Non-Epic B5 S4 Single Turbo Conversion Thread

[VMCB5S4]

IMG_0764 by Vince Cassello, on Flickr

IMG_0678 by Vince Cassello, on Flickr

Untitled by Vince Cassello, on Flickr

Untitled by Vince Cassello, on Flickr

Flickr Album for all STK related photos:
https://www.flickr.com/gp/197521097@N03/gMb91029TR

I’ve wanted a B5 S4 for many years and finally got my hands on one mid summer of 2021. This car just so happened to be on Craigslist when I was actually searching for a B6/B7 S4 and I’m thankful it was. Furthermore, I’ve been reading single turbo build threads and watching videos since 2014 so these ideas were in play for quite some time. I’ve been collecting single turbo related items during the last 3 months of 2022 and began my first engine removal a few weeks ago. Shout out to Justin Ballou and CIP GAS on YouTube for those very helpful videos. I love documenting the progress I make with projects in hopes that something I either did or figured out might help someone else who goes through the same issues in the future.

This conversion process is as basic as I can make it so there won’t be any high horsepower, built engines, powder coated valve covers or huge turbo with firewall cut out for fitment. This should be geared more towards installing a Project B5, XS Power or older 034 STK with the goal of simplifying and/or deleting anything that is unnecessary while making power in the Stage 3 area. How expensive/cheap people go with parts is up to them. My previous setup is Stage 3 with BW RS6 turbos running roughly 22-23psi.

I’ve been in communication with user Monty23 who supplied the 034 STK hotside and Precision 6062 turbo. Thank you again! He and so many of you have helped me along the way. I hope to return the favor in some way down the line. To kick things off, below is the build list along with items I intend to delete.

Build List:
-Stock BEL Long Block
-Early Style “Monster Plenum" Intake Manifold (Stock 2.7t Runners)
-A8 W12 76mm Throttle Body
-Reversed Valve Covers w/ Project B5 Oil Catch Can Kit
-2.8 Exhaust Manifolds
-034 Motorsports Single Turbo Kit Hot Side Piping (3.5” Downpipe) - Catless
-Exhaust – 3.5”-3” adapter
-Exhaust - Custom 3” Downpipe back w/ Vibrant Resonator/Muffler
-Precision 6062 Turbo (.82AR Hot Side)
-Tial MVR 44mm External Wastegate (16psi Spring)
-4” Vibrant Performance (2875) Custom 45 Degree Inlet Pipe Cut to Fit w/ 4" HPS Offset Coupler (HTSOC-400-BLK)
-AEM 4" DryFlow Air Filter (AEM 21-3059DK)
-Project B5 FMIC Kit (Piping = 2.5” Hot Side / 3” Cold Side)
-FMIC Size: (3"x11.5"x30") (2.5” Inlet/Outlet) (Bar & Plate Core Rated to 600hp)
-New NGK BKR7E Spark Plugs (.022 gap)
-3 Bar MAP Sensor
-PMAS HPX MAF Sensor (Blow Through)
-Tial Q 50mm BOV (Vent to Atmosphere)
-Stock N75 for boost control
-Bosch EV14 1000cc Injectors
-Walbro 450lph Fuel Pump
-Spec Stage 3 Clutch with Lightweight Flywheel (Capacity: 580 Torque at the Crank)
-Innovate Motorsports PSB-1 Dual Boost/Wideband A/F Ratio Gauge
-034 SAI Delete Kit
-Exhaust Gas Temp Sensors Deleted
-Secondary 02 Sensors Deleted
-N249 Valve Deleted
-Coolant After Run Pump & Switch Deleted
-Clutch Fan Delete (PB5 Electric Fan Kit Installed)
-N80 Valve Deleted

I have acquired just about all of the parts with the exception of the Project B5 FMIC kit. Nick is in the process of building that. The kit will come with all wrinkle black charge piping, black silicone couplers, water/meth bung for AEM kit (future install), 50mm BOV flange, MAP sensor flange, blow-thru HPX MAF sensor flange and correct coupler to fit the A8 W12 throttle body.

8AF075CC-7587-4EA3-83C2-415FD2134157 by Vince Cassello, on Flickr

5E82654F-DEE3-43E9-9057-4C6451204B7C by Vince Cassello, on Flickr

BCGB0225 by Vince Cassello, on Flickr

[VMCB5S4]

B5 S4 by Vincent Cassello, on Flickr

B5 S4 by Vincent Cassello, on Flickr

B5 S4 by Vincent Cassello, on Flickr

[VMCB5S4]

If anyone is interested in seeing the build sheet I created with excel PM me and I'll send it to you. Contains full list of all required items to do this conversion along with notes I've made along the way.

[VMCB5S4]

B5 S4 by Vincent Cassello, on Flickr

B5 S4 by Vincent Cassello, on Flickr

Oil return line sleeve came out of the oil pan on driver side. Had to clean up the inside/outside surface and reinstall using Dirko HT Grey sealant. I tapped it back in very slowly with a hammer and small block of soft wood.

[VMCB5S4]

Coolant crossover pipe removed and carefully disassembling everything I plan to sell.

B5 S4 by Vincent Cassello, on Flickr

Intake manifold removed and now focusing on deleting the coolant after run pump.

B5 S4 by Vincent Cassello, on Flickr

B5 S4 by Vincent Cassello, on Flickr

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[VMCB5S4]

After run pump ports capped along with turbo coolant return line ports behind each motor mount bracket.

B5 S4 by Vincent Cassello, on Flickr

B5 S4 by Vincent Cassello, on Flickr

Oil feed fitting installed for turbo and opposite side plugged on oil distribution block.

B5 S4 by Vincent Cassello, on Flickr

B5 S4 by Vincent Cassello, on Flickr

Coolant crossover shaved down, cleaned, painted and reinstalled with new o-rings.

B5 S4 by Vincent Cassello, on Flickr

[VMCB5S4]

Prepping the modified early style intake manifold with W12 throttle body. Mating surfaces cleaned, new IAT sensor installed and fuel rail set up. I removed all vacuum related plumbing from the fuel rail assembly with my trusty Dremel tool, installed the EV14 1000cc injectors and fastened everything down to the manifold. I put DEI protective sleeving along the rear section of the fuel rail since it's right next to the heat source. I'll be running a PTP turbo and wastegate blanket to help manage heat in that area.

B5 S4 by Vincent Cassello, on Flickr

B5 S4 by Vincent Cassello, on Flickr

B5 S4 by Vincent Cassello, on Flickr

B5 S4 by Vincent Cassello, on Flickr

B5 S4 by Vincent Cassello, on Flickr

B5 S4 by Vincent Cassello, on Flickr




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[VMCB5S4]

2.8 exhaust manifolds installed with fresh gaskets/hardware. Swapped passenger and driver valve covers with fresh Elring gaskets and Dirko HT. Installed new NGK BKR7E spark plugs and gapped to .028. Old plugs looked rough....

B5 S4 by Vincent Cassello, on Flickr

B5 S4 by Vincent Cassello, on Flickr

B5 S4 by Vincent Cassello, on Flickr

Ran into one issue which I'll address at a later point. The passenger upper timing belt cover bolt used to thread into to the valve cover. I'll need to figure out an alternative here. Have some ideas but open to suggestions.

B5 S4 by Vincent Cassello, on Flickr



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[VMCB5S4]

Up pipe installed. Loosely installed turbo to set up feed/return lines. I want to make sure everything fits snug and is routed on the path of least resistance. Awaiting an 034 22mm oil drain flange so I can attach the return line. Slow climb but doing a little work whenever I get time.

B5 S4 by Vincent Cassello, on Flickr

B5 S4 by Vincent Cassello, on Flickr


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[wbrunner23]

Curious to hear your impressions going from rs6 turbs to single.

Did the rs6 setup have rods? Think i read your building a motor on the side, so maybe not.

Torque onset is the best part, rs6 or single, get that motor built and ramp it up!

[VMCB5S4]

Curious to hear your impressions going from rs6 turbs to single.

Did the rs6 setup have rods? Think i read your building a motor on the side, so maybe not.

Torque onset is the best part, rs6 or single, get that motor built and ramp it up!

I'm curious to know as well! RS6 setup was run on this stock long block. Definitely interested in turning the boost up on the next engine build. I wanted to do this conversion as an initial learning experience. I figure if I'm going to go through the trouble of installing rods, it will be done on a completely refreshed block with 2.8 heads, supertech valvetrain and port matched intake runners. It's going to look real pretty with brand new accessories, engine paint etc. This is more budget friendly too now. Hoping to sell all the stage 3 items to pay off the stk balance... All in good time. I'll certainly give the best review and comparison possible once I'm on the road again.


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[CELison]

What are you going to do for an intercooler? Don't hack up that nice imola bumper lol. And if I were you I would just drop rods in that motor. If you build another one down the road just re-use them. Rods, rod bearings, done. No rings, no hone, leave the crank in. You don't need all that fancy stuff to go fast.

[VMCB5S4]

What are you going to do for an intercooler? Don't hack up that nice imola bumper lol. And if I were you I would just drop rods in that motor. If you build another one down the road just re-use them. Rods, rod bearings, done. No rings, no hone, leave the crank in. You don't need all that fancy stuff to go fast.

Copied from my first post above: I have acquired just about all of the parts with the exception of the Project B5 FMIC kit. Nick is in the process of building that. The kit will come with all wrinkle black charge piping, black silicone couplers, water/meth bung for AEM kit, 50mm BOV flange, MAP sensor flange, blow-thru HPX MAF sensor flange and correct coupler to fit an RS4 throttle body. I’ll plug the water/meth bung for now. Good to have the option in the future though.

Link to kit:
https://www.projectb5.com/product/pr...rge-piping-kit

Quick link to show the intercooler that comes with the above kit:
https://www.projectb5.com/product/pr...stk-fmic-kit-3

I'm worried about the bumper too lol. I'll have to wait until the intercooler kit is installed and assess what needs to be done for it to fit. I have a feeling that part of the process will provide some tears haha

As for the rods, I'm just about ready to reinstall this engine/trans now. It's tempting but this would be my first experience disassembling and reassembling an engine which I know will take me awhile. I'd rather take my time building an engine on the side while still getting to enjoy my car. A couple of other factors are money and other plans. I'm slightly over budget as it is and still need to pay for tuning/exhaust work. If I buy a set of rods and the rest of the reassembly material this will set me back too much at this time. Once I sell the spare stage 3 parts and payoff the STK balance I'd like to upgrade my brakes, tires and start fixing cosmetic issues. Building an engine on the side will be a fun thing I do little by little. That will be a target of around 700-800whp.


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[Monty23]

Looking good so far. I'm worried that the oil line won't fit between the up pipe and the secondary firewall AND I would keep the feed away from heat sources. It would suck if the line rested on the up pipe for some reason as cooked oil is a quick way to kill the CHRA. I had my oil line point forward and fed it through the openings between the intake manifold runners. And if you get some spark blowout, you might need to gap in the .022-.025 range. I am currently gapped at .018" to prevent blowout at ~40 psi.

Attachment 293665

[VMCB5S4]

Looking good so far. I'm worried that the oil line won't fit between the up pipe and the secondary firewall AND I would keep the feed away from heat sources. It would suck if the line rested on the up pipe for some reason as cooked oil is a quick way to kill the CHRA. I had my oil line point forward and fed it through the openings between the intake manifold runners. And if you get some spark blowout, you might need to gap in the .022-.025 range. I am currently gapped at .018" to prevent blowout at ~40 psi.

Thanks and thank you for the feedback. I'll definitely redirect the feed line. I saw some previous builds in that orientation. To be honest the line is very tight between the coolant pipe and engine right now.

I'll adjust that next. I'll keep an eye on the plugs and tighten the gap if necessary. The old plugs that I removed were all gapped .030 or higher and I didn't have any noticeable issues. 40psi on a compound setup will do it lol. I'm not sure how much boost will be required on this turbo to make 450whp.


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[Silverex]

Probably not a bad idea to throw some of that DEI thermal wrap on the oil line also

[VMCB5S4]

Probably not a bad idea to throw some of that DEI thermal wrap on the oil line also

Good idea. I've got plenty left over. Once I sort out plumbing/routing of everything I'll assess and add extra heat protection for sure.


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[VMCB5S4]

Started tonight by removing the plastic fittings off the spider hose assembly so they're ready for the catch can kit. The crank case vent port under the intake manifold is now a tight area because of the turbo/wastegate. Picked up a 90 degree fitting so I can route that hose around to the passenger side where it will meet the catch can.

B5 S4 by Vincent Cassello, on Flickr

B5 S4 by Vincent Cassello, on Flickr

B5 S4 by Vincent Cassello, on Flickr

B5 S4 by Vincent Cassello, on Flickr


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[VMCB5S4]

Started on the wastegate assembly. The red, yellow and black spring combo is the listed setup for 16psi. Played around with the orientation and what ports to use for vacuum lines. Very tight fit and close to the cylinder head. I have Vast 10mm spacers that may pose an issue with fitment. Planning to test that next.

B5 S4 by Vincent Cassello, on Flickr

B5 S4 by Vincent Cassello, on Flickr

B5 S4 by Vincent Cassello, on Flickr

B5 S4 by Vincent Cassello, on Flickr

B5 S4 by Vincent Cassello, on Flickr




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[VMCB5S4]

Finished hooking up the rest of the turbo and downpipe. It's tricky as you have to assemble/remove things in a particular order to fit properly. The wastegate to downpipe is a snuuuug fit lol. Wastegate vacuum fittings are at the proper angles and fastened down. The downpipe touches the up pipe and back of the cylinder head ever so slightly. I'm hoping to mess with things tomorrow and gain a little more clearance. The coolant crossover pipe fitting that leads back to the reservoir will need to be angled differently since the downpipe is too close. Also rerouted the oil feed. We'll see how the intake fits as well...

B5 S4 by Vincent Cassello, on Flickr

B5 S4 by Vincent Cassello, on Flickr

B5 S4 by Vincent Cassello, on Flickr

B5 S4 by Vincent Cassello, on Flickr

B5 S4 by Vincent Cassello, on Flickr

B5 S4 by Vincent Cassello, on Flickr

[Monty23]

Keep in mind, things will probably need to move around once you get the engine in the bay, and the downpipe in the tunnel. You should really do a test fit ASAP so you know how everything is going to fit. But, feel free to hammer a dent in the downpipe to get the clearance you need to the cam sensor. It won't affect anything performance-wise (you'll want to remove the wrap first though).

[VMCB5S4]

Thank you for the heads up. It's a pain in the neck to test fit with my severely cratered concrete floor. I want to have the engine all buttoned up first so once I sort out the test fit I can install immediately. Last big items on the list are adjust downpipe near cam sensor, sort out routing of coolant pipe to reservoir fitting/hose, route crankcase breather to oil catch can hose, ensure there is clearance between wastegate and intake manifold phenolic spacer, sort/route wiring harness and install JHM shifter linkage/cross rod. Provided nothing else goes wrong of course lol.


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[VMCB5S4]

Played around some more with fitment. Hammered in the downpipe so it no longer touches the cam sensor. Trimmed the phenolic spacer to clear the wastegate and installed the PTP wastegate blanket. Next up will be installing the 034 oil drain flange and finish routing the oil return line. That SHOULD be a quick process. Once complete, on to routing the wiring harness.

B5 S4 by Vincent Cassello, on Flickr

B5 S4 by Vincent Cassello, on Flickr

B5 S4 by Vincent Cassello, on Flickr

B5 S4 by Vincent Cassello, on Flickr

B5 S4 by Vincent Cassello, on Flickr


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[VMCB5S4]

Trying to upload photos but the app is having issues. Is there some limit to the amount of photos you can upload?


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[VMCB5S4]

Emailed Nick at Project B5 to order his custom coolant pipe to coolant reservoir hose as seen in the photo below. There is little to no clearance with the downpipe so it's a must.

IMG_1774.jpg

He agreed to it and will send it out with the FMIC kit. Awesome customer service btw. He's been great with communication so far. He plans to send me photos prior to shipment which I'll add to this thread asap.

At this time the charge piping is complete and out for paint. Going wrinkle black to match the intake manifold. In my opinion, I think that color looks simple, sharp and professional.

[marty20dev]

Not sure if this is an issue on my end only but when I click on the photo links I get the following message: "Invalid Attachment specified. If you followed a valid link, please notify the administrator"

[Nichtknicken]

Attachment links are doing the same for me.

[VMCB5S4]

Ugh. I deleted all of the photos from the "attachments" section under profile settings thinking I was clearing space.....

I have officially deleted every photo from every single thread/post I've ever created. Sooo I'll work to at least repost pictures in this thread.

Very sad. Didn't know I had a limit on how many photos I can post. I remember the photobucket debacle years ago. Thats why I've stayed away from that method of posting photos.


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[Monty23]

I use Imgur now for photo hosting. Seems to be working fine.

[marty20dev]

Ah Jeez! That's a pain!! Anyways, the car is class, great job so far!!

[VMCB5S4]

I use Imgur now for photo hosting. Seems to be working fine.

Nice. I got a Flickr account. Attempting to fix photos today.


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[VMCB5S4]

Ah Jeez! That's a pain!! Anyways, the car is class, great job so far!!

Thank you very much! I'm enjoying the process so far.


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[VMCB5S4]

Woooo! Photos are back up and I also updated some posts so I recommend skimming through the thread again if you're interested.

My next plan will be extending all wiring from the speed sensor, crank position sensor, reverse light switch and oil pressure sensor. My plan is to bundle this wiring and route it up the firewall to meet the existing wiring harness away from the high heat areas. I'll be using large heat-shrink sleeving and DEI protective wrap. Need to order more of that stuff.


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[VMCB5S4]

If for some reason there are issues viewing photos in the future I've included a link to my Flickr account so you can view the entire album. I added the link to the initial post and below as well.

https://www.flickr.com/gp/197521097@N03/gMb91029TR

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[VMCB5S4]

Spent some time messing with the JHM shifter linkage last night. Nothing most people haven't seen before.

I'm currently waiting on a multicolored box of wiring to arrive before I start extending the wiring harness to meet the hard to reach sensors (crank position, speed, reverse and oil psi). Did a test fit of label/clear heat shrink and I think it will look good.

More to come soon. I want the engine/trans back in the car and mounted by mid February so I can begin finishing the wiring harness routing, vacuum hose routing and front mount intercooler install.


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[VMCB5S4]

Finished JHM shifter linkage upgrades. Started on creating the harness extensions for electrical connections on or near the transmission. Labeling away as well.

Untitled by Vincent Cassello, on Flickr

Untitled by Vincent Cassello, on Flickr

Untitled by Vincent Cassello, on Flickr

Untitled by Vincent Cassello, on Flickr

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[VMCB5S4]

Got a few items in today to include 3 extra 36" DEI Heat Sheaths and a few rolls of Tesa tape.

Untitled by Vince Cassello, on Flickr

I finished extending the wiring from the crank position sensor, oil psi sensor, speed sensor and reverse light switch. I then bundled everything up together with the Tesa tape which apparently is good for up to 350 degrees.

Untitled by Vince Cassello, on Flickr

Untitled by Vince Cassello, on Flickr

Lastly, I wrapped the crank position sensor wiring in DEI wrap and used some of the leftover shielding from the old spider hose assembly to cover the crank position sensor connector finishing off with sliding the extended harness through the DEI heat sheath. Apparently all the DEI shielding I used is good for 500 degrees direct heat and up to 2000 degrees radiant heat. We'll see how long it lasts...

Untitled by Vince Cassello, on Flickr

Untitled by Vince Cassello, on Flickr

Next up will be replacing the heater core hose quick disconnect fittings.

Untitled by Vince Cassello, on Flickr

Untitled by Vince Cassello, on Flickr

[wbrunner23]

Im frustrated you wont commit to dropping rods. I wouldve skipped the coolerworks shifter if its $ youre worried about. Go shovel a few snowy driveways or something.

Otherwise, good work so far.

[VMCB5S4]

Im frustrated you wont commit to dropping rods. I wouldve skipped the coolerworks shifter if its $ youre worried about. Go shovel a few snowy driveways or something.

Otherwise, good work so far.

I've given it a lot of thought and it's just not going to work out on this go around for me. I've had the Coolerworx shifter installed since mid 2022. At this point I'm just replacing/repairing consumable items and "while I'm in there" stuff so I can begin reinstalling shortly. I mentioned a few thoughts in post #13 on this issue as well.

The gain in horsepower doesn't justify all that work and money at this time. Working on grabbing a used BEL engine at the moment that I can build top to bottom. I'm talking girdle, rods/pistons, balancing, 2.8 heads, supertech valvetrain, large plenum intake with 2.8 port matched runners, upgraded fueling, larger turbo, upgraded clutch/flywheel with fresh accessories etc. etc. etc. After alllll that is complete I'll shoot for 700+awhp which will be well thought out and very worth it in my opinion. Quite the jump from a measly 450ish awhp.

I'm with you though and thanks for the positive feedback. Maybe I'll start shoveling a few snowy driveways to buy parts for that build next lol.


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[CELison]

You can make well over 600whp with drop in rods. I would argue there's a huge jump in power from stock block to drop in rods. And not much between drop in rods and an all out built bottom end.