Engine rebuild

2.7 V6 30v biturbo - 380 bhp
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IchBautAuto
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Location: Australia

Engine rebuild

Post by IchBautAuto » Wed Apr 14, 2021 2:42 am

I'm in a happy place where my RS6 requires no work..at all! I have had a spare complete AZR engine for the RS4 since 2015 and it's about time it was refurbished and waiting to be used. It ingested a foreign object in the PO car and did a piston and lightly scored the bore of No 6.
before strip.jpg
A quick strip down. Very lucky to have all the more unusual tools to hand so it was a very easy task. Surprisingly the bearings exhibited a little wear which is a bit unusual but the crank was perfect.

The block is now ready to head off for machining.
ready to go.jpg
I'm have 82mm Woessner pistons ready to go. All expectations are that machining will remove the score and other superficial damage.
score.jpg
I have most parts for the rebuild, bearings, full set of ARP studs, new turbos, new heads, loba cams, most seals and gaskets, tube manifolds and so on. Just a matter of joining the various queues for machining etc.
C5 RS6, Milltek and Wagners: B5 RS4 450 + HP: A4 1.8 GP TQS original: 1963 UNIMOG 404:

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IchBautAuto
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Posts: 597
Joined: Thu Feb 20, 2014 11:23 pm
Location: Australia

Re: Engine rebuild

Post by IchBautAuto » Fri Apr 16, 2021 12:00 am

Well, as expected. some gaskets are NLA from the factory but are available from aftermarket sources. Onlinecarparts UK are a good source UNTIL they want to charge 108 pounds for a 16 pound gasket to be shipped to Australia. The same product from EBay (ex UK) or Europe is about 20 pounds shipping. Clearly a case of business not wanted here. Otherwise their prices are comparable.
C5 RS6, Milltek and Wagners: B5 RS4 450 + HP: A4 1.8 GP TQS original: 1963 UNIMOG 404:

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IchBautAuto
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Posts: 597
Joined: Thu Feb 20, 2014 11:23 pm
Location: Australia

Re: Engine rebuild

Post by IchBautAuto » Tue May 04, 2021 11:49 pm

On the way to the machine Shop. Reminds me of the two engined mini.
on the way.jpg
C5 RS6, Milltek and Wagners: B5 RS4 450 + HP: A4 1.8 GP TQS original: 1963 UNIMOG 404:

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IchBautAuto
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Posts: 597
Joined: Thu Feb 20, 2014 11:23 pm
Location: Australia

Re: Engine rebuild

Post by IchBautAuto » Tue May 11, 2021 8:46 am

and it's home again
home.jpg
New capacity 2737cc.
bored block1.jpg
Big clean first and then will get the bottom end and Woessner pistons in while procrastinating about whether to use the Loba mechanical cams or the originals.
C5 RS6, Milltek and Wagners: B5 RS4 450 + HP: A4 1.8 GP TQS original: 1963 UNIMOG 404:

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IchBautAuto
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Posts: 597
Joined: Thu Feb 20, 2014 11:23 pm
Location: Australia

Re: Engine rebuild

Post by IchBautAuto » Tue May 18, 2021 6:33 am

Progressing, there are a few fiddly jobs before the clean is complete and then assembly starts.

Multi-tasking, finalising the parts for the turbo refurb and finding adjustable wastegate actuators hasn't been as straight forward as it once was. Mr google has only thrown up a couple of options, all from the US. I'm looking at around 10 psi but that may not be optimum so the ability to swap springs will make life a little easier. I've settled for Mamba as the other vendors were slooow in arranging a sale.
C5 RS6, Milltek and Wagners: B5 RS4 450 + HP: A4 1.8 GP TQS original: 1963 UNIMOG 404:

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IchBautAuto
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Posts: 597
Joined: Thu Feb 20, 2014 11:23 pm
Location: Australia

Re: Engine rebuild

Post by IchBautAuto » Tue May 25, 2021 12:33 am

Mambas are here, so another piece of the puzzle sorted. At this stage other than a few o rings and small gaskets I have all the parts ready to start the build up.
mamba.jpg
Woessner 82mm pistons
pistons.jpg
UK manifolds
manifolds.jpg
+15 clutch
clutch.jpg
Loba mechanical cams
solid lifter cams.jpg
The cams are a yet to be confirmed option at this stage as the added lash adjustment is a PIA.

Sticking with factory rods, bearings etc. Turbo specs still on the drawing board as this is a street car to be driven, not a coffee bar car that is all about brands and unuseable top end power.
C5 RS6, Milltek and Wagners: B5 RS4 450 + HP: A4 1.8 GP TQS original: 1963 UNIMOG 404:

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