JJ's Cactus Green Audi S4 B5

[JJ.]

Hi all,

Bought another S4 B5 two weeks ago, second attempt ( http://www.audizine.com/forum/showth...464-JJ-s-S4-B5 ). I hope this ones stays longer than 1,5 week.

This time it's a Cactus green S4 Limo from '99 with the silver leather interior, it's in much better shape than the avant I had before but it

needs the clutch done.
Never thought me being someone that would buy a car that was not black or silver but I really love this colour.

Options:
- Full electric silver leather s4 interior with heated seats.
- Sports steering wheel.
- Double din (with the wrong RNS-D, A6 C5 I think).
- Carbon belttrim.
- Telephone in the armrest, not so nice because it has a hole in the quarter panel now for the antenna.

The wrong options the previous owner liked:
- Imitation RS4 grill, original S4 grill is with the car.
- Imitation Lamborghini Galardo wheels.
- A bunch of S4 stickers.
- Not lowered a bit.

The plans:
- Replace the clutch, bought the Loba RS4 clutch.
- Bearlock and as much other anti-theft mods.
- Polish the exterior and clean the rest of the car.
- Lower it!

[JJ.]

Monday evening I've started with the engine pull, I've done this before on my 1.8 turbo A4 b5 so I'm familiar with some parts, not with the

2.7 v6.
Found out this radiator has no drain valve and that there are lines coming from the transmission going into the radiator. Extremely hard to

remove.

[JJ.]

The work from Tuesday and Wednesday.
On tuesday I've received my RS4 clutch from Loba.





Disconnected the exhaust, both clamps rusted and broke when I tried to undo them.



Aircon compressor removed, all the DIY engine pulls did state that was the easiest way and you don't have to drain the airco.
Even with the oil cooler and parts in front of it removed, it still was a though fit the get it out of the way.



Unbolted the axles



Coolant tank will be replaced.



Disconnected the engine loom from the ecu box.



Current state:




I'm trying to work a couple of hours on the car every evening so it might go a bit slow but i'll get there.

Whats left to remove before I can pull the engine:
- Powersteering lines from the engine
- Earth cable on the passenger side (drivers side for you guys, any tips on this one?)
- Central driveshaft bolts are out, but I can't get the driveshaft of the transmission flange.
- Engine and transmission mounts.
- Hood of the car, the garage I'm working in has a crane which is mounted on a rail on the ceiling, quite handy but I need the vertical space.
- Slave cylinder.
- The other sensor things on the transmission.
- Heater core hoses.

Trying to get those things done tonight.

Some other pics that I've taken:

[S4 00 2.7]

Very nice and paint looks pretty good as well. Congrats on the new ride.

[MacFady]

Looks to be in great shape, really like the interior color with the cactus. Agreed with the wheels, even with the right drop and stance I don't think they suit, I'm picturing something dark with an aggressive offset.

[mpsmith]

This thing is awesome man. The RS4 grill isn't so bad, ecs or oem. Both are fine.

[demonmk2]

nice find
great color too, you don't see a lot of B5's in that color.

[Audimilo]

you're in Europe. otherwise id take your wheels off your hands.

[topquarkpc]

why not rs4 next time since you're in Europe...??? maybe netherlands didnt get any from get-go?

[mark@hardocre]

Looks great. You may want to wet sand that trunk lid. Looks like someone didn't when they painted it. (Orange peel) love the colour!


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[JJ.]

Thanks guys for all the nice replies :D

Last Saturday I managed to get the engine out!

why not rs4 next time since you're in Europe...??? maybe netherlands didnt get any from get-go?

Why not? Because they are way to expensive. Some of the cheapest are still 22.000 usd in The Netherlands, plus the weight of the car decides how many tax you have to pay monthly. That would be around 110 usd a month, insurance is also that expensive so I'll have the S4 for now.
Maybe some other time, they are lovely :)

Looks great. You may want to wet sand that trunk lid. Looks like someone didn't when they painted it. (Orange peel) love the colour!


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Yeah, it's not really visible with the naked I, the shot you are talking about was taken with a 100mm macro lens haha. But I will tidy the exterior when I'm done with the engine.
Thanks :)

[JJ.]

Good news, the engine is out Did that Saturday.

The bad news is, the battery of my camera was empty so i don't have any pics from Saturday when I took the engine out.
Friday evening I took care of the last few lines and bolts that were needed too come out to pull the engine:

- Earth cable on the chasis leg
- Powersteeringfluid lines and reservoir
- Axle (yes, only one
- Prop shaft
- Shifter rods from inside the car
- Hood

Saturday was planned to take the engine out, I hooked the crane onto the engine hoist points, undid the bolts on the engine and transmissions mounts and lifted it up a bit.
I was only to take out one axle because I couldn't get the other one out due to a stuck pinch bolt, I thought that one axle out of the way would give me enough clearance to take the engine out. Well that wasn't true.

I got the engine out of the mounts, both engine mounts are broken now because the alloy mount base with the stud sheared lose from the mount itself. That's also going to be on the list of new parts to order.
With the engine being out of it's mounting point it still wouldn't come forward to unhook the clutch slave cylinder and pull the heater core hoses out of the chassis.

The thing was, even one axle kept it from coming out, stuck against the heat shield above the axle. Dropped the suspension by undoing the three bolts on top in the engine compartment and took the axle out, finally the engine came forward.
Time to unhook the clutch slave cylinder and route the heater core hoses out and the engine was free.

So I will hopefully get some pics tomorrow.
All I have are these pics from friday:

Earth cable and powersteering reservoir:





The big pile of parts:

[demonmk2]

did it come with a stubby mirror or are my eyes deceiving me?

[JJ.]

did it come with a stubby mirror or are my eyes deceiving me?

Did come with one yeah :)

[JJ.]

As I've mentioned before, the engine is out and the clean-up progress has began.
Camera is also back up and working so I've got some pics for those who are interested. Nothing like a thread without pics tho.

Received my order from the Audi dealer today with new bits and pieces that needed to be replaced.







Leaking valvecover gaskets together with the tensionergaskets I believe.



Dirty



Clean





This discovery scared the hell out of me, it's never good when you find a loose banjo bolt, especially on the turbo. Glad that it wasn't from the coolant or oil feed/return lines but some pressure line (who can enlighten me about this line, what does it do exactly and could this have been a major problem?).
New banjo bolt is going in tonight, with new washers off course.

[lorenzob27]

Its great to have all that work room. I need a bigger garage. good stuff

[JJ.]

Its great to have all that work room. I need a bigger garage. good stuff

Thanks, the room is so great to have, makes everything a lot easier!

[JJ.]

I must say I've done quite a lot last Friday and Saturday.

Picked up some parts from the dealer so I could continue working and replace worn and missing parts.
The missing banjo bolt I was talking about earlier is back in the place where it belongs along with new washers.

I've also managed to separate the transmission from the engine block so I could replace the clutch, which was the reason for this engine pull all along.
Got 2 bolts that secure the pressure plate to the flywheel out, the other 4 were fucked, luckily my mate was helping me that day and he can weld, pretty good!
So he welded the allen key to the pressure plate bolts so we could take them out.

Next surprise, a flywheel that was gone, far gone! So I'll need a new one for that, I did order the Loba RS4 clutch earlier in good faith the flywheel was good enough to stay put.

On to the next point on the list, valvecover gaskets!
Both heads were leaking quite badly from those gaskets, so I've ordered everything necessary to replace them, to bad that when I wanted to do the seconds camshaft chain tensioner gasket the VAG3366 tool failed, it exists of 2 pieces now, stupid plastic.

Also removed the intake manifold because the aux. waterpump was leaking. Was planning on removing it anyway and bypass it, just need to buy some silicone hose now.

I will probably start painting the valvecovers and intake manifold today, would be a shame not to do so now that everything is of.

Time for the pics.

Missing banjo bolt:





Old vs new:


Transmission off:


Verrotte koppeling:


DMF:


Old gaskets, in many parts


VAG 3366 tool:


Valvecovers and intake manifold:

[Jmills]

Awesome pictures! What camera are you using?

Love the color as well

[JJ.]

Awesome pictures! What camera are you using?

Love the color as well

Thanks! I use a Canon EOS550d, just a basic dslr but it does everything I want for now haha.
I believe they call m Canon Rebel in the USA.

[Audimilo]

hey are those gallardo wheels 18" or 17'? thx

[Yesmar]

you're an awesome photographer,
nice car man

[JJ.]

hey are those gallardo wheels 18" or 17'? thx

Yeah, Lardo reps, 18''

you're an awesome photographer,
nice car man

Haha thanks, not anywhere close to where I want to be with my photography but it will do for now :D

[jpurre]

Nice thread, I enjoy watching you bring this car back up to spec.

[JJ.]

Nice thread, I enjoy watching you bring this car back up to spec.

Thanks, appreciate it :)

[JJ.]

I've never liked like the old spiderhose assembly, brittle and full of gunk.
After a bit of DIY with silicones hoses I've created this:

Old mess:




My new creation:





The old tool, broken after one time of using it:




Old gasket:




Leaking afterrunpump:




My mate came by to help with some thing, he started cleaning the engine bay, no further words necessary I think:




Preview of the valve cover:



And the Y-piece in primer:

[JJ.]

The engine is ready now for going back into the bay, cleaned the last bits, even the engine loom and it's connectors.
Put the newly painted valve cover and intake manifold on with some fresh gaskets so I hope it won't leak again.

Installed the flywheel and Loba clutch, got to borrow the centering tool from the dealer where I order all my parts. So that was really cool of them :)

There are of course still a couple of things to do and to order before it can go back in again.

- Clean the engine bay completely
- Clean all removed parts like the intercooler, rad support, ducts etc.
- Replace driveshaft boot
- Get new engine mounts, going for the RS4 ones I think.
- All new fluids, oil, coolant, transmission oil, ps oil.

Some pictures now :lol:

Painted intake


Fuel rail and other bits installed


Afterrunpump by-pass (changed it's path after finding out the temperature sensor on the underside of the intake manifold was in the way)


Getting all of the old oil out, ready for some new Redline oil.


Fresh valvecovers:






Loba RS4 clutch and flywheel mounted


VAG TOOL 3176


Transmission back on, ready to go back, more or less

[Tec_Nine]

Great progress thus far. Keep up the good work

[JJ.]

Great progress thus far. Keep up the good work

Thanks, will do for sure!

[JJ.]

I hope, and that's also my plan, to drive the S4 out of the garage next Saturday on it's own power.
Didn't do much last week, except for cleaning parts, done with that now, really done with that haha.

I hope to receive the RS4 engine mount from the dealer on monday and yesterday I received the Redline gearbox oil.

The things left to buy are:

- Engine oil (Kroon 5w40 specialsynth I think.)
- Powersteeringfluid
- Coolant
- Axle boots, front right
- Axle gaskets, cork things
- Those big bolts that lock the axles in place in the upright, anyone know the parts number of those?
- New bolts for the propshaft
- 2 exhaust sleeve connection things

If I have any cash left, some new diverter valves might be nice :)

Traded the imitation RS4 grill with a forum member of the Dutch Audiforum for some brake caliper paint, just plain metallic silver, looks neat now :)





Clean bay:





Box full of clean parts, even cleaned the driver side axle, the correct driver side.

[oppositelock]

Don't put Redline MTL in your trans. Use Fuchs Titan SintoFluid 75W80. Lots of bad experiences with Redline MTL:

http://www.audizine.com/forum/showth...Gear-Oil-75W90

[JJ.]

That's a disturbing thread, but I've also heard a lot of good story's about that gearbox oil. We'll see how much I like it, thanks for the concern.

[JJ.]

The engine is back in since last Monday, all was going to plan till I woke up with the flu on Thursday. Messed up my ''schedule'' so instead of taking it for a ride today it will have to happen next week.
Didn't take as many pictures as before, was to busy with wrenching everything back together :D

Here are some pics from last week, I've done more than the pictures show though.

Cleaned intercoolers:



New RS4 engine mounts:



Engine back to where it belongs, together with the hood:



Got some cleaning to do as well when it's out haha.

[demonmk2]

I wonde why they did not do the antenna like the US models

coming together though! going with the same wheels?

[JJ.]

I wonde why they did not do the antenna like the US models

coming together though! going with the same wheels?

That's not the radio antenna but the antenna for the oldskool mobile phone, which is located in the armrest, will snap a pictures of it later!
Thanks :) definitely not the same wheels, don't really like them haha

[JJ.]

Pleased to say, it's running again!

Yesterday I topped up all the fluids and fired her up, after 3 seconds she had gas and was running.

Ran into a small bleeding problem, the heater wouldn't get hot. Figured the heater was one big bubble of air where the coolant couldn't go so I bled it by taking back the hose a bit so the bleeding hole was free, took the coolant reservoir, held it up as high as possible and there was heat coming out of the vents :D

Going for a testdrive tomorrow so I hope she'll still be fine after that :) Can't wait to drive it again.

[Uber]

Great read and nice workmanship!

[JJ.]

Great read and nice workmanship!

Thanks mate :)


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[155VERT83]

Congrats on a great build!

[BaseDrifter]

Looking good JJ! Keep up the good work.