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2001 B5 S4 Rebuild

  #1  
Old 03-24-2016, 02:18 PM
1st Gear
Thread Starter
Join Date: Apr 2010
Posts: 11
Default 2001 B5 S4 Rebuild

Man it has been a while since I have been able to get back on the forums. Looking forward to it again. Anyway I decided I should document my little project on here to maybe help or inspire others to keep these cars alive.

The backstory: I bought the car back in 2006 and it had right around 107,000 miles on it. It was immaculately cared for which was why I decided to take a chance on a 107,000 mile Audi in the first place. It came with a Milltek catback exhaust, APR bipipe, and diverter valves. I almost immediately made some changes myself, including downpipes, cold air intake, rs4 clutch, GIAC chip, short throw shifter, AWE drivetrain stabilizer, and improved the sound system a little. After all of this I then used it as a daily driver for about another 100,000 miles before it finally blew a head gasket.

The plan: Now that it is going to require me to tear the car apart to replace the head gasket and fix whatever else went wrong I decided that it is worth going a little bit farther than that. So what I have done is try to break this rebuild up into multiple stages.

Stage 1: Tear the engine apart and rebuild it from the inside out. The goal of this stage being a rebuilt engine with stock internals ready to go back into the car.

Stage 2: Consists of everything else it is going to take to install the engine back in the car properly. This stage includes some big ones like clutch and new turbos. The end result of this being that the car is running again.

Stage 3: This is where everything gets buttoned up the way I want it, bumper needs replaced, would like to paint it nicely, big brake kit, etc.

Stage 4: This is simply dreamland, all of the other ideas I have had for the car that I will probably never get to .

Anyway pictures are attached of how she looked when I first got her, next post will be about how tearing her apart went down.
 
Attached Thumbnails 2001 B5 S4 Rebuild-254748_503331179328_1981_n.jpg   2001 B5 S4 Rebuild-252088_503331199288_2789_n.jpg   2001 B5 S4 Rebuild-255028_503331209268_3185_n.jpg  
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  #2  
Old 03-24-2016, 04:38 PM
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Join Date: Apr 2010
Posts: 11
Default Teardown

My buddy Tim and I began tearing down the car. See the attached photos for it's progress. Teardown went well, no big surprises. Once we got to the internals of the engine it is apparent that one of the heads is definitely warped from the head gasket blowing. That is no surprise though, the good news is that is it only slightly warped. Looks like maybe a few thou. The piston bores look nice still, dimensions are shockingly tight still and there looks to be enough of a groove pattern to get away with not honing it. Overall I have to say I am fairly shocked at the low amount of wear on this engine considering the amount of miles on it, especially miles with upgrades. Anyway take a look at the pictures, I would love to hear any feedback that you all might have. Hopefully you don't notice something bad that I may have missed.

Currently the block is out at my machine shop getting cleaned and decked, will be working on putting the block back together first, while I start on the heads.

I will continue to update as progress continues.
 
Attached Thumbnails 2001 B5 S4 Rebuild-10294512_10100172522870788_4228970015914113222_n.jpg   2001 B5 S4 Rebuild-944940_10100172522591348_8465290832434561277_n.jpg   2001 B5 S4 Rebuild-943998_10100172522646238_3214379038007340342_n.jpg   2001 B5 S4 Rebuild-20160227_222805.jpg   2001 B5 S4 Rebuild-20160227_195638.jpg  

2001 B5 S4 Rebuild-20160227_220939.jpg   2001 B5 S4 Rebuild-20160302_205257.jpg   2001 B5 S4 Rebuild-20160316_222506_030.jpg  
Attached Images  
  #3  
Old 07-06-2016, 10:35 PM
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Join Date: Aug 2015
Posts: 24
Default

Nice build. any new updates?
 
  #4  
Old 07-07-2016, 03:43 PM
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Thread Starter
Join Date: Apr 2010
Posts: 11
Default

I wish, sorry for the post and run, but unfortunately too much has been going on lately. Came across an opportunity I couldn't ignore and am now starting my own business which has completely sapped all spare time but good news is now I have a large warehouse to work in instead of a garage. Things are finally calming down though and hopefully I can get back to this soon though.
 
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