RS6 rebuild

[Marke300]

Hi All,
I have decide to completely rebuild my RS6 '04. The car was running fairly well, but its done 103000km and I know it needs to be done, as I plan to keep this car awhile.
I have stripped the block right down. I have made sure that I don't mix the conrods and pistons up. All looks good inside, but I can see that the rings are starting to go.
The questions I have are:
1. I have had various recommendations, but not sure which one to follow. With the sleeves been made of Alusil, can I just clean them put the pistons back with new rings and bearings without honing (as honing may do more damage than good) or should I hone/deglaze them. If I hone them do I need to go oversize on the pistons.
2. With the conrods I know they are made in a special way, can I just put new bearings and bolts and put them back.
3. Is there any issues that i need to be aware of that is unique to the RS6 when rebuild the motor outside of a tradition motor rebuild.

Regards

Mark

[PALETTE]

Hey Mark, Where are you located? Who is doing the Work?

[Marke300]

Hi palette, I am based in South Africa. Currently I am doing all the assembly work my self. I have an engineering company that is very reputable. But I am just doing sum background research myself. Regards mark

[DonS]

In Porsche cylinders we just scuff them in a cross hatch pattern with scotch-brite pads - assuming the cylinders are within tolerances. Here is a motherload of Alusis info: http://www.sunnen.com/NewsDetails.aspx?NewsID=11

[Marke300]

Hi Don, I like that idea. The sleeves seem to be in good condition other than the usual carbon and oil build up. The piston don't seem to have any scuf marks. As I mentioned the motor was in fairly good condition other than piston ring wear. Maybe a light rub just to get them clean may work. I am really hesitant to hone them

[r8dream]

have a look here http://www.motorgeek.com/viewtopic.php?f=10&t=37611&sid=3ae4d3da7f10e8de8d958f164b1e7999

[ben916]

MAN!!!! this is GREAT information!

[Marke300]

Thanks for the link, it is very informative and will definitly use it, But I am also looking for more specific advice from people that have done work on RS6 motors. Is honing a definite. do i have to oversize the piston if I do honing. What has been there experience with these motors when rebuilding them. Is there a specific process that works for them on RS6 motors that I should follow. The issues is that I don't mind spending the money to get it done, I just don't want to do it twice.

regards

Mark

[RS6...]

Mark300 - My answers which I hope are helpful are:

1) If the bores measure up simply clean them with solvent and scotch brite and re-use. If they require re-finishing this requires specialised tooling and capable workshop
2) The only thing to check is if the rod bolts are torque to yield like the other bolts (ie head bolts)
3) Alusil requires special pistons and rings. The best option is the Audi OEM but I am pretty sure Audi wont sell them seperately and also wont have them in oversize.

I am currently going through the same process and have purchased a spare block to determine which is in the best condition and then work out of we are going to simply clean the existing bores, re-finish or sleeve them.

Good luck and if I can be of anymore help just ask.

[hahnmgh63]

As RS6 said, do not try to Hone yourself, if they have carbon just use Scotchbrite to clean them up. You might check with ARP or Raceware to see if they have rod bolts. For not much more than OEM, Raceware or ARP bolts are stronger and re-useable. The Alusil process has been around for a while but I'm not sure if Audi's finish is any different from Porsche's.