Edgar's (i3oricua's) Progress and EFR 7163 Build

[i3oricua]

CAR INFO
2006 Audi A4 Base, FWD, 6 Speed, Engine Code BPG

Exterior Mods
Morimoto Headlight mod
Rotiform BLQ, 19x8.5
Brembo 18Z Calipers w/EBC Yellow Stuff Pads
Relak Carbon Fiber Side Skirts
S-Line Front Bumper w/RS6 mesh grill conversion
Cupra Front Lip
Carbon Fiber Duckbill rear wing (ECS)
Carbon Fiber Side Mirror Covers (ECS)
Carbon Fiber B-Pillars
Fenders rolled and pulled
Smoked side markers and smoked side blinkers
S4 Door Blades

Suspension
Eibach Springs w/ECS Coilover system
RS4 Rear Sway Bar
ECS Rear End Links
ECS Front Sway Bar End Links
Performance Front Sway Bar Bushings
Ultra Racing Upper Strut Bar
SPC Adjustable Upper Control Arms
ECS Billet Subframe Steel Bushings (Front)

Interior Mods
Custom Flat Bottom Steering Wheel
BFI Shift Knob
Custom Interior Wrapped Trim
Custom Suede Wrapped Black Headliner
Black Interior Swap
B6 Front and Rear Recaro Seats
Podi Gauge Pod w/Boost Gauge
Innovative Wideband in Custom Vent Pod
VFiz
R8 Pedals
Wrapped e-Brake Handle
Blackvue Front and Rear Camera
Different Head Unit (S100 Android)
Kicker 10" sub in Custom Side Mount Trunk Box
Greddy PROFEC Electronic Boost Controller

Go Fast Mods 405.6 WHP/328 ft/lbs Tq (prior to forged internals; stock block; stock clutch)
Motoza Tune - Pending - Still getting tweaked
PagParts Turbo Kit (purchased from Mitchbartoo)
PPT Manifold
Borg Warner EFR 7163 Turbo
Tial MV-S 38mm Wastegate
Custom Downpipe
RamAir Cold Air Intake
IE Adjustable Camshaft Gear
FluiDampr Pulley
Intake manifold flaps delete
B8.5 Throttle Body (3" opening)
RS4 Injectors
APR HPFP
155 Bar Upgraded PRV
JHM DW200 LPFP (died) - new pump is Walbro 450
Water Methanol Injection Kit (2 nozzles), Tank in the Trunk
Custom Catback Exhaust
Torqbyte PM4
Mishimoto Catch Can
ECS Oil Filter Housing
ECS Engine Mounts
Apikol Transmission Mount
Polyurethane Snub Mount
Treadstone TR18 Front Mount Intercooler
Forged H-Beam Rods
King Racing Bearings
JE Pistons 82.5mm (standard bore), 8.5:1 compression ratio
IE Titanium Valve Springs & Retainers & valve stem seals
Ferrea & Supertech Titanium Valves
ARP head studs & cam girdle studs
Clutchmasters FX350 Flywheel & Clutch Combo
GFB DV+
2.0T oil pump w/balance shaft delete

So I've had my car since 2006. I've been the only owner of it and I've made lots of choices and gone through lots of parts and wheels. I've done a pretty good job taking care of it and just wanted to document a few things from start to now. Please feel free to comment/hate/like. I'm pretty thick skinned.

First two things I did was install Eibach springs and get some wheels. I ran these RPM 505's for probably about 7 or 8 years before finally getting some different wheels. Oh, and I tinted the windows.



After moving from Germany to Wyoming I really didn't do much to the car and just kind of neglected it. But then I moved to California and started giving it some love. Bought some new black Rohana 20's and started with a black theme with black grill and some black S4 door blades. Also threw some Relak skirts on.



Eventually got a custom exhaust put on.



With some exterior mods I started focusing on fixing the car and modifying it engine wise. Especially when I decided to go with a JHM tune.

At that point the engine mods were:
Test pipe
JHM upgraded HPFP
Full exhaust
Front mount intercooler
Intake




Wheel swap time to some Rotiform BLQ's (I still have them but I curbed one and have to try to fix it)






With this faze came some 18Z upgrades, custom made steering wheel, and BFI shift knob.




I said to myself, "This car is fast, lets put it on a dyno and see what kind of power I'm making!"



Disappointment...



So with that disappointing result I started doing some more exterior work.

Changed rims - Bronze JNC 026's - rears are19 x 10.5’s, ET25 w/ 275/30/19's !!!!
Rolled the rear fenders
Got the S4 blades painted red to match the car
Morimoto headlight conversion and new lenses

[i3oricua]

And with that started a new phase of go fast parts. First I installed water/meth with a kit I put together.




This was a nice addition as it really livened the car up but just wasn't enough.

So after a lot long texts with a good friend and bad influence I found Mitchbartko selling his old kit and purchased it.

His kit came with:

Pag Parts (PPT) manifold
Borg-Warner EFR 7163 turbo
Tial Wastegate
Associated downpipe and fittings

Parts I had:
S3 injectors

So I started ripping out the K-03 and installing the new kit when it arrived!










After the install I scheduled an appointment with a tuner in NorCal and got a very conservative tune done. He never provided me a graph or proof of numbers but he stated that my tune was making about 286 whp at about 7 PSI.

At this point I was out of time and the tuner told me the engine wasn't healthy because he saw some smoke and other things...I probably should have just waited but that's hindsight. I had to ship the car to the UK with me.

In the meantime, I've collected a bunch of parts to build the bottom end to include a spare bottom end. I'll get this done sometime in 2018. Those parts are:

JE Pistons
Forged Rods
Integrated Engineering Crank Bolt
APR main studs and head studs
Southbend Stage 3 Clutch and flywheel
and still to come are Integrated Engineering crank bearings








In the meantime, I just got the car retuned out here in the UK with a company name SA Tuning/ which netted pretty amazing results. I have some issues that need working out as you can see in the graph with it being shaky around 4800 - 5500 or so but you can see what the previous tuner and the new tuner out here was able to push on the stock bottom end. He actually said that once I fix the fueling or whatever the problem is to come back and he'll finish things up on the house because he's confident there's some left there to be safely extracted.



So until I build the bottom end next year I'll just get these things worked out and update the thread as normal and as things come along.

[Operator]

Ahhhh, peer pressure! Glad you're still 'ing

[aluthman]

Good choice on the turbo. Which version are you getting? I went twin scroll and love it.

[Operator]

Good choice on the turbo. Which version are you getting? I went twin scroll and love it.

I venture he'll fill you in with more detail, but it's mitchbartko's setup.

[aluthman]

Ahh gotcha.

[i3oricua]

Good choice on the turbo. Which version are you getting? I went twin scroll and love it.

I venture he'll fill you in with more detail, but it's mitchbartko's setup.

Correct. It’s Mitchbartko’s old setup. I installed late spring/early summer 2017. I just have to fill in the details above.


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[i3oricua]

A little throwback. For those that know Operator his car is on the left naked and afraid before he went insane modding it.

The second pic is at the base of Pikes Peak that Operator and I went on a group drive to the top. If I remember right they made me pull over on the way down after checking the temp on my brakes. Good times.





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[i3oricua]

Finding more pics as I go through my phone.

Installed some B6 Recaros about 2 months ago and the RS4 fuel controller. Really love the seats. If you’re on the fence about it just do it. They feel so much better than the stocks.

I also redid my gray interior to black and wrapped my headliner in suede. Did it myself. Not too bad for my first and only time.






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[Operator]

I remember the park rangers on Pikes Pike waving at us on the way up to slow down. We were one of the last groups to go up while there was still an unpaved section. Good times!

[i3oricua]

Got my new Southbend Flywheel in to install with my Southbend clutch.

Might install on Sunday.




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[i3oricua]

Did my cam follower and cam chain tensioner today. Tensioner was broken. Car runs nice and smooth. Loving it.

Also threw in a fake carbon fiber drivers door handle thing where the window switches go.





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[i3oricua]

Got my new interior trim and put it in. Have a few pieces that I still need to get fixed but overall they look great.




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[i3oricua]

Received my PRV and an upgraded fuel pressure sensor.

I accidentally dropped the PRV when I was trying to thread it in and t went into the deepest, darkest crevice my engine had. I had to take off the whole intake manifold to get to it. What was supposed to be a 30 minute job took me like 4-5 hours!!! 🤦🏽*♂️

Also installed a small fire extinguisher on the passengers side. Just in case.






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[QuattriumMT6]

I can’t believe you were able to stuff 275/30’s with just a fender roll and yet still have that much tire patch in contact with the ground! Very impressive! 👍🏾 Glad you decided to fix it after hearing news about your motor. I too am currently undergoing a lot of mechanical issues with mine ($$$) and battling myself to just fix it and keep it.

[i3oricua]

I can’t believe you were able to stuff 275/30’s with just a fender roll and yet still have that much tire patch in contact with the ground! Very impressive! Glad you decided to fix it after hearing news about your motor. I too am currently undergoing a lot of mechanical issues with mine ($$$) and battling myself to just fix it and keep it.

Thanks and keep at it man. I had to add some camber to the rear because of the drivers side. It rubs from time to time but I’m gonna take the wheels off in the next month and throw my Rotiforms on after I fix them. In hindsight if I had gone with 265s then I probably could have for the wheel and tires under those fenders much easier. But they fit with some work albeit.

What issues you having?


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[QuattriumMT6]

Thanks and keep at it man. I had to add some camber to the rear because of the drivers side. It rubs from time to time but I’m gonna take the wheels off in the next month and throw my Rotiforms on after I fix them. In hindsight if I had gone with 265s then I probably could have for the wheel and tires under those fenders much easier. But they fit with some work albeit.

What issues you having?


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Honestly my mechanic is stumped himself. My car has been at his shop for the past 2 months. What we though to to an easy fix turned out to be pain in the ass. New PCV, new N80, new HPFP and LPFP, new intake camshaft and cam follower, new PCV hose, new AFE dry filter and MAF sensor, new spark plugs, cleaned up injectors and installed new hardware and seals, full carbon clean and man was it bad. Car is loping intermittently. Using the VAGCOM to smoothen the idle out and then shortly after back to loping. When it’s not loping the car is driving quicker and harder than ever that is until you come to a stop and it’s all back to the loping issue. Another thing that’s odd is everytime the car fires up the plugs immediately foul up and there’s some oil in the combustion chamber. Needless to say the struggle has been real and all I want to do is drive my car and fall back in love with it.

[i3oricua]

Honestly my mechanic is stumped himself. My car has been at his shop for the past 2 months. What we though to to an easy fix turned out to be pain in the ass. New PCV, new N80, new HPFP and LPFP, new intake camshaft and cam follower, new PCV hose, new AFE dry filter and MAF sensor, new spark plugs, cleaned up injectors and installed new hardware and seals, full carbon clean and man was it bad. Car is loping intermittently. Using the VAGCOM to smoothen the idle out and then shortly after back to loping. When it’s not loping the car is driving quicker and harder than ever that is until you come to a stop and it’s all back to the loping issue. Another thing that’s odd is everytime the car fires up the plugs immediately foul up and there’s some oil in the combustion chamber. Needless to say the struggle has been real and all I want to do is drive my car and fall back in love with it.

Do you have any smoke or oil consumption?


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[QuattriumMT6]

Do you have any smoke or oil consumption?


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No smoke or oil consumption. Also I feel bad for clogging your build thread lol so feel free to reach out to me via PM. Mods feel free to remove any of my irrelevant posts within i3oricua’s thread!

[i3oricua]

Deleted the intake flap runners today and replaced my S3 injectors with more S3 injectors to correct a misfire. No pics as I wasn’t working against the clock but I think you guys have seen that stuff before.

The delete was easy and the cold start is an interesting rumble that I honestly don’t mind too much. I’ll see if the tuner can tune it out when I go see him next but not bad at all.


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[i3oricua]

No smoke or oil consumption. Also I feel bad for clogging your build thread lol so feel free to reach out to me via PM. Mods feel free to remove any of my irrelevant posts within i3oricua’s thread!

I don’t mind. I’m not sure what it could be either though. Pretty puzzling.


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[canadianA4B7]

Solid progress!!

The start up issues have tuner double check the run flap maps been completely changed to 0 values. I’d say jump up idle too a bit with no run flaps. Will shift things a bit higher to ease on start ups and at stop idle if it seems loping.

You post those wheel specs? I’ve been trying to find some relevant data on wider wheels just seems it’s hidden I the 1000+ pages in wheels thread. 18 or 19? X 10 @ what ET?

[i3oricua]

Solid progress!!

The start up issues have tuner double check the run flap maps been completely changed to 0 values. I’d say jump up idle too a bit with no run flaps. Will shift things a bit higher to ease on start ups and at stop idle if it seems loping.

You post those wheel specs? I’ve been trying to find some relevant data on wider wheels just seems it’s hidden I the 1000+ pages in wheels thread. 18 or 19? X 10 @ what ET?

Thanks. I’ll have him check that out next time I’m there. I think it should be easy. I wish I could do it in VCDS but that’s wishing too much.

The wheels are 19 x 10.5, ET25. My advice is don’t go above a 265 tire. Might be some stretch on that but it should help save your fenders.




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[canadianA4B7]

VCDS will allow you to raise idle. I believe I was able to jump up to 800 rpm maybe slightly higher. I bet it would help a tiny bit at idle. If the loping remains I would look at the cam adjuster valve to be failing soon.

Thanks for the specs! That’s ET 25 on all 4 corners? Your also pulled, rolled and repainted? I picked up 18x9” ET 20 I think I’ll have to sell em and pick up something different.

[i3oricua]

VCDS will allow you to raise idle. I believe I was able to jump up to 800 rpm maybe slightly higher. I bet it would help a tiny bit at idle. If the loping remains I would look at the cam adjuster valve to be failing soon.

Thanks for the specs! That’s ET 25 on all 4 corners? Your also pulled, rolled and repainted? I picked up 18x9” ET 20 I think I’ll have to sell em and pick up something different.

Thanks for the info. I’ll have to look into VCDS to figure out how to do that. I just recently got my cable so I’m still learning how to use VCDS.

The ET25 is just the rears. I can’t remember what the fronts are. I think ET38 but there only 19 x 8.5 I think.


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[canadianA4B7]

Perfect info!! I bet now that I read your sizes/ET I might be able to get away with ordering 2 wheels for the front ET 38 I know was an option. I’ll have roll and pull.

Huge help mate!

[i3oricua]

Perfect info!! I bet now that I read your sizes/ET I might be able to get away with ordering 2 wheels for the front ET 38 I know was an option. I’ll have roll and pull.

Huge help mate!

Do you have a BBK? If so, you’ll have to run spacers at that ET. I have to in order to clear the calipers on my Brembos. I think they’re 10mm spacers but I’d have to look to be sure.


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[canadianA4B7]

10-4, they clear the rs4 calipers w no spacers. Which I’m assuming should clear the 18Z calipers I have. Then again I often forget “this is an Audi” so I will now be looking for some small spacers and likely have to test fit before I can actually do anything further.

[i3oricua]

Started putting together a couple of things. Got a vent pod on eBay. A guy in Spain makes them. Just have to install it in he car. Mounted my AFR gauge in it.



Also installed a rocker switch to wire up a kill switch to my fuel pump. Feeling a little paranoid lately and I want some added security. Just have to put it all back in the car this weekend.




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[i3oricua]

Sooooo.....I've had to order a new intake manifold. Got a decent deal on ECS and while I was at ordered a Walbro LPFP from JHM.

I went to my tuner and he discovered I had a significant boost leak on the intake manifold where the throttle body meets the manifold. It was definitely caused by me over torquing when I installed the 145 PRV. The Integrated Engineering spacer I have on there for meth injection comes with some really aggressive screws that were the culprits. The last two times he's spent a significant amount of time fixing minor things and was not really able to maximize the tune so he wasn't able to finalize the tune yesterday, 5 February 2018, as I had planned. Quite a bummer. So this time I've ordered the parts, I'll have him install the fuel pump and the intake manifold, test, and tune it all in one shot. Up to this point I had done all work on my car myself so I guess I can let someone I'm fairly confident knows what they're doing work on it.

So now I sit impatiently waiting for parts to arrive....overnight...from Japan...

[onedumslack]

I had the same problem because of the screws provided with my spacer. I also got another intake manifold but haven't put it on yet. I think I'll switch my spacer to the iabed industries one that uses stock screws when I swap manifolds. For now I used a helicoil in the plastic to get new threads and tighten the manifold again with standard m6-1.0 bolts. Those vendors selling these spacers that ruin manifolds suck.

[i3oricua]

I had the same problem because of the screws provided with my spacer. I also got another intake manifold but haven't put it on yet. I think I'll switch my spacer to the iabed industries one that uses stock screws when I swap manifolds. For now I used a helicoil in the plastic to get new threads and tighten the manifold again with standard m6-1.0 bolts. Those vendors selling these spacers that ruin manifolds suck.

Yea I would prefer to use the stock bolts since the threads are less aggressive than the IE ones but I might look into getting slightly longer stock bolts to see if that works.


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[onedumslack]

Yea I would prefer to use the stock bolts since the threads are less aggressive than the IE ones but I might look into getting slightly longer stock bolts to see if that works.


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Please post up if you're able to find the stock m6 with 1.5 pitch about 60mm long. I have been searching and cannot find the stock thread pitch in this size which it seems is why all these vendors supply these bolts that strip our threads and iabed came up with the new install type that uses cut stock bolts to mount the spacer to the manifold and then another set of bolts that mounts the throttle body to the spacer.

[canadianA4B7]

Please post up if you're able to find the stock m6 with 1.5 pitch about 60mm long. I have been searching and cannot find the stock thread pitch in this size which it seems is why all these vendors supply these bolts that strip our threads and iabed came up with the new install type that uses cut stock bolts to mount the spacer to the manifold and then another set of bolts that mounts the throttle body to the spacer.

I have those I think. I think i used the same bolts I removed from the HPFP?? I believe the closest they make is actually 55 mm.

[i3oricua]

The cars been driving me crazy lately chasing vacuum leaks and trying to figure out why I’m getting such bad gas mileage. I’ve done a few things lately that has probably contributed to it. So I’ve replaced some intercooler piping then there’s the intake manifold/throttle body leak that I fixed. I also replaced my nasty cold air filter with a RamAir brand one and sealed up those connections really well. I also took the DV off (Rev C version) and cleaned the oil and gunk off of it. Some of these things have helped raise the boost a little and now it holds better but it is definitely down on power.

Some other notable things I’ve done in the last month or so is change my S3 injectors since one was misfiring. Installed my innovative wide-band which caused me to move my O2 sensors. This might be a primary offender too but I’ll start messing with those in a day or so. I also installed my 145 PRV.

I’ve ordered a new intake manifold (stock but new). The IE and HPA were just too expensive with no real $ per HP benefit. I also have JHMs walbro kit in the mail. Those two things will go in together at the tuners shop and then he will tune it after the install.

I just want to get rid of all the leaks and problems before it makes it to him.

I’ll post back if there’s any changes after swapping things around in case anyone else runs into these problems.

I will say that if you are losing boost somewhere and are down on power I would check your fittings around your cold air intake or ram air intake and also take your DV off and clean it if you’ve had it on for a long time. Mine had a lot of oil in it and gunk and that seems to give me 2-4 pounds of boost back that I had lost.


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[funkypterodacty]

MAF is also something worth cleaning/replacing if you haven't yet.

[i3oricua]

MAF is also something worth cleaning/replacing if you haven't yet.

Oh yea. Wiped it down too but I need to get something to clean it better. I’ve seen a tutorial that uses alcohol to clean with in a zip lock bag. Gotta try that out too.


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[i3oricua]

Well in the last few weeks I’ve done a few things but nothing major. Replaced some couplers for intercooler piping and intake. Put in a new intake by RamAir and did a DIY project in my valve cover. I used some high temp epoxy on it to seal the crack at the seams on he inside. Seems to help with getting oil in the intercooler pipes quite a bit. One thing I will say is try to keep the epoxy as thin as possible and avoid putting it anywhere you’re expecting the valve cover gasket to provide a seal. I had to scrape some of it off because the gasket wasn’t getting a good seal and started leaking oil that way.

After all that I’ve dropped my car off with the tuner and they’ve installed my new intake manifold and JHM Walbro LPFP and he’ll be finishing the tune today hopefully. They did a smoke test and found the vacuum pump to have a leak so they’re replacing that. Hope that’s it and I’ll report back once that’s all said and done.

I have a video of the leak that I’ll post up once I figure out a way to do that.

https://1drv.ms/v/s!AvthiyCcaP29g_EdpIwPV2EQiNCAMw


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[i3oricua]

Got the car back today. New intake manifold on almost all the leaks are gone with the exception of one actually coming from the lid of the catch can. I’ll see if I can fix that. Think it’s missing the rubber grommet that was there before.

He also finished up the tune since I was able to replace the failing injectors and the upgraded PRV. They weren’t able to do the walbro fuel pump so I’ll do that on my own this Sunday hopefully. I know they usually do videos of their dynos so I’m hoping they did one of mine and post it up. If they do I’ll link it up. Here’s the final dyno sheet. The blue is/are with the most current tuning he did. Really smoothed out the graph.



Boost comes on nice and pulls really hard. I think I still have a boost leak even though they didn’t find one. I’m gonna change my DV from the rev C to the rev D. Just don’t trust that the rev C is holding the boost right. I could be wrong but it doesn’t hurt to change it I guess. If there’s nothing wrong with it then I’ll just see if I can sell it.

Still to come. A clutch install and sending the spare bottom off to get honed and balanced. I leave in about a week and a half and will be away from the car for a while so both of those things will have to wait until I return.


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[tloft4]

no disrespect to your thread, but how is glue going to fix any problem? it'll "harden" to a point softer than the materials that are there to do the job in the first place?