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

4.2 V8 32v Naturally Aspirated - 414 bhp
r8wut
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Re: All comes at once - DIY: SAI, DRC, Oil cooler, Carbon clean, Fan, Tyres, Paint Corrosion, Injector Service

Post by r8wut » Fri Jan 26, 2024 1:04 am

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:
IMG_20231220_121427.jpg
IMG_20231220_155647.jpg
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 :thumbsdown:

r8wut
1st Gear
Posts: 56
Joined: Sun Aug 13, 2023 12:13 pm

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

Post by r8wut » Fri Jan 26, 2024 1:20 am

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

Here you go:
IMG_20231203_182104.jpg
IMG_20231028_173008.jpg
:nogarors4:

lugars4
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Posts: 267
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Location: Kent

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

Post by lugars4 » Sat Jan 27, 2024 12:10 pm

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.
06 - B7 RS4 Saloon - Milltek Non-Res Valved. BMC Filter.

lugars4
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Posts: 267
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Location: Kent

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

Post by lugars4 » Sat Jan 27, 2024 2:04 pm

r8wut wrote:
Mon Nov 06, 2023 12:41 am
Pulled the 77k Fuel Injectors.. 2 of which were seized in there really nice .. and got out eventually.. but cracked :roll:

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?
06 - B7 RS4 Saloon - Milltek Non-Res Valved. BMC Filter.

lugars4
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Location: Kent

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

Post by lugars4 » Sat Jan 27, 2024 4:24 pm

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.
2024-01-27 14.06.30.jpg
2024-01-27 14.04.59.jpg
06 - B7 RS4 Saloon - Milltek Non-Res Valved. BMC Filter.

lugars4
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Posts: 267
Joined: Tue Apr 27, 2010 3:34 pm
Location: Kent

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

Post by lugars4 » Sun Jan 28, 2024 5:52 pm

r8wut wrote:
Fri Jan 26, 2024 1:20 am
Alright.
I change the mood music..
instead of being Mr misery-guts.

Here you go:

IMG_20231203_182104.jpg

IMG_20231028_173008.jpg

:nogarors4:
Where did you buy the injectors? I note there is a part number change.
Capture.PNG
06 - B7 RS4 Saloon - Milltek Non-Res Valved. BMC Filter.

r8wut
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Posts: 56
Joined: Sun Aug 13, 2023 12:13 pm

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

Post by r8wut » Sun Jan 28, 2024 11:15 pm

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 :drink:

including new PCV separator, aux rad, sump, sparks etc..
IMG_20240127_154455.jpg
IMG_20231201_175857.jpg
IMG_20231208_175606.jpg
IMG_20230901_145710.jpg

r8wut
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Posts: 56
Joined: Sun Aug 13, 2023 12:13 pm

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

Post by r8wut » Sun Jan 28, 2024 11:52 pm

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 :roll:

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
IMG_20240126_165439.jpg
IMG_20240117_131409.jpg
A few of the tools I'm using:
IMG_20240112_155511.jpg
IMG_20240115_115328.jpg
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
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Re: All comes at once - DIY: SAI, DRC, Oil cooler, Carbon clean, Fan, Tyres, Paint Corrosion, Injector Service

Post by lugars4 » Mon Jan 29, 2024 6:50 pm

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.
06 - B7 RS4 Saloon - Milltek Non-Res Valved. BMC Filter.

r8wut
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Posts: 56
Joined: Sun Aug 13, 2023 12:13 pm

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

Post by r8wut » Tue Jan 30, 2024 10:11 am

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

Post by JamesBaby » Tue Jan 30, 2024 1:54 pm

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

Post by lugars4 » Wed Jan 31, 2024 8:33 pm

Interesting observation, the latest injectors from audi have the metal filters.
2024-01-31 18.25.39.jpg
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).
2024-01-31 19.08.06.jpg
2024-01-31 18.09.37.jpg
06 - B7 RS4 Saloon - Milltek Non-Res Valved. BMC Filter.

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

Post by JamesBaby » Fri Feb 02, 2024 11:15 am

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

lugars4
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Re: All comes at once - DIY: SAI, DRC, Oil cooler, Carbon clean, Fan, Tyres, Paint Corrosion, Injector Service

Post by lugars4 » Sat Feb 03, 2024 11:12 am

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.
2024-02-03 10.05.41.jpg
2024-02-03 10.05.35.jpg
06 - B7 RS4 Saloon - Milltek Non-Res Valved. BMC Filter.

JamesBaby
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Posts: 264
Joined: Tue Jan 29, 2019 5:26 pm

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

Post by JamesBaby » Mon Feb 05, 2024 10:24 am

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.

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