2005 Noggy Blue S4 - Project

4.2 V8 40v Naturally Aspirated - 339bhp
JimGreen
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Re: 2005 Noggy Blue S4 - Project

Post by JimGreen » Fri Aug 15, 2014 2:28 pm

Thanks Ben, Hope it proves helpful to you and others.

The final days of the rebuild......

I have the weekend off work and my main man is working flat out to finish it so hopefully I'll be back on the road on Monday.......... At last.

Have to say a huge thanks to Kal at Moorland Motors (Gosport - England) who's experience of the Audi V8 has proved invaluable in the rebuild, a very knowledgeable guy who's attention to detail is second to non.

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Sorry for the quality of the pictures (Good Old IPhone)........... It's been a long, hard and more expensive job than I intended, but believe it'll be worth it in the end. A lot of the extra time was taken in deep cleaning everything once she was dismantled, plus a few unexpected bits that would have been stupid not to replace while the engine and transmission was out.... Sensors, gaskets that were looking a bit tired, Clutch assembly & Flywheel replaced, Valve covers bead blasted and powder coated, a couple of hoses here and there ...... Plugs, Filters, Fresh Oil etc etc etc ... the list goes on.

And of course the time taken to keep this thread updated...... LOL.

Need to spend a bit of time cleaning up the engine bay (Greasy/Oil finger marks everywhere) but feeling very close to the end now.


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JimGreen
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Re: 2005 Noggy Blue S4 - Project

Post by JimGreen » Sat Aug 16, 2014 2:34 pm

Whey Hey......... She's up and running and sounds so sweet Just putting a few miles on her then back on the lift, pull of the underside shields and check for any leaks.

Pics to follow very shortly

Bits Done :

1. Total Timing Gear Overhaul (Using every item listed in JHM's "Full Plus Kit").

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2. Cam Covers Bead Blasted and Powder Coated.

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3. All One way return valves Replaced (Two underneath the Valley Pan + Jet Replaced + One in each Cylinder Head).

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4. -25mm H&R Springs Fitted.

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5. BBS CH 19x8.5 Wheels & New Tyres.

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6. DeCat'd Down Pipes (Piggy Pipes).

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7. Milltek (Non Resonated) Exhaust System.

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8. New DM Flywheel, Pressure Plate and Clutch Plate.

Didn't get pics of these, my tech fitted them before I got the chance.

9. Numerous gaskets, Seals & Sensors Replaced.

Couldn't be bothered to take pics of boring gaskets.

10. ARP Snub Mount.

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11. Oils & Filters all replaced.


Now I'm just trying to find someone local to me (Portsmouth - Hampshire - England) with a laptop running Windows 7 (Mines too modern running Windows Eight :bash: : ) to download JHM's Tune.

JimGreen
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Re: 2005 Noggy Blue S4 - Project

Post by JimGreen » Sat Aug 30, 2014 6:07 pm

:jump: Back on the road again...... Isn't there a song called that.

Well...... we finished the job this morning just before mid day, cleared all the previous codes that had caused us to half remove the engine again, took if for a drive (About ten miles) ran perfectly, really strong on torque and power.

So, I took it home, gave it a really quick wash and then went for a long drive, steady for about the first ten miles and then gave it a little more and gradually started to increase the rpm further up the range.

Suddenly when accelerating hard in third gear I felt the engine flutter and hesitate, and a loss of power. So I slowed down a little and pulled into a service station, got out my little VAGSCANNER and checked if I had any fault codes...... Sure Enough : 16405 bank 2 camshaft a (intake) p0021-002 <beep> setpoint not reached (over advanced) mil.

F-ck.....Sh-t..... and a lot worse...... So I cleared the code and started on a very disappointing drive home, BUT suddenly after driving for about five minutes and deliberately driving on and off the throttle, full power returned and she responded perfectly to the throttle. So I decided not to go home but continued on my driver for another hour in all types of roads and traffic, clocking up over 50 miles...... Without any further problems. Arrived home, checked everything physically, ran another scan, NO Fault codes at all. Went for another thirty minute drive, no problems at all, pulling really strong and just wanting to go.

Oh I'm hoping whatever it is has sorted it's self out.

I did wonder if the pistons in the actuator/solenoid could be a little tight, with it being brand new and maybe now they're bedding in. This fault code is caused by the variable timing not retarding sufficiently which is controlled by the ECU sending a signal to the electronic timing unit via the actuator/solenoid. The actuator/solenoid has a piston in it which the signal causes to move a piston in the actuator/solenoid (The part which has the wire coming from it), allowing oil to flow under pressure which releases the locking pin in the mechanical adjuster allowing it to adjust the variable timing. We did have a faulty unit supplied initially, with exactly the same fault code. When we tested it the piston was jamming in the solenoid. Now it's been replaced the new solenoid has had this one single hiccup, but I'm keeping my fingers crossed it was a one off.

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I'm certainly hoping so.

Just going to let the car cool down so I can start it from cold and go for another run tonight.

So, for the last sixty miles she's running perfect, after that one hiccup....... Keeping my fingers crossed and it is so nice to have no timing chain rattle on cold or warm start up.

Here's a few pics of today, back on the road at long last. Haven't really given it a good clean yet, but what the hell.

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I'll keep you informed...........

JimGreen
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Re: 2005 Noggy Blue S4 - Project

Post by JimGreen » Sat Aug 30, 2014 9:48 pm

Another sixty miles with no further issues or fault codes.

:jump: :jump:

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R Black
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Re: 2005 Noggy Blue S4 - Project

Post by R Black » Sun Aug 31, 2014 9:47 am

Happy days :thumbs: :nogarors4:
Great thread, impressive amount of work, in a short time of ownership. Love the look of your S4, the alloys work well, So your still to get the JHM tune right? be interesting to see your thoughts on how much stronger it feels after that.
Past & Present: Audi S4 B6 Avant, SupraTT <Gone>, Audi S2 <Gone>, Mustang 69 302ci.

JimGreen
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Re: 2005 Noggy Blue S4 - Project

Post by JimGreen » Sun Aug 31, 2014 12:22 pm

Thanks for your comments.

JHMotorsport Tune (93) was ordered yesterday :biggrin3:

So will have an update by the end of the week..........

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ASC
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Re: 2005 Noggy Blue S4 - Project

Post by ASC » Fri Sep 05, 2014 12:44 pm

Jim, how did you get on with the tune?
Current - 07 Sprint Blue RS4 Avant Black optics / Buckets / FBSW / MRC Stage 2 / De flapped Manifold / CAF / BMC filter / Decat / Non Res Miltek / Bilstein B16's / Tarox discs, pads and lines / H&R ARBs / 19x9.5 Ispiri ISR1 wheels / MPSS tyres / DTM carbon splitter
Previous - 06 Sprint Blue B7 S4 Avant JHM 91 tune / 2.5" Custom Cat-less DP's / Miltek Non Res Cat back / BMC filter / H&R springs / 19" Fox MS007 wheels/Good Year F1's / EBC TG discs / Yellow stuff pads

orangio
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Re: 2005 Noggy Blue S4 - Project

Post by orangio » Thu Jan 15, 2015 4:05 pm

Epic build :notworthy:

How's it been running?

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