olethalb Active Member

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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
    [​IMG]
    A/C pipe cover from TDI
    [​IMG]
    fittings
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    abs / fluids side
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    spacer and grommet fitted
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    cover fitted
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    A/C pipe cover will need modifications to work with my set up
    [​IMG]
     
  21. ASC

    ASC Member

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    Very, very, very nice mate.. Grand job!
     
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  23. ChrisFurlong

    ChrisFurlong Avantageous

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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!)
     
  24. Golfedd

    Golfedd Active Member

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    oh dam! I want your centre console with the flip up ciggy lighter! damn it!

    Looking good bolllywood!
     
  25. ANDYTQ

    ANDYTQ Well-Known Member

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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.
     
  26. olethalb

    olethalb Active Member

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    well cam day today

    as it started

    [​IMG]

    loom pulled back, intake off

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    metal coolant pipe pulled back to access HPFP

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    HPFP union undone

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    unbolted

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    removed

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    fuel pump follower

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    withdrawn with finger

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    500 mile wear on existing cam

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    cam cover off

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    vacuum pump off

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    cam chain cover removed

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    HPFP cam lobe

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    cam marks and pointers

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    cam box and cam out

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    cam lobe - heavily worn

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    comparison

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    valve lobe lift comparison

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    new cam in

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    new follower

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    all back together and cam cover painted satin black

    [​IMG]

    my cam was the A version
     
  27. wilbo

    wilbo New Member

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    Love this build thread.
     
  28. sewell10

    sewell10 Member

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    Good info keep up the good work
     
  29. olethalb

    olethalb Active Member

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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
     
  30. AudiB7Jay

    AudiB7Jay Member

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

    olethalb Active Member

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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.

    [​IMG]

    [​IMG]

    [​IMG]

    [​IMG]
     
  32. olethalb

    olethalb Active Member

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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

    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

    [​IMG]

    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

    [​IMG]

    so i removed the pipework completely

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    and removed the two ends i needed from the pipe

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    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

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    used heat to form the pipe to the shape i needed

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

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    so used a blanking plug

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

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

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    [​IMG]

    bit of etch primer and satin black

    [​IMG]

    [​IMG]

    re assembled

    [​IMG]
     
  33. Golfedd

    Golfedd Active Member

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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?
     
  34. carl-1968

    carl-1968 A4 sold, lots of bits available, ask for details

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    Superb build thread, some quality work put in there :thumbsup:
     
  35. olethalb

    olethalb Active Member

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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...

    [​IMG]

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

    olethalb Active Member

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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

    [​IMG]

    [​IMG]

    then ebayed an RS4 intank pump controller

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    se b7 grill

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    rs6 grill

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    carbon fibre bumper strip

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    another centre console - without phone holder cut outs

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    TT flat bottom wheel

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    then changed my mind and went RS4

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    and RS4 gearknob

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    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 :)
     
    James.c likes this.
  37. DTM_T4

    DTM_T4 New Member

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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 :(
     
  38. olethalb

    olethalb Active Member

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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.
     
  39. DTM_T4

    DTM_T4 New Member

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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.
     
  40. olethalb

    olethalb Active Member

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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.
     
  41. craichouse

    craichouse Member

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    [​IMG]
     
  42. Golfedd

    Golfedd Active Member

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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 :)
     

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