wanting to rebuild my motor need some insight
Probably more money than the results will justify. Light, balanced bottom end, light flywheel, gasket-matching or port-matching manifolds, built heads (valves, springs, retainers), bigger injectors if you use cams and a high redline, cc'ing the chambers, angle job, etc. And to really see any sort of gain, you'd probably be best off with a 3.0 crank and lightened S4 flywheel instead of a light A4 unit, for a custom 3.0 stroker setup. Expect to spend a lot and not increase a tremendous amount...
The 3.0 will make more power/torque for sure but won't have a high rev ceiling unless you lighten the bottom end and build the heads to handle the airflow without valve float. On its own, without the high-rev parts, you'll gain still but not as dramatically. The OEM 3.0 was rated at 225hp. You'd probably be a bit under that as the 2.8 breathing and tuning is centered around that smaller displacement.
Considering S4 guys run 2.8 heads as an upgrade, for higher flow, I'd probably forget about building them for high revs. I'd clean everything up, port the water galleys as much as permissible for block cooling, gasket-match the intake and exhaust manifolds (since the supersprint headers are huge money and they made like 2-1/2 sets of them since the beginning of time), put in new rings, swap the 3.0 crank and S4 flywheel, throw on a G2 blower, and do the 4:1 diff shim. A stroker 3.0 with a supercharger and 20/80 front/rear torque split sounds like a hell of a lot of fun.
This is, of course, assuming funds are sufficient.
This is, of course, assuming funds are sufficient.
Buy another motor. I did for my build and only paid 250 for a long block with manifolds and turbo. In fact I just picked up a 30v v6 locally for a 50 bottle of scotch that I'm parting out. Deals are our there and its way better imo to have a modded motor and a stock one for when the modded one breaks.
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