2000 A4 Avant FWD Manual N/A | Build & Turbo Conversion
History
2000 Audi A4 B5 Avant with S-line and Sport package
- Sport steering wheel and seats
- 1BE suspension with original Sachs Touring shocks
So the car was imported by a local city guy from Germany using a trailer. I bought it in August 2017. It needed a few things for maintence, the car was sitting for 1-2 years ( I think ). It had 289000 original Km's on it , with service manual.
In the same month the following were replaced:
- QWP disc brakes front & rear
- QWP front fenders both side
- Small trunk lid above the license plate holder repaited ( paint chip off )
- Bosch Air & Pollen Filter
- All brakes rebuilt
- Bosch Oil filter
- Oil change to Castrol 5W30 Titanium
Also changed all the wipers and in meantime we managed to crack the windshield aswell.
Few things that I did first is that I got a VCDS. Scanned the car and it said it had a Camshaft adjustment DTC on bank 1. After searching on google and eventually stumbling on Audizine , I made a thread about it here.
In the end I decided to get a new camshaft tensioner.
With the tensioner job I replaced the following:
- FAI Camshaft Tensioner
- FAI valve cover gasket
- Muller Fuel Filter
- F.A.G Front wheel bearings
- Elring Fuel Injector gaskets
- Pascal Front outer CV joints
So then my temperature started acting up so I replaced:
- VEMO Coolant Temp sensor
- Topran thermostat
Car was running fine after all this. Yay!
Here it is in May 2018 , next to my friends modified Ford Mondeo MK3 2.0L.
Except it had quite the chain rattle so in the summer, I decided to replace the chain with the chain that I got with the tensioner for this I took the front end to make it easier on my legs , not like last time :D when working on the tensioner.
So everything was fine until I had to go the city , and halfway I see my coolant sensor came on , and I ignored it because I had just had the car started up and everything was fine no leaks or nothing, but I did drive in neutral for halfway basically.
When I reached a stoplight in city, I realise something is smoking under the hood, then 5 seconds later oil warning came on. Instantly pulled over in some alley. Wellp. Found out that I had no coolant in the tank, because my dad did not put the lower radiator hose back on properly. So some very generous stranger fella brought me some hot water( I was parked next to his house), and I waited there waiting for the motor to cool off adding water slowly. Eventually got it fixed up and drove home changed coolant all that stuff.
But noticed a few weeks later that it was loosing oil at valve cover , so I ordered a new valve cover gasket, oil , and additive oil, and filter. This was in late october. I was waiting for weekend to change all the parts but...
On Nov 1st I was going somewhere again, and in 3rd gear about 5-6k RPM I heard a bang, oil pressure warning light came on and car lost power. Thankfully I was close home ( about 5km) This is what happend:
https://i.imgur.com/LKHrgpc.jpg
Basically the cam gear /bolt broke off , still unknown reasons , could be many if you check out this album you'll know what I am talking about :)
https://imgur.com/a/km9Adx6
https://i.imgur.com/WfFVgx0.jpg
Bent 1 intake valve, and 2 exhaust ones barerly touched cyl 4. But it was enough to warrant a new head job, because the head was damaged aswell as one of the lifters was stuck.
So I picked up an used AEB turbo motor for 245 usd and took the head off , which was rebuilt & replaced using the following parts:
- Febi Bilstein Valve Stems
- AJUSA Camshaft gaskets
- AJUSA 1.35mm (0.1mm more than stock) Headgasket
- FAI Camshaft Tensioner & Chain from old head
- Camshaft position sensor from old head
- VEMO Coolant Temp sensor from old head
- AJUSA big port intake gasket
- Topran coolant temp sensor housing gasket
- Victor Reinz Cylinder head bolts
So I put the engine together and replacing the following stuff aswell:
- Elring Oil Filter housing gasket
- Febi Bilstein Oil Cooler gasket
- Dayco Waterpump belt
- Airtex Waterpump
- Bosch Power steering pump belt
- Hutchinson AC belt
- INA Timing belt Kit
- NTN / SNR Hydraulic Tensioner
- Lemforder Front Snub Poly. Mount
- MANN Oil Filter
- Oil change to Mobil1 Super 3000XE with LiquiMoly MOS2 Additive
After engine rebuilt my thermo decided to go so it was replaced with a Gates one.
Meanwhile in september I bought an ebay t3/t4 turbo to convert my engine to forced induction.
It's a Vevor TBCT04ET:
-0.48 A/R Comp housing & 57 Trim
-0.63 A/R Turbine
But since this rebuild took all money it was on backburner but its kinda back now.
I am gonna use the stock manifold that I got with the AEB motor , and I made a custom adapter that bolts into the 3 bolt manifold and the other side bolts to the T3 turbine flange.
I am also gonna be making a custom drain adapter.
Currently I also need to get and intercooler - likely one from a Ford Mondeo mk3 -, bigger injectors - unsure, oil drain hose, Oil feed kit, and piping.
This is where we are right now.
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