New TFSI Project

neilA4

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Picket up a bargain 2006 A4 TFSI Quattro special edition from eBay with a boost problem a couple of weeks ago.



Cost me £1090, needs a bit of work but has recently had a hybrid turbo and remap from turbo clinic, they also replaced the Pcv and cam chain tensioner.

I’ve found the source of the boost problem allready, actuator has come loose and is only attached to the vacuum hose!

Plan to get it running first with New discs/pads/braided hoses and a full service with cam belt and oil pick up mod at the same time.

It also needs an exhaust and some lower arms. Front wings need doing also. And the air con doesn’t work so will do the condenser/dryer whilst it’s in bits.

It has the Bose stereo but not much else in terms of optional extras, no rsne or hid lights.

Need to get it running by end of August as the company merc goes back!

I want 300bhp from this, would be good to know what supporting mods it needs.

Cheers
 
Reactions: BakPak, Rob Avant and Sidrick
Hi Neil, that's a nice looking car, Hope you enjoy it. don't forget if you looking for any new oem parts then give Tom @creweaudiparts a message.
 
Reactions: creweaudiparts
I'm sure its 270hp ish with turbo back echaust with de cat or sports cat, fmic, induction kit, uprated fuel pump, and a stage 2 map then I think the next jump is bigger turbo, s3 injectors and whatever other little bits to support the mods with the stage 3 map but your be way past 300hp then think its more 350hp, ill be keeping my eye on this thread I've not long got my b7 s line special editon (fwd) and plan on going to stage 2 so will be cool seeing another similar project.
 
Reactions: Rob Avant
As above... 270-280 is max on the stock turbo/ injectors with Stage 2+ and all supporting mods.
I’m weighing up options for stage 3 at the moment, although it’s a lot of money for a car/ engine that’s 12 years old and will probably need upreated internals if I want to keep it reliable.
 
Reactions: Sidrick, Ricky Burrows and Charlie Farley
Some bits arriving now, making use of the ECP and GSF 50% offers and searching for bargain bits.

Found some big side mounts to go in!


Also got filters/discs/pads/coolant/cam belt/water pump to go in

 
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Reactions: Sidrick
Well it’s up in the air, turbo removed.

I’ve bolted the actuator bracket back to the turbo body, should solve the no boost issue.
Wastegate was just flapping around!
 

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What make are the intercoolers? The look very similar to mine which a evolution Racewerks
 
Not sure mate, got them from eBay 2nd hand for £178 apparently they were custom made
 
Side mounts are on, CTS changed, next up it’s cam-belt/tensioner/water-pump/snub mount/oil pick up pipe

Interestingly it’s missing 2 sump bolts near the bell housing and the blue sealant looks recent, may find the pick up pipe has already been done!
 
Reactions: Dan_Avant
How did you find the fitment of your SMIC's? My drivers side IC just doesn't sit quite right. Going to need to fabricate some decent bracketry somehow!

Project looks like it's going well though mate.
 
It is a bit tight in there, had to cut the LH bracket up a bit. Both now tight, can wiggle a bit without knocking/rubbing things.

 
Cambelt and water pump done, I’ve also fitted an INA follower for the fuel pump, got one on amazon for £27!

Picture below of the one that came out, DLC coating has gone so needed replacing. It’s a 2006 BUL 122k for reference.

 
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Inlet manifold off, cleaning the carbon buildup should release a few ponies!

Can’t believe how much **** there is.

 
Yep they get really covered, more reason to do a full pcv delete.
 
Yes I really need to get a catch tank sorted!

Huge amount of oil in the intercoolers, also the breather hose going to the top of oil cooler/filter housing was blocked with emulsified **** so that needs to come off now too!
 
Oh the joys of audi tfsi ownership....
 
Reactions: antwan64og
Slow progress, inlet ports/valves now cleaned. Access to the rear coolant flange is good with the inlet removed but decided to lift engine out for clutch change. It’s basically now loose ready to come out.
 


Engine now up in the air.

Clutch is ******

DMF has 20mm play in so guessing that is ******

Also took the sump off and I was correct in thinking it had been off before, but Instead of fitting the revised pickup it has just been Perforated

Also only one bolt holding the rear coolant flange in lol!



 
Well after checking the flywheel properly it would seem within tolerances.

It has 3 teeth of free play (max 5 teeth or 16 degrees)

And has 2.2mm of rock (max 2.9mm) and that’s with me giving it a bit more force than required.

Looked at a video on YouTube of a new TFSI LUK flywheel and it is very similar to my old one!

It’s going back in the car but may try putting a Sachs clutch in from the 2.0 TDI for the extra torque
 
New clutch is on, made use of the 60% Off offer from GSF, only cost £168

As per Audi instructions with a sac clutch cover, the bolts were done up a 1/4 turn each until pressure plate was fully down.
 
Intake flaps removed and cleaned


Getting somewhere now, engine is in, turbo primed with oil, new ac rad on the front and aux belt. Just need to fill with G12 and power steering fluid then bolt everything back on.

 
Got it all fired up and running, then smelt petrol so off with the inlet manifold again. Seems I forgot to put a drop of oil on the injector o rings so destroyed them!
 
Slow progress but engine runs without leaking petrol now. I’ve retrofitted a genuine arm rest and will retrofit cruise control next.

Still a few things on the list to fit...

Upper arms
Lower front arms
Blistein B4 dampers all round due to rust
Pagid Discs/pads all round
Braided brake hoses
Replacement passenger wing due to rust

Hopefully get a lot done next few weeks
 

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Reactions: Ross Blount
Bit more playtime today, struts are off, see below pics for ****** upper arms and dampers.

Only bit I’m not doing is lower rear arms as ball joints and bushes are ok. Everything else will be new.



 
Front now done with discs pads and braided hoses


Took the rear arch liner off to find rusty ****** hoses

 
Looking a bit better now.

For some reason the damper is 30mm longer than the original, it’s even listed for the s4 so part number is correct. If it looks and feels ok will leave alone but if not will have to contact billstein.

 
I never measured my new rear bilsteins but they were definitely longer than what I removed, and a fair battle to get in place.

Great graft you're putting in here!
 
Sidrick said:
I never measured my new rear bilsteins but they were definitely longer than what I removed, and a fair battle to get in place.

Great graft you're putting in here!
Click to expand...

Thanks it has been a lot of work!

Next is to bleed brakes and clutch then it’s change front wing, fit an exhaust I’ve picked up along the way and get it through the MOT

Will get a dyno run when all finished
 
Brakes and clutch now bled with new Dot4 fluid. Old fluid was full of ****.



Noticed rear timing chain cover is leaking so looks like the fuel pump and rear cover need to come off for a new gasket!

Also changed the fuel filter which was the original from 2006.

At least the oil leaking out was nice and clean. Not black
 
And 2 hours of fiddling later.... not a fun job.

 
Reactions: Sidrick
Picked up this exhaust. It’s a bit bent and squished in places but with a few couplers and some cutting should be good.

4” to 3” downpipe/decat
2.5” at the back boxes

 

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Reactions: AL (A4 B7 Avant), Sidrick and Charlie Farley
looks like a serious pipe chap, where did you find that, not sure its going to be MOT friendly and a bit of a bind taking it off for MOT's , worth a go though.
 
Just Rob. said:
looks like a serious pipe chap, where did you find that, not sure its going to be MOT friendly and a bit of a bind taking it off for MOT's , worth a go though.
Click to expand...

Yes should release a few ponies hopefully and was a bit of a bargain as with everything on the car so far!

Came from the same person who sold me the intercoolers.

Planning to get the mot done next week with original exhaust/cat then fit this. I may take the down pipe off next year and get a 200 cell cat welded in.

Will be interesting to see what it makes on the dyno with the free flowing exhaust, large side mounts, hybrid and remap. Plus fully serviced with new clutch and inlets de-coked!
 
Failed the Mot on emissions ***. The lambda value at fast idle was 1.03

Can’t find any exhaust leaks so plan is to change the lambda sensor, give it some 99 Ron fuel, also change thermostat as it looks to be stuck open.

Car does go well though, was good to finally take it out!
 
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