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2001 Audi A4
My 2001 A4 Big Turbo Build Thread
I've been meaning to make a thread on here for a long and just haven't gotten time. Well I got a 2001 A4 1.8t quatro manual. I picked it up after i totaled my Mazda. I couldn't decide whether to get an a4 or a s4, prob should have gotten the s but oh well. picked the car to be my daily and was planning on doing just mild bolt on to keep it reliable and some what quick. i started off with a chip on stock turbo with a 3" catless test pipe. these mods made the car much more fun to drive, it was a huge dog before this. well after have some more power and about 100k on the clock, the stock clutch was starting to slip. Knowing I would be adding some more power at some point I wanted a clutch that would be able to handle it. I talked to sponsor Mike Hood at Ringer Racing and he directed me to the best clutch for my goals. I planned on making about 300whp so he suggest the Clutchmasters 240mm fx300 kit. Well ordered that baby up installed it when it came in. After about two weeks of driving, the flywheel bolts somehow loosened up. I thought I spun bearing, it vibrated so hard the knock sensors detected stuff and starting making my car misfire haha. Well after pulling the motor out and finding the flywheel loose, I got some new bolts and put everything back together. Next i had to tackle the suspension as some of my control arm bushings were cracking and the car was just loose. So I ordered a full front control and tie rod kit from ECS and picked up a set of ST Coilovers. Went to buddy's shop at BMW and spent a long ass night fighting years and years of corrosion but we finally got everything installed. Spring of '11 came piCked up a set of ASA wheels with Falken fk452's with great tread left for a great price. Come June of'11 my stock turbo just couldn't take the 23lbs of boost anymore and started whining like a girl. So I contacted Doug at Frankenturbo and ordered a turbo, mani, and inlet pipe from him. Now this turbo is a hell of deal. Its got a great price tag and it held up great for the 5000 miles I put on it. The only issue I had was that my tune was too aggressive causing me to overboost. I didn't really feel like paying $1000 for a custom tune, so I bought a Hallmann Pro boost controller and set it to 24lbs. This turbo hit full boost by 2800rpm and held it till past 5500 where it went to about 20 at redline. I'm sure alot had to do with my crappy stock SMIC. But that was fun, nothing beats the torque that thing created.
Well that brings us till about a month ago when I went to a bunch of maintenance to the car. I had a leaking rear main, coolant flange and some other small things that I was gonna fix while I had the motor out. I decided to a timing belt even though I wasn't due. Ordered everything, put the motor back in to find some nasty valve ticking. Turns out my brand new timing belt tensioner failed and well I lost cylinders 1 and 3's valves. At this point I wasn't sure what I wanted to do. I was tempted to just buy a new car and part the Audi out, but I had invested so much money into with mods and maintenance that I couldn't stand the thought of just ditching it. I mean yes I could have just thrown a head on the motor, but my previous compression and leak down tests have shown that I was losing compression through the rings so doing the bottom end was needed as well. after a few weeks of thinking, test driving cars, I found a fully built 2.0l stroker motor for sale on AZ from a 2000. Being that this motor was from a 2000, it has a different block than I do. Luckily for me the previous owner was using my wire harness on his 2000 for tuning capabilities, so a lot of that would be needed to make the swap work was already done. After doing more research it looked like all I need for this swap was coolant hoses from a 2000, transfer my AWM knock sensors into the 2000 motor, everything else was either already done by the previous owner or the same between both engines.
Well Saturday I pulled the trigger and drove up to Massachusetts and bought the motor. The entire trip I was doing more research about the swap and everybody kept saying that it was wasn't, and most previous triers bailed. So during that 5 hour trip back all I kept thinking was what did I just get myself into haha. After a good night sleep Saturday I got up and pulled the motor out of my car. Set up the new motor on the engine stand and started organizing everything and figure out whats next.
I then contacted Mike Hood at Ringer Racing again for insight for turbos and everything else. I decided that i wanted to make about 450 to 500whp and that the Precision 5857 turbo would get me to those goals. Well I was right it would, but after doing some more research I ended up bailing on that one. I was thinking of getting a Garrett and even a Forced Performance modded Garrett, but I talked to some people and they suggested a Comp Turbo. One of the guys I talk to I respect a lot and he's all Garrett, and Precision, and Comp on his 1.8t and is just nuts about the Comp. Since everybody and their mother runs Garretts I decided that I'd go with the Comp. I know alot of big horsepower supra guys run them so i know they legit, and their triple ball bearing technology intrigued me. So I contacted Mike and had him order me a Comp CT-4 5857, along with the necessary oil and coolant lines for the PSI Concepts T3 bottom mount manifold. I also ordered a set Mike's custom 1000cc EV14 Bosch injectors to take care of the fueling. Mike is getting me a 3" downpipe made that will taper to 2.5" to mate to my Neuspeed exhaust. I still need to order my Warlboro 255 intank fuel pump and some other little things to get the engine to work with my car.
Tuning will be taken care of through Maestro Tuning Suite 7 so I can have full adjustiblity when I decide to change some hardware or make different tunes for the different seasons we have here. I really like the fact that this software allows me to fine tune anything and everything is in my hands. My friend just blew a rod through his EvoX because his tuner went a little too aggressive. Maestro comes with a base file that I will then be able to tweak and get the most out of my set up. Once I get it running well, I'd like to throw it on the dyno fine tune it and see what kinda numbers it puts down.
Engine Build Specs:
Eurospec Sport 2.0L Complete Forged Stroker Kit w/Big Bore Gasket
Eurospec Sport 4340 Billet 92.8mm Crankshaft
Eurospec Sport Forged Connecting Rods
Eurospec Sport Head bolt Set
8.5:1 JE Pistons
Raceware Main Bolts
ARP Rod Bolts
034 Motorsports Coated Rod and Main Bearings
Rebuilt/cleaned and intake ported ATW Head
Autotech Intake Cam
Autotech Adjustable Cam gear
Supertech 20 Valve Spring Set w/Titanium Retainers
Supertech Iconnel Exhaust and Intake Valves (single groove)
AEB Intake Manifold
Fueling:
Ringer Racing 1000cc Injectors
Warlboro 255 in tank pump
Aeromotive A1000 fuel pressure regulator
034 Motorsports Big Fuel Rail
Turbo/Exhaust
Comp Turbo CT4-5858 Billet Triplex .82 a/r
PSI Concepts T3 Mani
PSI Concepts 3"-2.5" dp with wastegate rerouted
Tial 38mm External Wastegate
Neuspeed d/p back
Tuning:
Maestro Tuning 7
B6 S4 MAF
Drivetrain:
034 Motorsports Track Density Engine and Trans Mounts
Apikol Snub Mount
Clutchmasters 240mm FX300
JHM Trio Short Shift Kit
Suspension:
St Coilovers
more coming
Wheels/Brakes
17" ASA with Falken fk452
Stock 15" Conti Extreme Winter Contacts
Stock Brakes...see how long they last haha
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Originally Posted by Extremesport3
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