Project S4-MH500

[grizz]

Well done , looking very good there bud. Keep us posted . grizz

[viperbl]

Good work and pics

[okkim]

I have made 12 mm threads to those holes, and then put M12 bolt in there. That is easy, and it is also easy to get out if needed.

http://picasaweb.google.com/mikko.valit ... 1486283762

[viperbl]

I am lost, what is this hole you are blocking up on the NA heads??? I am putting some 2.4 NA heads on my RS4 engine, will I need to block these holes up?!!??!

[grizz]

The hole is for the secondary air system , you can leave the hole's if you keep the system on your rs4 engine. g

[confusionhunter]

sounds like a plan!!!! cheers!!

[confusionhunter]

Made good progress today.... well actually I spent ages correcting a fluff up as it turns out the guy who built my heads had popped the inlet cams in the wrong heads.... of course I didn't spot that till I tried turning the engine over after Id put the heads on and set the timing up..... as you can imagine I wasnt overly pleased about that so I ended up spending hours correcting that rather than getting cracking....
Anyway.... still made some progress....
Threaded the heads as okkim suggested and got some shrt M12 bolts in the ports....

Job done!

Got the manifold on and had to make modifications to the bracket that sits over the manifold. Left side was fine but well as you can see I had to cut away a fair chunk and then there was sod all room to get the bolt in....


So I made mini stud..... hmm not much room to get a nut on there:

I managed to get a stainless one on so the threads are a little stonger, as to get the nut on I had to put the stud in a couple more threads.... It doesnt look good but its on very tightly. I guess I could file the nut smaller and pull the stud a thread or so but I feel thats good enough as its not exactly crucial.


so I did make fair progress but not as much as I'd liked to have. Maybe do it tomorrow too...
SO... to summarise, heads are on timing belt is on, engine turns over nicely, Gaskets doubled up for low compression, cam covers on , plugs and coil packs in, some of the water pipes and auxilury electric water pump......


Next is the water pipes, inlet manifold, big injectors, and the turbos!
Then I might get it off the stand and get the flywheel, RS4 clutch and release bearing... mate it to the box then Im ready to start the custom downlpipes..... pah.... easy!

[confusionhunter]

Well... I have prepped the turbos..... Plain Ko4s but I decided I would take the risk and flow the hotside. Its fairly obvious where the attention is required, as the gas comes out the turbine and smacks straight in to about 1.5mm lip on one side, not ideal, especially if you think about the rpm and amount of gas going through there.....
Lip is at the bottom...



SO I under took a bit of a delicate operation as I did not want to dismantle the turbos....
I dug out my powerful vacuum cleaner again. From flowing the manifold I knew that the suction on the hoover was good enough to leave no debris at all so I was happy enough to give it a bash with the turbos together...... funnily enough the suction was strong enough to spin the turbine....
Very peculiar flowing a spinning turbo! I suppose it made me happier that any particles would be deflected better is any did go the wrong way... I think it went well but I did skiff one of the blades annoyingly... ah well you live and learn you can see it in the pics..... I think it should be ok. If not.... bring on the garretts
Here was the result: each side....


I was happy enough that they were ok and I’d just made their life easier by a significant reduction in back pressure….

So on to the manifolds they go….. and this is where we find out why £1200 manifold are better than £150 ones!!
The left side was fine, but as I tighten up the turbo bolts on the right side one of the bolts felt a little peculiar as it got about 2/3s of the way down…. But it felt like the threads were sticking, which is not uncommon for exhaust parts because of the heat they get…. Tightened it down a bit more…. And it felt worse…. Hmm not happy with this…. Upon closer inspection the issue became apparent…..

Not good…. The was turbo pressing against the manifold, but not where you would want it…. This pushed the turbo at an angle and once I took the turbo off again I discovered the one bolt had cross threaded. It definitely started ok so my only explanation is the manifold…. Dammit!

Typically the tap and die kit I used on the heads was a mates and I have returned it, so this repair will need to wait…. Pants… I think I'll buy my own kit at the next Machine mart VAT free day!

[confusionhunter]

Well then!! Ive done lots more over the last few days so Ive got some catching up to do on this thread...... well to address the immediate problem I had, I got hold of the tap set sorted and the turbo thread without too much bother.... but I did have to skim the outside of the compressor housing and took a large hammer and a blow torch to the manifold to make some room....

about 2mm of clearance now:

Good stuff...

Next fit the new 630cc ish injectors and clean up the std inlet manifold. I know Im not making the most the big port head using the std S4 inlet manifold but I have a set of throttle bodies I may use.... just need to get the thing working for now....



To make the new injectors fit I did have to fabricate some little 8mm spacers so thatthe fuel rail sat correctly...


so the inlet manifold went on, put on some new timing belt covers on:

And I was happy with the overall set up of the exhuast manifolds:

To summarise each manifold head flange needed trimming, the left side needed heated and smacking to clear the turbo and I needed to remodel the pressure control hose to avoid the manifold. I also needed to elongate the hole on the RS4 inlet pipe so it could bolt to the head bracket correctly.

the right side neede far less, needed to trim the head bracket for the inlet pipe, and that was about it (and trim the head flange). I of course welded the inside and flowed both manifolds as seen in earlier posts.

so after all that, the engine was looking like an engine!





Pulled it off the engine stand:
and offered it up tp the box...


phew.... I have attached the flywheel and clutch and am just about to bolt up the box.... then its just aboutready to go in the car once I've fabricated some downpipes....
speaking of which Got some more trick bits from ESP engineering.... some flanges made to order for my cat replacement pipes: so I'll use these on my downpipes

should work well, i did something similar with my old S4....
and some nice leightweight alloy pulleys.... weigh a lot less than the std items!

So thats it..... you are all up to date now.

While I was in and around the engine I tried a few arty shots for a laugh....
enjoy:







can you guess where they were all taken from and what angles??

[Siena]

Nice work ther, will be worth all the hours you've put in.

[spen]

Just an idea: your oil feed is a couple of mm away from a manifold containing gas at 900 degrees. I wrapped the oil feed pipes with insulating cloth. A couple of quid which might stop my oil turning to carbon when the engine is switched off. At worst I've wasted a fiver.

[confusionhunter]

good call.... I have some heat proof stuff already.....

[confusionhunter]

Well got the box on today just about ready to go in. Im going to replace the engine mounts with RS4 ones while the engine is out... (cheers Brett!) looking good:


I also fitted the esp pulleys, which fit well! nice!


And I chopped off the Downpipes, so I'm going to use them as templates to make bigger ones... using the flanges on the end of these downpipes I can fit the engine and make the rest of the exhuast later once the car is on the road....

thats it for now...
Next is the custom downpipes....

[AdamS4]

Awesome work... keep it up

Keep us up to date on the status and hold up of them manifolds when its up and running as i have a set too.

[confusionhunter]

will do! I was chatting to brett about the heat proofing the oil lines and we had concluded that its a bit pointless given they are bolted to the turbo.... and the turbo will be hotter than that manifold and its bolted to thet so the heat tranfer from that will be far more than heat rediated from the manifold..... so insulating it might actually make the oil line hotter! Best thing would be to wrap the manifolds but sod that.....