Brads A4 B7 DTM progress thread

[Bradderz_1988]

Thought id start a progress thread for my DTM as my cars never seem to stay standard for long have a look at my B5 thread if you fancy a read sadly its been scrapped had big plans for it but it never panned out the way i was hoping loved that car hopefully this DTM will fill its shoes for some years to come.

http://www.audi-sport.net/xf/threads/brads-a4-2-0-tqs-build-thread.125338/

Firstly the motor

Started of pretty good but all was to good to be true, serviced it saturday then had the oil pressure light come on on Sunday after some vigorous driving, dropped the sump last night and the chain and sprockets are all intact had a look at the pick up and there was quite alot of carbon deposits lodged in the gauze so i presume the fresh oil and vigorous driving/high oil temps dislodged some carbon build up causing the light to come on luckily i was a street away so just coasted on to my drive so hopefully no other damage to the turbo/engine has been done.

Its got a dreadful chatter from the gearbox on take off and on overun in the lower gears service book mentions new clutch and flywheel fitted so i was under the impression a solid flywheel had been fitted and whilst the sump was off my suspicions were correct and its got this fitted unsure what brand it is anyone recognise what solid flywheel it is and what the brand maybe ??

 

[Bradderz_1988]

I believe this fitted to my car is the ecs ra4 stage 1 with RS4 clutch ??

 

[Bradderz_1988]

Well its back on the road fitted new pick up pipe and its fixed, fitted the modified pick up that is superseded from the original pick up as it has a valve in this extra pipe that im presuming when the pick up blocks up it will open this valve as a fail safe. Part number is 06F 115 251 B for anyone maybe wanting to future proof the pick up blocking and causing further damage to your motor.

 

[Bradderz_1988]

Looking at starting to aquire parts needed for going the k04 route

So ive already got a miltek non-res system (pic below as didnt update this thread when i done it lol) also has 034 transmission insert, 034 snub mount, PCV delete, 034 TIP, R8 Coils, ECS RA4 kit (already picked up a new replacement LUK RS4 clutch for £130 as its started to slip) just had new HPFP follower.

Now back to K04 my list so far is :-

• K04-064 Turbo
• S3 DV housing (will standard DV + GFB DV+ work on this setup ?)
• S3 Injectors
• RS4 pressure relief valve
• HPFP internals (recommendations?)
• Decat/High Flow Cat (recommendations will be leaning towards FS and LC also is this custom flange or are aftermarkets readily available?)
• Runner Flap Delete kit
• APR carbonio intake
• Air-tec front mount intercooler (pipework modified to accommodate S3 DV)
• Unicorn remap

Anything else ?

Any input appreciated

 

[Bradderz_1988]

Well today was a good 5hrs worth of work could of been quicker as hit a couple of niggles whilst at it but main one being the coolant housing to hard pipe hose being fused to the hard pipe. Cheers @Just Rob. for the heads up on this on his thread about the connecting hose would recommend ordering what he says in his thread in the stickys.

So anyway here goes, Today i replaced the rs4 clutch and as i initially thought after having the sump off it is an ecs RA4 stage 1 setup fitted to my car so the RS4 clutch i ordered for it did the job and I didn’t need to leave my car stranded at work till i could source the right clutch if it was something else that was fitted lol

As the gearbox was out i thought i may as-well future proof my coolant housing for some years to come it wasn't leaking but i replaced the heater matrix hoses last month when i did the CCT housing as the fuel pump bolts stripped from being over tightened (this was me rushing a job over 12 months ago and they finally let go) and i can say theres plenty of room once that box is out the way and it was an absolute doddle (except the fused hose) so would recommend if you are doing a clutch do this at the same time save you trying to get at it from the engine bay.

Few pics nothing special lol

ECS Tuning RA4 hiding away that i had no history/paper work for just a hunch from when i did the pick up took me 1 hour and 20 mins to get to this point so was going good to start off with lol

Wasn't leaking but probs not far off !

Removed

Installed

Fag break and quick rear end ramp shot after the box was removed lol

Drained the lower Rad hose too get most the other coolant out then vacuum bled with works VAS 6096 coolant vacuum kit and some fresh G13 ready mix.

 

[Charlie Farley]

Making good progress chap, I noticed you found that water flange, it can be a right knuckle scrapper.

 

[Bradderz_1988]

Making good progress chap, I noticed you found that water flange, it can be a right knuckle scrapper.

Yes luckily it was sat right were it was situated so it come out with ease, as soon as i removed the housing i could tell it looked a bit ‘short’ so luckily it hadn’t gone into the head any further. I wouldn’t like to tackle the housing from up top hence why i used my brains and ordered all the bits when i got the RS4 clutch as this cars just hit 175K so its done some milage so im expecting some jobs to be coming up in near future lol

 

[antwan64og]

Original engine and oil pump at 175k?

You mustn’t of got a Friday afternoon or hungover Monday morning car like me

 

[Charlie Farley]

I have a Friday afternoon special too , but with a lot of TLC over 5 years ownership its become a little bit more reliable.

 

[Bradderz_1988]

Not updated this in a while

fitted RM motors 3” decat to the non-res miltek

Did the brembo 18Z upgrade with 350mm A4 AMG disc.

Now on to the S4 300mm rears.

Picked up a set of used calipers for £180 from eBay need to order some repair kits as piston covers have split ever so slightly (Does anyone have the TRW part numbers?) the rear disc/pads are on route from autodoc and should arrive soon i went for zimmerman disc and brembo pads, rear HEL braided hoses in red are on back order so need wait for them to match my front hoses.

cleaned them up with wire wheel and brake cleaner.

Gave the carriers a first coat with hammerite ‘smooth red’ earlier this evening

 

[Charlie Farley]

 

[Charlie Farley]

What's your plan at MOT time chap, that's a decat and a half but swapping it over every year seems a bit of a task.

 

[Bradderz_1988]

What's your plan at MOT time chap, that's a decat and a half but swapping it over every year seems a bit of a task.

Yeah im probably going to look at getting a HFC instead at somepoint, but for now i can get a pass with the decat on (shhh)

 

[Bradderz_1988]

Ive finally finished the refurbishment on these and ready to fit the S4 B6/7 300mm brakes at somepoint.

New pistons, seals, boots, bleed nipples and slide pin boots, i reused the old slide pins as they wasn’t seized and just needed cleaning and greasing.

 

[Charlie Farley]

Nice work, look forward to seeing all on.

 

[Charlie Farley]

My only reservation with painting these types of metal calipers is that they do tend to look hand painted, nothing wrong with that but i don't find it suits them as well as alloy calipers that need to be anodised, painted or clear coated due to the nature of the product material..
I think i'd go with a very dark grey or steel colour for plain metal calipers and stick to brighter colour schemes to ally ones, just my input .
good job all the same.

 

[Bradderz_1988]

Nice work, look forward to seeing all on.

Just need find time to fit them now, i also read that the rear shock bolt needs removing to gain access to the caliper carrier bolt and can be a bit of a pig to do ?!?

 

[Charlie Farley]

Plenty of penetrating fluid on the bolts over the course of a few days before hand has very good results.

 

[Bradderz_1988]

Couldn’t wait so fitted them after work this evening.

unfortunately I couldn’t fit my HEL brake hoses as my brake pipes are done for so i had to keep the stock hoses and will tackle the brake lines when i refresh the rear end.

also didn’t have any issues removing the carrier bolts and didn’t need to remove the rear shock to access them which was a bonus, pedal is a tad spongy so will give them another bleed tomorrow as probably an air lock due

not much difference in size and appearance but the zimmerman disc do look miles better and the colour of the calipers match the front 18Z’s.

Stock

S4 B6/7’s

 

[Charlie Farley]

nice work, calipers look a lot better now fitted aswell.

 

[Charlie Farley]

Couldn’t wait so fitted them after work this evening.

unfortunately I couldn’t fit my HEL brake hoses as my brake pipes are done for so i had to keep the stock hoses and will tackle the brake lines when i refresh the rear end.

also didn’t have any issues removing the carrier bolts and didn’t need to remove the rear shock to access them which was a bonus, pedal is a tad spongy so will give them another bleed tomorrow as probably an air lock due

not much difference in size and appearance but the zimmerman disc do look miles better and the colour of the calipers match the front 18Z’s.

Stock
View attachment 243008

S4 B6/7’s
View attachment 243009

those discs look very snug in the carriers too, must be 1mm to spare by the looks of the pics.

 

[Bradderz_1988]

those discs look very snug in the carriers too, must be 1mm to spare by the looks of the pics.

Just standard S4 setup so presume they are all like this not actually checked how much clearance the disc has to carriers, re bled the rears today after work and the pedal is so much better presume the pistons had an air lock that didn’t budge first time round the VAS brake bleeder at work made it a lot better especially when i did the 18Z’s as believe they can be a mare to bleed. Will probably give them another bleed all round in next few days just make sure as its a tad off what it was before fitting the S4 rears.

 

[Charlie Farley]

The 18z's can be pain but there is really effective way to get them bled.
After fitting leave all 4 bleed valves open , then refill with system with fluid, after a short while gravity does a very job of pushing out air, nip up the valves . i use it everytime now followed by a quick bleed with a gunson kit a few days later but that's just for a belt and braces job as there is rarely any air left to bleed out.

just an alternative method that works very well.

 

[Bradderz_1988]

Finally time to start taking some milage off the rear end it is just about to hit 195k !!!

Went and picked up an S4 Rear axle for £100 today thats going to be shot blasted/powder coated and billet bushes fitted along with fully polybushed rear suspension and diff mounts and 034 rear ARB and bilstein shocks and eibach springs also gives me chance to replace the rear brake lines as the hose unions are corroded and done for so they need replacing along with the hoses for the HEL ones i already have to fit, bonus is rear wheel bearings can be done in situ in future.

Any of the S4 B6/7 guys know if the Rear wheel bearings are the same front and rear can’t find any rears listed on auto-doc ?

 

[Charlie Farley]

Have you cross referenced the parts listing to see if the same bearings are used on differing platforms?

 

[Bradderz_1988]

Have you cross referenced the parts listing to see if the same bearings are used on differing platforms?

Not looked that far into it yet, surely the fronts will be the same as the rears but who knows, will look further into it when the time comes to get the bearings, i need to sort the snapped abs sensor bolts out in the bearing carriers first

 

[Bradderz_1988]

Have you cross referenced the parts listing to see if the same bearings are used on differing platforms?

It looks like the front and rears are the same according to autodoc on the FAG bearings

 

[Bradderz_1988]

Fitted the 20mm S4 Rear ARB from the axle i got above at work today as my stock 18mm one had gone south on one of the plastic sleeving’s at the D bush.

Great Mod and the extra 2mm makes a massive difference to the cars feel the DTM should of had the 20mm as standard IMO

 

[Bradderz_1988]

Latest mod for the DTM is a brushed aluminum look headlight switch for a Golf MK5/6, next on the list is the B8.5 window switches and mirror switch along with a TT MK2 FBMFSW.

this mod isn’t plug and play and looses the switch release function so needs be removed via the fuse panel access and also the switch dial needs spacing 1/2mm so it sits flush with the outer fascia ring.

 

[Bradderz_1988]

Few shots of the DTM @ Black Rock Sands, Porthmadog, Wales

 

[Charlie Farley]

Few shots of the DTM @ Black Rock Sands, Porthmadog, Wales
View attachment 255765View attachment 255766View attachment 255767View attachment 255768

looks great, why the towing eye though.

 

[Bradderz_1988]

looks great, why the towing eye though.

Dunno really lol im 50/50 on it, just thought it gives it more of a DTM feel having the red rear kook eye plus my towing eye cover has seen better days.

 

[Bradderz_1988]

Well I finally got round to replacing my leaking oil filter housing/seperator and oil cooler.

Looked on Elsa pro which said to remove the alternator and inlet manifold/fuel rail yeah wasn’t doing that lol

All done from under the bonnet with some manoeuvring round the coolant hard lines it came out pretty easy TBH old gasket was no longer rubber and just brittle hardened rubber.

Genuine oil filter housing/separator - 06F115397K - £172 all in at cost price +vat.

OEM Mahle oil cooler - CLC174000S - £60 from eBay.

Both oil and coolant drained and refilled, all in all about 1.5-2hrs in total.

 

[tr7]

Nice work, look forward to the next update

Great to see cars getting properly maintained

 

[Bradderz_1988]

Nice work, look forward to the next update

Great to see cars getting properly maintained

Next is S4 rear axle refresh, just ordered the Verkline subframe bushings and the rear diff bushes, just trying find a powdercoaters local who can shot blast the frame and powdercoat it, then i can get the verkline rear polybush kit and start building the arms up then get on to the next job on the list lol

 

[Bradderz_1988]

So I finally got round to getting my wings replaced today a little hungover and just under 5 hours there done and i have no dent or rust/bubbling.

Also changed the coil harness conduit to the red one from iirc the 2.0 N/A FSI

 

[Rob Avant]

So I finally got round to getting my wings replaced today a little hungover and just under 5 hours there done and i have no dent or rust/bubbling.

View attachment 259510View attachment 259511View attachment 259512View attachment 259513View attachment 259514View attachment 259515View attachment 259516View attachment 259517View attachment 259518View attachment 259519View attachment 259520
Also changed the coil harness conduit to the red one from iirc the 2.0 N/A FSI
View attachment 259522View attachment 259521

I’ve got the red coil pack harness cover… adds an extra 3bhp

 

[Charlie Farley]

I’ve got the red coil pack harness cover… adds an extra 3bhp

Same here along with R8 coil packs it worth a whopping 3.5 bhp, power to the people.

 

[tr7]

NIce. Where did you source them? Fear it may be on the cars for me too

 

[Bradderz_1988]

NIce. Where did you source them? Fear it may be on the cars for me too

EBay mate £80 for the pair