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
lugars4
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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 » Wed Nov 08, 2023 7:16 pm

Radtec cooler arrived, very nice!
2023-11-08 18.13.17.jpg
06 - B7 RS4 Saloon - Milltek Non-Res Valved. BMC Filter.

JRC1
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Re: All comes at once - DIY: SAI, DRC, Oil cooler, Carbon clean, Fan, Tyres, Paint Corrosion, Service

Post by JRC1 » Wed Nov 08, 2023 7:39 pm

r8wut wrote:
Wed Nov 08, 2023 4:58 pm
Yes, have heard good things about Reyland discs - but apparently they do not recommend the use of Ferodo pads citing bedding and uneven pad build up issues .. :?

weighing it all up .. ultimately depends how aggressive setup you want I suppose.. there are always some trade-off's ..

some owners have been perfectly happy with the OE braking setup.. a good friend just installed brand new Brembo's in his b7 RS [oe discs and pads] up front and I can tell you personally - it stops just fine!

anyway, no didn't get unlucky with purchase.. as you've probably gathered I'm 'fairly' competent with an adjustable

Knew the discs and pads were due.. so factored in the cost of the KW's and the Forge unit - price wasn't particularly cheap, but then again neither expensive .. as I was looking for a particular spec and this one pretty much ticked all the boxes..

As planning to keep long-term wanted to do the Carbon Clean from the outset at the very least .. and you know.. the list of jobs just expands a little here and there.. :boohoo:
Lots of people keep saying and repeating the thing about Reyland discs and DS2500 pads ... that's the issue with forums and stuff people read it once and repeat it and misinformation gets out there! I called Reyland about this before purchasing and they said that it was an issue with the J hook disc type and people not following the bed in procedures correctly. They said that they had to put a disclaimer on their website to cover themselves, but by choosing another disc/groove type and following the correct procedures, you won't have issues.

I went for straight groove discs and followed both pad and disc bed in procedures (probably overly so) and have fully even wear now after a few thousand miles. They have been excellent.

Yeah fair point on the OEM discs/pads, but they also aren't cheap - so when comparing these prices to the uprated Reylands it was a no brainer for me. Also fills the rear up nicely as the OEM 324mm looks so small at the back.

Yeah also agree about the aggressiveness. Ultimately I guess it depends what the car is predominantly used for. Mine is just a fast road occasional weekend toy so I wanted the best performance possible but if it was a daily I'd probably reconsider going for such an aggressive pad.

r8wut
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Re: All comes at once - DIY: SAI, DRC, Oil cooler, Carbon clean, Fan, Tyres, Paint Corrosion, Service

Post by r8wut » Thu Nov 09, 2023 1:35 am

lugars4 wrote:
Wed Nov 08, 2023 6:56 pm
What are your plans for Carbon Cleaning?

Ive just ordered my walnut shells..... If you have a compressor and a bagless hoover, its a cheap job to diy.

With my rad fan out, its also dead easy to turn engine over. Plan to use a home made pulley tool from the old aux belt to grip on pulley and turn over.
Well. Some weekends ago, the weather was nice and I decided to go ol skool and 'manually' clean all the inlet ports with good ol elbow grease, some toothbrush's, cloths, long cotton buds, long picks, brake cleaner and my air compressor.

In a wal 'nutshell' - I would not recommend it.

Although, I got the job largely done.. still need to finish cleaning up a bit .. it ended up taking the entire weekend, I ****** my back up as it was a lot harder and gunked up than I envisioned!

If I had bothered to purchase the walnut shells, it would have taken a fraction of that time :roll:

Anyway, should have known and will do for next time.. haven't got any recent pics of the results - but will try and update thread with them

Be interested to see your progress and results with the shells, compressor and pulley tool to move the valves..

r8wut
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Re: All comes at once - DIY: SAI, DRC, Oil cooler, Carbon clean, Fan, Tyres, Paint Corrosion, Service

Post by r8wut » Thu Nov 09, 2023 1:42 am

lugars4 wrote:
Wed Nov 08, 2023 7:16 pm
Radtec cooler arrived, very nice!

2023-11-08 18.13.17.jpg
Agree Radtec looks very nice, post some install pics ..

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

Post by lugars4 » Thu Nov 09, 2023 5:21 pm

r8wut wrote:
Thu Nov 09, 2023 1:35 am
lugars4 wrote:
Wed Nov 08, 2023 6:56 pm
What are your plans for Carbon Cleaning?

Ive just ordered my walnut shells..... If you have a compressor and a bagless hoover, its a cheap job to diy.

With my rad fan out, its also dead easy to turn engine over. Plan to use a home made pulley tool from the old aux belt to grip on pulley and turn over.
Well. Some weekends ago, the weather was nice and I decided to go ol skool and 'manually' clean all the inlet ports with good ol elbow grease, some toothbrush's, cloths, long cotton buds, long picks, brake cleaner and my air compressor.

In a wal 'nutshell' - I would not recommend it.

Although, I got the job largely done.. still need to finish cleaning up a bit .. it ended up taking the entire weekend, I ****** my back up as it was a lot harder and gunked up than I envisioned!

If I had bothered to purchase the walnut shells, it would have taken a fraction of that time :roll:

Anyway, should have known and will do for next time.. haven't got any recent pics of the results - but will try and update thread with them

Be interested to see your progress and results with the shells, compressor and pulley tool to move the valves..
Sounds fun!, i plan to do a manual clean then final polish up with walnut on stubborn areas.

Shells arrive today. Quick delivery from https://www.sandblasters.co.uk/walnut-s ... 1020-p.asp

See how far 10kg goes, should be re-useable if it doesnt get too dirty from cleaning.
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06 - B7 RS4 Saloon - Milltek Non-Res Valved. BMC Filter.

r8wut
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Re: All comes at once - DIY: SAI, DRC, Oil cooler, Carbon clean, Fan, Tyres, Paint Corrosion, Service

Post by r8wut » Sun Nov 26, 2023 11:50 pm

ok, well this is the result of my manual Carbon Clean.. I'd say pretty good success across all ports.. considering my back was aching like hell!
IMG_20231115_151313.jpg
How did yours go?

r8wut
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Re: All comes at once - DIY: SAI, DRC, Oil cooler, Carbon clean, Fan, Tyres, Paint Corrosion, Service

Post by r8wut » Sun Nov 26, 2023 11:56 pm

Managed to get the sump off, thankfully nothing hiding in the sump oil.

Inspected the Oil Pickup gauze, which looked pretty clean - certainly no sign of blockage
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r8wut
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Re: All comes at once - DIY: SAI, DRC, Oil cooler, Carbon clean, Fan, Tyres, Paint Corrosion, Service

Post by r8wut » Mon Nov 27, 2023 12:23 am

Moving onto the Brakes.. brake lines to the Front Brembo's were fairly rusty and highlighted in last MOT "...front brake pipes corroded."
Covered the unions in rust penetrating spray.. left overnight.

They were quite corroded and stiff - but very carefully working it back and forth..
got lucky and they finally opened up :
IMG_20231117_171549.jpg
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After it finished dripping brake fluid, I sprayed the entire area with hot soapy water.. brake fluid is not kind to bodywork!

As you can see, wheel arches are notorious spots for corrosion or bubbling .. unfortunately couple areas showing signs of light corrosion.

Will have to give it a good clean, sanding back to bare metal to remove the rust spots - brush on some 'Hammerite Kurust' then apply zinc / anti-rust primer, then further coat with some stonechip shield guard of some sort..

Any recommendations? Upol, isopon? Trick is I guess, is to match the Sprint Blue body-paint..

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

Post by lugars4 » Sat Jan 20, 2024 10:25 pm

Update:

Carbon clean is well under way, was a Mess in there, looking forward to having it back on the road clean.

Decided to strip and clean the manifold, couldnt see a good way to clean it otherwise, will also look to fix the bit of play on the arms, not bad but will see what i can do. The gasket between the two halves is easily re-useable, its metal and comes off easilty.

Will loctite threadlock the screws on the manifold flaps! Have read a few thread of them coming loose!

Walnut blasting made it a relatively easy task, used my old hoover and it collects the shells easily in a new bag for re-use, didnt use hardly and shells this way.
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06 - B7 RS4 Saloon - Milltek Non-Res Valved. BMC Filter.

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

Post by lugars4 » Sun Jan 21, 2024 10:17 am

r8wut wrote:
Mon Nov 06, 2023 12:34 am
lucky your Aux Rad is still ok..

Well.. I'm working through a Full overhaul / replacement of mostly everything.. will briefly try and break it down:

1. Completed Installation of KW V1's front and rear to replace leaky DRC setup.
2. new Front & Rear Discs and Pads all round - yet to decide.. Reylands ?
3. Front + Rear Anti Roll Bar Bushes
4. Need to purchase HEL Braided Hoses Front & Rear
5. Replacement of ALL fluids: Engine oil, Gearbox and Diff oils, coolant, power steering and brake fluids
6. Sump replacement, due to corrosion. Would have done anyway, as perfect opportunity to inspect Oil Pickup pipe gauze for any blockages
7. Full Carbon Clean inc. PCV valve replacement, vacuum valves, oil filter housing seals
8. New Rocker / Valve cover seals x2
9. Deliberating on 8x new OE / Hitachi Fuel Injectors (expensive!)
10. Oil Filter, Fuel Filter etc.
11. New Bonnet latch
12. New Fuel Flap cap release actuator latch

Suffice to say.

Looks like I might need to re-mortgage the house.

IMG_20231008_153643.jpg
How did your refurb go in the end?

I note you are replacing the PCV oil separator. I have always thought this must be a contributor to the carbon buildup, and i noted when reading today that MRC replace it when doing a stage 2 with carbon clean, https://mrctuning.com/site/rs4-b7-4-2-v8-fsi/ - Oil Separator – B7 RS4 (079103464F).

WIll pull mine today and take a look at it and see what availability it.

Some info on how it works here, there are some moving parts.
Crank Case Ventilation.pdf
(169.29 KiB) Downloaded 15 times
PCV Oil Separator.pdf
(132.55 KiB) Downloaded 17 times
Then im left with injectors....... tempted to pull one and inspect it, what did you conclude? Get them tested? Ultrasonic clean (i have a small cleaner i could put the tip into)?
Last edited by lugars4 on Sun Jan 21, 2024 8:25 pm, edited 2 times in total.
06 - B7 RS4 Saloon - Milltek Non-Res Valved. BMC Filter.

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

Post by lugars4 » Sun Jan 21, 2024 10:26 am

Good guide on stripping the intake manifold.

https://www.034motorsport.com/docs/034m ... ctions.pdf
06 - B7 RS4 Saloon - Milltek Non-Res Valved. BMC Filter.

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

Post by lugars4 » Sun Jan 21, 2024 10:52 am

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
I see you can buy a seal kit for the injectors, 06E998907G:
GENUINE https://www.darksidedevelopments.co.uk/ ... 06e998907g
ELRING https://www.darksidedevelopments.co.uk/ ... 8907g.html

Also purchased a removal and seal mandrel kit from ebay for £28. One injector wont budge. Other came out Very easily.
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A bit on home cleaning:
https://www.ttforum.co.uk/threads/clean ... e.1961485/
06 - B7 RS4 Saloon - Milltek Non-Res Valved. BMC Filter.

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 » Sun Jan 21, 2024 8:37 pm

Injectors not looking bad, small amount of carbon on the tips, wiped off easily, 3rd photo shows one wiped clean and one as removed.

Will test them for spray pattern and take it from there.

Removed filters, will replace all seals and filters.
Filters came out with a screw and pliers, trick is to get a good fitting screw, tights enough to give a up and down motion as pulling hard, they come out fine.

Would benefit from beinf replaced by look of them, intact (ive heard the can break up), but not overly clean.
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06 - B7 RS4 Saloon - Milltek Non-Res Valved. BMC Filter.

r8wut
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Re: All comes at once - DIY: SAI, DRC, Oil cooler, Carbon clean, Fan, Tyres, Paint Corrosion, Service

Post by r8wut » Fri Jan 26, 2024 12:44 am

lugars4 wrote:
Sun Jan 21, 2024 10:17 am

How did your refurb go in the end?
Great to see some progress on your Carbon Clean.. looks good :thumbs:

I think mine is in for the long haul refurb :roll: Lots and lots to do really..

Moved onto rear brake lines.. and that's where I got a nice surprise:
IMG_20231130_150931.jpg
IMG_20231130_160036.jpg
Funny. None of my spanners seemed to fit :audibash:

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 12:48 am

Time to bring out the Angle grinder:
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