All comes at once - DIY: SAI, DRC, Oil cooler, Carbon clean, Fan, Tyres, Paint Corrosion, Injector Service

[r8wut]

Unfortunately, in the process got to see some nice surface rust / corrosion issues going on in the rear wheel arches..

To boot - whilst tackling the Fuel Filter - which requires removing panels (I removed both sides) I got another nice surprise:

From what I've seen and read, the above is very common on our RS4's .. and obviously I need to tackle it now before it gets any worse

[r8wut]

Alright.
I change the mood music..
instead of being Mr misery-guts.

Here you go:

[lugars4]

Its nice to see your progress, its a shame we are finding rust as we go, ive yet to take to a body Shop for the roof and front wings, wonding what else i will find.

Love the new injectors, i see you also purchased the Elring seal kits, did the new injectors not come with seals? Crazy.

I cant wait to get it back on the road with the full refresh.

My PCV oil separator looks in good order, i can move the valves by hand and they all feel in good order so going to wash it out and keep it. Saving another £220....

Will be updating over the weekend as i rebuild my manifold and get the stuck injector out.

[lugars4]

Pulled the 77k Fuel Injectors.. 2 of which were seized in there really nice .. and got out eventually.. but cracked

IMG_20230924_095050.jpg

Mine isn’t coming out, slide tool just broke the plastic off and isn’t gripping the metal lip. Any tips on how you got them out?

[lugars4]

Coulnt let that ruin my day.

The tool kit i purchased from ebay, pretty useless, only part i will get value from is the bore cleaning brush and cone / mandrel for fitting teflon seals.

As far as removing the injector, no point using the kits tool for gripping on the plastic, thats never going leave you with a working injector if its stuck fast. Brittle, old, heat cycled plastic.

Needs to be gripped on the top metal lip, dont try levering either - ive seen many images of snapped injectors being drilled out of the head.
I had already mangled mine with pliers, but still had enough for an old home made tool i had to grip it. I forgot i made this years ago to remove stuck glow plugs from my land rover.

The other problem with cheap kits is the slide hammer travel, 100mm isnt enough, its pathetic.

Home made tool came right out. New injector needed sadly. Will test the other 7 to see if i feel any others need replacing after clean and flow test.

[lugars4]

Alright.
I change the mood music..
instead of being Mr misery-guts.

Here you go:

IMG_20231203_182104.jpg

IMG_20231028_173008.jpg

Where did you buy the injectors? I note there is a part number change.

[r8wut]

Yep, that's right - the revised OE Audi [Hitachi] Injectors are:

079 906 036 AB

Got those and a whole load of parts from TPS .. total bill around ~ £2.6k

including new PCV separator, aux rad, sump, sparks etc..

[r8wut]

Glad to see you got that stubborn, final injector out! I recall one of them being really stuck in there also.. think I used some large pump pliers and tugged like hell.. it eventually came out.

As of now, no time to install any new engine parts.. as trying to tackle the rust

It's interesting really..

I would at a guess , think ~90% of convo I've seen on B7 RS4's relates to the engine and electrics etc..

Maybe I'm wrong.. but aren't owners aware of the rust issues..? or maybe not so high on the list of priorities?

Personally, quite concerned.. RS only done 77k and the rear subframe looks crusty already!

.. anyone on here done a good write on rear - subframe removal?

Sanding areas previously mentioned back to bare metal and applying a some Hammerite Kurust

A few of the tools I'm using:

First time I'm using the Makita file sander - cannot recommend enough, absolutely brilliant tool.

Also, manged to bend and flare the rear brake lines (not easy as quite hard stainless steel) ready for new HEL brake lines.

[lugars4]

Nice job there.

I will no doubt be doing the same one day.

Check out this guys refurb, subframes included! viewtopic.php?f=121&t=132374&hilit=corrosion

Ive retained my DRC, was watching a video last night on hwo to replace the pipes when the time comes. Sub frame off job too.

Injector on order. And ive booked them in for flow testing so i can match them up into sets of 4 for each ECU bank.

[r8wut]

thanks for the link.. will have a good read!

ok so thinking about it, I'll probably start a new thread under there also .. considering I'm going further than i originally planned .. so guess would be nice to document the journey for everyone.

yep my DRC pipes are well corroded.. and didn't fancy removing the subframe few weeks into ownership ! .. hence why I went with the KW's.

good shout on the injector flow testing .. please post results.. would be interesting.

[JamesBaby]

Superb thread mate and tremendous effort on your car. Credit to you.

Check out my thread in Readers Rides to when you get a moment.

I'm pulling my injectors soon. Hope mine aren't stuck.

[lugars4]

Interesting observation, the latest injectors from audi have the metal filters.

Injectors (and the new one) ready for flow testing with seal kits fitted and fresh filters. (Oh and my favourite carbon cleaning product, best of many i tried when doing carbon clean).

[JamesBaby]

I'm doing another carbon clean in a few weeks. How are you using that Carb cleaner in the process?

[lugars4]

I actually found this method best for me, contrary to many ideas of soak first.
I found soaking and digging about made a hugh gunky mess, harder to extract.

These were great, long picks. https://www.amazon.co.uk/gp/product/B07 ... UTF8&psc=1

• Pick the heavy carbon off, dry, and hoover / blow it out. Gets maybe 50% off. Big chunks on mine.

• Spray and pick / scrub with the Liqui Moly spray, gets its looking much better.

• Blast with walnut shells. On inspection, there will be small areas that need a final spray / pick / blast.

• Fishing off with a wash down with spray.

• I walnut shell blasted all the metal flaps and even the inlet manifold internals (stripped down). Again finished with a wash down with spray.

• The shafts from the inlet manifold cleaned up real easy with the Liqui Moly, its great stuff.

[JamesBaby]

Good work cleaning up the shafts. I detailed a similar procedure in my thread when I did my CC last January. By cleaning the shafts I removed the play that was in them so they functioned correctly. I also added the 034 Motorsport billet intake arms.

However I loctited the screws for the flaps in and the inlet plugs, so on my next carbon clean in a few weeks I won't be undoing them. I will get a chance to inspect the screws and flaps however to ensure they are firm etc.