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Thread: Me Manual RS6 "Project"

  1. #1
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    Me Manual RS6 "Project"

    Okay, get ready. Gonna post up a build thread for viewing pleasure as you sit on the toilet at work (Don't lie to yourself, we all do it).

    Can't read? Your boss is chill and let's you watch videos at work? You are Mr. Boss? Well here, follow the build so far on Youtube ---> https://www.youtube.com/playlist?lis..._NDx1XZPUrmgUt

    Bought the damn near perfect 88,000 mile Daytona Grey RS6 from a long time friend in GA on December 31st. Hung out with the family for a few days and then drove it back home to NJ. 1000 miles and not a single hiccup. Love it.
    20190118_095537 by Joel Francisco
    20190105_234157 by Joel Francisco
    20190106_155550 by Joel Francisco

    Had a few issues including leaking valve covers and bufkin pipe. Ordered some parts and went to make it happen. Had some extra 75W-90 lying around that I put in the picture for sh*ts and gigs (More on that later).
    -Rotor's all round
    -Oil Change Kit
    -Timing Belt Kit
    -Lot's o' Coolant
    20190125_145321 by Joel Francisco

    Front end is off, time to do the timing belt and Bufkin Pipe.
    20190126_194409 by Joel Francisco

    Oh, you stripped the bolts for the oil cooler housing and can't get them out now, perfect! You can pull me out now...
    20190128_200731 by Joel Francisco

    Haha, you moron, you thought you had enough room to remove the engine? Think again! At this point I'm livid because I ran out of room for the hoist. Now I have to tighten the subframe back up, throw the wheels on and roll it out of the garage. *Cue the part where my brain tell's me to start recording*
    20190203_220730 by Joel Francisco

    Went ahead and did the complete timing belt job on the car save the cam seals. Bufkin pipe is done, engine is ready to go back in!
    20190210_180304 by Joel Francisco
    20190215_162213 by Joel Francisco

    Wife: I wanna goto Staten Island to visit my family and get pizza.
    Me: Okay *Searches on Craigslist to see what's what*

    At this point it's important to note that there wasn't anything wrong with the auto transmission, but hey.. Better to ask for forgiveness than permission. So I tell my wife that I'll goto Staten Island for her pizza if she lets me look at a car.

    My 2000 Audi A6 6sp with 131,xxx and I drove it 100 miles home. Yay.
    VideoCapture_20190219-104547 by Joel Francisco
    20190222_161912 by Joel Francisco
    20190217_110313 by Joel Francisco
    20190217_110000 by Joel Francisco

    And the next day I took the engine/trans out.
    20190222_161627 by Joel Francisco
    20190301_235033 by Joel Francisco

    Well damn, SteveKen and Spec came in "Clutch". Haha, sorry, no more puns here on out.
    But seriously, Spec Stage 3+ Clutch...
    2019-03-06_05-56-14 by Joel Francisco

    Stripped all the flywheel bolts, thanks Audi for using Loctite and TQ'ing them down to what I can only assume is 500+ ft-lbs. I had my 1/2" Breaker Bar and 5ft cheater bar on this thing. The Crank lock pin was going to snap before these bolts were going to come loose. So I did the next logical thing... I cut them off with a cutting disk. Not a grinding disk, but a cutting disk. Needless to say I was scared sh*tless and hiding behind the turbo waiting for it to break off at 9000 RPM.
    20190308_150329 by Joel Francisco

    Mounted and installed with my good boy.
    20190313_100819 by Joel Francisco

    And now the transmission's on. Damn, looking back I really wish this could've happened as fast and effortlessly as it's taking me to write these sentences and copy pasting picture links...
    20190323_220626 by Joel Francisco
    20190323_220637 by Joel Francisco

    Note the sawzall. That's going to come back to bite me very soon. (Foreshadowin' Myself)

    Ready to go in. Giggity.
    20190325_160148 by Joel Francisco

    Last little touch I did at work. Widen'd the stock shift surround to accommodate the rowing of thy gears.
    20190327_024605 by Joel Francisco


    Installation time!
    2019-03-31_11-35-45 by Joel Francisco
    20190330_233243 by Joel Francisco
    2019-04-01_12-01-09 by Joel Francisco


    And she's back in!
    20190331_225937 by Joel Francisco
    20190331_225848 by Joel Francisco
    20190327_180958 by Joel Francisco

    Wired and ready to fire!
    20190401_180927 by Joel Francisco
    20190401_181149 by Joel Francisco
    20190401_180908 by Joel Francisco

    Pulled the fuel pump relay fuse to prime to turbo's real quick and gave her a crank...

    Wait?! The car started? WTF?! Oh well, it's the though that counts I guess. Still a happy man.
    Insert the first start-up video here Joel:


    Well that's a relief. Guess it's time to finish bleeding the clutch... After that let's fill up the power steering fluid...
    Tell you what, before we go ahead and try and fill it up with coolant to rule out possible leaks, let's do everything else we can....

    Axles, Driveshaft, you name it, literally everything BUT the coolant.

    Anddd... it's pissing the coolant out as soon as I put it in. Anddd it's somewhere that I can't see. Anddd it's somewhere not accessible with the engine in the car...

    Mucho Bueno.

    So (And this is going off my timestamps here) First picture with everything installed minus from bumper - 5:12pm
    20190406_171241 by Joel Francisco

    Unbolted front clip, engine mounts, transmission mounts, exhaust, driveshaft, axles, clutch line, shifter assembly. Drained all the new fluids I just put in. Removed engine/trans, set on dolly. Timestamp - 8:11pm
    20190406_201125 by Joel Francisco

    So, remember that bit of foreshadowing I mentioned earlier with the sawzall...

    Well...

    I was cutting the bracket that secures the turbo coolant feed lines so I could install the bellhousing bolts and nicked the coolant return hose going into the aux waterpump underneath the intake manifold.
    20190406_202933 by Joel Francisco

    Hating life, but not too too much, I took off the fuel rail, intake manifold, and then the hose.
    20190407_143927 by Joel Francisco

    And that's where I lye as of now... New hose should be here tomorrow, and after that it's back in the car she goes.

    Pro's:
    -I know the timings perfect.
    -Car starts and sounds amazing.

    Con's:
    -Gotta re-bleed the clutch and reinstall everything LOL

    While rolling the car in and out of the garage with the front axles supporting the wheel bearings, I must've damaged them because there was SO MUCH play in them with the wheel fully bolted in and axles installed.
    Old bearing and hub taken off, presses out, pressed in, and installed.
    20190410_155332 by Joel Francisco
    20190410_155200 by Joel Francisco
    20190410_155912 by Joel Francisco
    20190410_160137 by Joel Francisco

    So yea... Hopefully next week she'll be back up and running, and I can go ahead and get some seat time.

  2. #2
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    Nice! Almost makes me want to work on mine again.
    RS6 #1, 01E, 2.5" straight pipes, AMD Stage 1 6MT tune, 460awhp/530awtq on AMD's Mustang dyno. TOTALLED.. RS6 #2, Ebony Black Pearl on black/silver combination with carbon, up and running with 6 gears and AMD tune.

  3. #3
    Registered User strlgag's Avatar
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    You are truly an inspiration and a braver man than I. Great job, great posts and your YouTube videos are solid.

  4. #4
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    Good work! I love how you went for pizza and came back with a car!

  5. #5
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    Quote Originally Posted by P1054 View Post
    Nice! Almost makes me want to work on mine again.
    Take it to a shop and save yourself the hassle LMAO

    Quote Originally Posted by strlgag View Post
    You are truly an inspiration and a braver man than I. Great job, great posts and your YouTube videos are solid.
    Stupid yes, brave?.. Eh

    Haha. I said to myself I was keeping it stock, that didn't last too long.

    Quote Originally Posted by GreggPDX View Post
    Good work! I love how you went for pizza and came back with a car!
    LOL. I'm from Georgia. Down there we have CiCi's Pizza and Little Cesears... Pizza is pizza to me. Tell that to an Italian women and they lose their freakin' mind . I figured if I was going to make the trip I may as well make it worth MY time.

  6. #6
    Registered User hahnmgh63's Avatar
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    I feel your pain. First thing is it looks like your right side Intercooler is leaking from the Oil at the bottom right. I thought I was just about done with my conversion and close to your hose there is the Turbo Pressure control line from the N75 to the Left Turbo, it was leaking. I just lowered the engine 4~5" but I think I'm going to have to drop the whole thing. Those Audi lines looks fancy and braided but they are shit. The Wastegate hoses from the N75 go to a plastic 'T'. I'm replacing it with a Stainless 'T'. Going to replace the hose you just showed as well as all of the others, what a pain in the ass. The Pressure control line, another fancy looking hard line with a crimped on stainless braided hose is leaking right at the factory crimp. I think I'm going to have some better quality aeroquip lines made up. Going from lowering the engine to pulling the engine tomorrow.
    How did I find out, my Requested Boost was lower than my actual Boost. So the pressure line was leaking a little boost so the N75 would tell the computer and it would pump more boost.
    Last edited by hahnmgh63; April 13th, 2019 at 06:24.
    2003 White RS6 BBS RS-GT, RNS-E, KW V3's & Hotchkis
    2001 225bhp tt roadster 2x944 Turbo's 1974 911 w/'91 3.6ltr motor
    Roy, WA

  7. #7
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    Quote Originally Posted by hahnmgh63 View Post
    Going from lowering the engine to pulling the engine tomorrow.
    TBH it's not even worth trying to fight it with the engine in the car. I struggled, fighting with it. Trying to gain access to get at the hose, until I finally made the executive decision just to take the engine out again. It couldn't have happened any other way...

  8. #8
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    Alright, new coolant return hose was recieved today. Installed with the addition of the intake manifold and all related parts.

    Seeing as the car is outside and that's were the install will happen, now I just need to wait for a nice sunny day.
    20190415_201716 by Joel Francisco

  9. #9
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    Working night shift:
    Pros:
    -I can come home at 8am and start working on the RS6.

    Cons:
    -Tired AF

    Started at 8am with the engine sitting in the garage. Install went very smoothly seeing as I just did it last week. Fired her up at 12pm. Going to call it a day and finish the rest tomorrow.

    Still to do:
    -Bleed clutch
    -Install CV axles
    -Install Driveshaft
    -Install Exhaust
    -Install Front End

    Tomorrow...

    20190416_113847 by Joel Francisco
    VideoCapture_20190416-122632 by Joel Francisco

  10. #10
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    Did you wire up pin #39?

    905594??? Heh, check my sig.

    Also, disconnect your TCU
    03 RS6 Avus/Ebony #905593 resurrected 6MT, 04 Avalanche Z71, 87 T-Bird Turbo Coupe (351W T5), 04 Aprilia RSVR Factory

  11. #11
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    Quote Originally Posted by bethridg View Post
    Did you wire up pin #39?

    905594??? Heh, check my sig.

    Also, disconnect your TCU
    Now that's pretty cool man. Interesting that ours were built side by side yet yours is Avus/Ebony vs my Daytona/Black.

    What is the advantage of Pin 39? Clutch vacuum vent switch right? Makes the car run a little less vacuum at idle when pushed in IIRC? And do I have to disconnect the TCU even if I'm getting a 6sp tune?

    Last question here. Can i drive the car around the block while I wait for the 6sp tune to be flashed?

  12. #12
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    Avus/Ebony aka black/wood trim. I've ran across ~230 VINs since I started keeping record a couple years ago. Amazed it took this long for yours to surface.

    Pin #39 to the clutch safety switch will disengage cruise control. Otherwise you set cruise, push in the clutch and watch the revs smack the limiter before you know what happened.

    Scroll down for more info: https://www.audizine.com/forum/showt...nsmission-Swap

    Disconnect the TCU and the ECU will default to a "manual transmission" mode. I drove mine around for a month or so prior to getting the 6MT tune. Having the tiptronic brain still connected may cause problems; been a while a little fuzzy on the details.

    Did you get a harness from Advanced Automotion for the reverse light/neutral safety switch or rolling your own solution?


    Edit: Back when I did my swap you had to source a S6/W8 ABS module; I'm pretty sure AMD can reprogram the original RS6 unit now. Maybe someone else can chime in if you need more info.
    Last edited by bethridg; April 17th, 2019 at 05:31.
    03 RS6 Avus/Ebony #905593 resurrected 6MT, 04 Avalanche Z71, 87 T-Bird Turbo Coupe (351W T5), 04 Aprilia RSVR Factory

  13. #13
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    Hmm I didnt know Scotty had a harness. I already wired the neutral safety switch in hence the car running. Reverse lights shouldn't be too bad. Already ran the pigtails under the dash, just need to find where to splice into. If the TCU has wiring for the reverse I could alway splice into that when I go ahead and remove it tomorrow.

    Thanks for the words of wisdom! I should have the car completely back together tomorrow morning as long as I dont run into any unforeseen issues. (Like me sawing into a coolant line haha)

  14. #14
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    A lot of misinformation there.
    There's no "manual transmission mode" in the factory RS6 ECU.
    Basically, untuned you can drive it both with TCU and without TCU.
    With TCU connected your ABS/ESP will still function, but the drive itself might be a bit more erratic (anti-jerk algos running in the ECU still accept signals from TCU, which goes bananas without the actual transmission).

    Reverse wiring: https://www.audizine.com/forum/showt...a-5-speed-swap

    Stock ABS unit can be retained and made to function with MT with proper ECU programming.

    Actual clutch switch "advantage" is that (when properly programmed) ECU actually *knows* you have disengaged the clutch and acts accordingly. It's *strongly" recommended to wire that in. People actually report "night and day" difference with it: http://www.rs6.com/showthread.php/33620-Nubcake-6-speed-tune-review

  15. #15
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    Quote Originally Posted by nubcake View Post
    A lot of misinformation there.
    I guess I was referring to the gauge cluster showing "Press clutch pedal to start engine" when the TCU is disconnected. I'd prefer no ABS/ESP with less erratic drive for a short period of time until it's properly tuned. Thank you for the clarification.
    03 RS6 Avus/Ebony #905593 resurrected 6MT, 04 Avalanche Z71, 87 T-Bird Turbo Coupe (351W T5), 04 Aprilia RSVR Factory

  16. #16
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    Oh, you can also recode the cluster to turn off reception of CAN messages from TCU.
    It was 1025 to 1024 or something, I might recall that wrong. VCDS will show you a hint.

  17. #17
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    So I went ahead and filled the car up with coolant BEFORE I connected everything this time. Sure enough there was a leak... Passenger side turbo coolant feed at the bango bolt. Talk about inaccessible... I had to cut down my 19mm wrench, reach up over the driver side of the transmission and over to the passenger side just to get an angle on it. She's tight now. Filled it up with coolant, let the thermostat open; she's fully bled (No, not that kind). With that I did a nice little break in rev which is at the end of the Youtube video. HOLY SH*T! These Chinese Spinyboyz spool like there's no tomorrow!


    Too tired to continue so I'll pick up tomorrow, and hopefully get it on the ground and rolling under its own powa.





    Here's that wrench I was talking about haha.


    20190417_123555 by Joel Francisco
    20190417_123612 by Joel Francisco

  18. #18
    Registered User hahnmgh63's Avatar
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    Hopefully helps but when bleeding the cooling system there is a bolt in the rear coolant manifold right behind the right cylinder head that takes a 10mm socket to bleed the system, just crack it a little with the engine running until a touch of coolant runs out.
    2003 White RS6 BBS RS-GT, RNS-E, KW V3's & Hotchkis
    2001 225bhp tt roadster 2x944 Turbo's 1974 911 w/'91 3.6ltr motor
    Roy, WA

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