"Budget" Modifications B5 2.7T S4 Avant - Nogaro B

[spanky]

Hello all,

I have read lots of posts on this site over many years, but never actively participated.

I have always been a fan on the S4, I used to own a VW Audi specialist and one of the jobs we did was convert an Audi A4 2.8 V6 Quattro to S4 Spec.

As the owner I obviously had a go, I was sold, but didn't at the time have the £20,000 or so it cost to buy one.

Many year past and finally I had the money to purchase a nice clean avant, I will post a pic, I actually bought the car in May of last year.

1998 Nogaro Blue, with the Blue Alcantara. Privicy Glass, usual extras.

I have had the car remapped to a quoted 304bhp by a friend of a friend, and I did feel the difference when it was done.

I have since had to replace 1 EGT sensor (the one on the Left - had to be!! £145 from AUDI.)

Did all the Suspension link arms this week, drop links, track rod ends.

Now it's due a cambelt, and I knew this and have saved some money.

I have considered that considering the front of the car has to be removed to do the belt I think it is time to do some of the modifications I have planned.

I would like to achieve 400bhp.

My Question is regarding the list of items I NEED / Should buy. Here is my current list.

RS4 K04 Chargers (found the info for these) Found a pair New for £600
Gaskets (found the info for these) Stealer?
Oil Feed Pipe - Need Part Numbers - Stealer?
Pipework (found the info for these) - Stealer or Aftermarket?
RS4 Clutch Kit - Need Part Number - Stealer or Aftermarket?
RS4 Fuel Pump - Need Part Number - Stealer or Aftermarket?
440cc EV1 Injectors - Seem easy to find new, cheap

Extras I had thought about??

Decat Pipes - Found some on ebay?
Exhaust System - Found a system, Cat Back for £450 on ebay?

I know it takes time, but if anyone has the missing part numbers it would be helpfull, I have about 3 weeks to source and fit the parts, plus a couple of days to get it remapped.
(A friend wants to go to the RWYB at Santa Pod on May 30th)

Any thoughts on anything I have missed that I NEED.

Will the setup run OK with the standard exhaust and cats?

Loads of questions, sorry, lets see if I can find a picture....

Nope, I will take one tomorrow.

Manifolds - Found some on ebay?

My budget for parts is about £2000 ish
(Depends on the parts I guess)

[Nige_RS4]

I'm not sure you'll get that lot done for £2k - a set of genuine RS4 turbos normally retail for £1600 - where are you finding them for £600? The ones one ebay are poor copies.

You won't need the RS4 fuel pump for 400 horses, nor the clutch kit unless yours is already fooked. Even the injectors may not be neccessary if you want to limit power to 400 horses (but watch the fuelling at the top end)

With regards the cambelt, do you plan on doing all the other associated parts, i.e. rollers, water pump, thermostat etc... ?

Your best bet would be to search the archives here - this question has been asked lots of times in the 6 years I've been on this forum.

[spanky]

The chargers are Borg Warner K04-025 / K04-026, they may actually be rebuilt rather than new, but they look new and original, I saw them yesterday. I do not believe they are copies?

My clutch certainly isn't fooked, however I have noticed if I don't quite lift the clutch at the correct moment I get quite noticable slip unless I back off a touch then re-plant the obvious foot.

I assumed that as the engine had to come out to get the chargers on it seemed stupid not to change the clutch?

Same goes for the cambelt, spoke to the stealer last week and got them to price match a local dealer that was advertising on eBay, At the same time I got the list of items usually changed, water pump and thermostat were added to my list then, same as above really, stupid not to install it when they are cheap in comparison to the cost of getting at it.

I have read through lots of posts and with so many different replies I have not been able to find the answer, lots of people like to quote different parts and I am sure they are all good, but I am looking for reliable performance in stages.

I can't afford to spend an extra £700 ish on exhaust & downpipes this time round, hence holding the output at 400bhp? I have not seen a post that shows what the likely safe maximum output is using the standard exhaust?

I do agree, this site is excellent, but one can only spend so much time reading.

I have VAGCOM, and access to a fairly well equiped large personal garage for a smallish fee.

Thanks for the only reply so far.

[spanky]

Found a photo of by baby.

Shows the excuse I used to get the wife to let me but it too, it was capable of pulling the caravan.

LOL

[spanky]

Anyone know how I can move this post to the B5 S4 Sub-Forum?

Thanks

[S2tuner]

You won't get a reliable 400 BHP out of all those mods and stock exhaust+cats unfortunately, or if you do, don't ever try to do a vmax run or extended high speed runs...

just my 0.02

[Blue_Thunder]

Take a look at http://www.vagcat.com/epc/ for all the part numbers you'll need.

You will want to upgrade the intercoolers to safely get you 400bhp. You'll also want to replace the exhaust manifolds as those on pre-facelift cars have a tendency to split up and feed your turbo shards of metal. 2nd hand RS4 ones should do the trick.

Budget-a-rama:

RS4 injectors - Can pick them up fairly cheap 2nd hand, more than capable of handling 400bhp

Ebay exhaust/DP's (xs-power) - Mikey-S is running 465bhp with one of these systems

Intercoolers - 2nd hand RS4 (make sure you get pipes and shrouds) or alternatively there are some fairly cheap FMIC's from American eBay

Stock S4 pump - Buzzard got 409bhp at the recent RR day with a stock pump. Still worth uprating at some point, but doesn't need to be done whilst the engine is out.

More air to the intercoolers - Ditch the front fogs
More air to the intake - Cut a hole in your airbox (search for Darintake mod)
Afterrun pump mod - Cost about £15 for sensor

[spanky]

I have seen some Manifolds on eBay too, not seen anything much on the quality though, swap the fuel pump for the manifold and a set of studs then. Had read about the old manifolds, mine do seem fine though.

I thought about knocking the front pre-cats out, I don't want to mess about with swapping them each year for the mot, Milltek etc are just too much money, hadn't decided what to do really.

I did have intercoolers on the list, but I was assuming they would do ok for 400, then do them a couple of months down the line, I have read several very good write up's on the Intercoolers, I do want the car to remain original outside.

Vmax, I assume you mean top-speed, I have no desire to drive it at speeds much over 120 - 130. I am more interested with getting there as quick as I can, if I had an extra 4 or 5 grand I would sell it and buy an RS. Unfortunately I don't.

I don't really want to remove the fogs.

[spanky]

I can tell you one thing, it has absolutely no problems pulling that quite large caravan about.

I dragged it 0-60 on the M69 late one Sunday Afternoon a while back, took about 7.5 seconds. LOL
(Good job everything's tied down and the wife wasn't around)

[searider]

You won't get a reliable 400 BHP out of all those mods and stock exhaust+cats unfortunately, or if you do, don't ever try to do a vmax run or extended high speed runs...

just my 0.02

What are the limiting parts in his list?

Exhaust?

Why not extended high speed running?

[Dippy]

Yes the exhaust. From my own experience it is clear that the stock system is restrictive especially at the top end. The difference when I got my full Miltek system fitted was really noticable. And my car is only stock K03 chipped, so only capable of low 300's BHP. Make the engine do 400 BHP and the back-pressure from the exhaust must surely cause problems at high revs.

[bobbler]

Front pre-cats - no issue with MOT time, mine sailed through this year with the RS4 system and decatted fronts. Why not go for a second hand RS4 system? I ended up replacing my Milltek with one when the missus destroyed it on a bump last year, seems fine though the fit on the tail pipe is not great. Will get the Milltek repaired at some point I just don't have that money spare at the moment personally and the car needs a service more than a bit of stainless.

Aren't those Ebay manifolds likely to need a lot of tweaking etc? Or am I thinking of some others that where posted up here? I thought they didn't fit so good without a bit of grinding and welding.