Happy Holiday's RS6.com

[Bigglezworth]

To all the guys that will pinch a few minutes away from the family to check the forums, here's wishing you all a happy holiday.

I have no family to enjoy the holiday with this year so going to enjoy the day by dropping the engine/tranny hulk from my one beast here... :lovl:

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[ttboost]

Ha..did our partying last night...nice quiet day... Have fun in the garage!!!! Merry Christmas everyone!!!!

[na1mt]

Merry Christmas!!

[Bigglezworth]

Santa came a bit late, but he still delivered! Woo Hoo. The moose is loose...

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[MaxRS6]

^Congrats!

Merry Christmas to all

[G2]

Nothing wrong with spending quality time with the 6 in the garage even on x-mas. Cheers to all!

[Turbowned]

Happy Holidays, guys! I'm pleased to be driving my car and not taking the engine out right now! Fingers crossed that it'll stay that way!

[Bigglezworth]

Slow and steady wins the race.

Half way there - per see. Going to start reassembling things tomorrow. Assembly will be slower because I'm going to see about having the turbo's overhauled while I have things all apart. Also going to take care of O2 sensors, the oil cooler pipe, SAI system block-off plates, and possibly a modification to the manner in which the coolant return pipe that snakes around the passenger side hooks up so that passenger side valve cover isn't such a pain to do.

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When I was first taking things apart, I was surprised on just how small the KKK turbo's were. I snapped a quick pick of the compressor adjacent to the compressor on the FI system for my NSX and you will see the KKK is half the size. There's a reason the tunes on the cars max out the flow through these units. Would like to see what options exist for other turbos while I have things apart, but really don't have the time. Need to get things back together in a moderately timely manner.

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Also, had another frustrating thing occur today when one of my specialty allenhead wrenches stripped out inside the head of the one header bolt that is tucked up way inside..... Can't get the wrench out now either. I think I will need to use an actuall puller to extract as bang and wrenching hasn't been successful to date... CRAP!

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[ttboost]

Don't recall 100%, but pretty sure a socket fits into all of these?

[Bigglezworth]

Don't recall 100%, but pretty sure a socket fits into all of these?Fastener similar to those used to couple the turbos to the exhaust, except that they have a 7mm Allenhead insert in lieu if the triplesquare. Yes a socket fits, but only a 13mm 1/4" drive (at least in my case. All the 3/8 drive sockets I own are too thick in the walls and don't fit inside the alcove). I was afraid if snapping a 1/4" drive so opted for the high grade Allenhead. Have now gotten the swivel head end of socket stuck. Lol. Damn.

[ttboost]

I know what they are..had mine out plenty of times...They are a bear. I seem to recall having to spray some monkey piss up there and hammer a socket in on a few of them. If I said I missed working on that car, I would be lying.

[Bigglezworth]

You would indeed know yes. lol I haven't gotten to the point of being totally jaded with basic repairs or even this labotomy yet though. I do however get super frustrated with simple aspects of engineering that could have been introduced or performed wiser that would have still enabled the manufacturer to shoehorn this hulk in to the engine compartment while accounting for even the most basic of repairs/maintenance at a later time frame. Things like CHEAP fasteners where high grade ones should have been used (exhaust clamps, header bolts, turbo bolts, etc.). Aluminum pipes in lieu of plastic where longevity is required. Improved locations for coolant return pipes that still accounted for the air cleaner assembly (although that would have necessitated another step in assembly once the engine was raised up in to the bay). There are a number of smart pieces of engineering for sure on this car, but it's the stupid ones that sit with you and fester. >ack<

[ttboost]

If you plan ahead when you have the engine out, you can make things easier. I deleted my SAI and my EGT's. I also disconnected my MAF's from my airbox when I first got my car. The elimination of these 3 things all but eliminated ALL my CEL's. THEN with the addition of the O1E, it's really not that bad to work on. You can reach and access MUCH more. HIGHLY recommend it. When I had my engine out, I replaced my 2 front O2's, (deleted the rears). I made new catless downpipes (with no rear O2 ports). I upgraded my wastegates. I just bought some 10lb cans on eBay and fabricated them in. Set them up on the bench to crack at 13psi. Other than not having the manual tune sorted, my car gave me 0 issues for the last 6-7 months I owned it. NOT ONE PROBLEM.

[Bigglezworth]

I'm looking to update my tune to delete the SAI & EGT's both (already removed from the engine bay while I disassembled everything). I did the rework for the MAF's a few years ago after the first pair of airbox removals. Again, smarter engineering would have elimintated this. I mean really - this one doesn't get any more obvious does it. lol

I'd like to talk with you more about what you're referring to with the wastegates. Definately want to improve the downpipes. You have any pics you can send?

[SteveKen]

I'm looking to update my tune to delete the SAI & EGT's both (already removed from the engine bay while I disassembled everything).?

I had a conversation with a tuner about removing the EGTs and coding them out like the 2.7T people are doing and it's definitely not recommended. Apparently they have added functionality in the ECU versus the 2.7T. Maybe that's why they're double what the 2.7T ones cost.

[Bigglezworth]

I had a conversation with a tuner about removing the EGTs and coding them out like the 2.7T people are doing and it's definitely not recommended. Apparently they have added functionality in the ECU versus the 2.7T. Maybe that's why they're double what the 2.7T ones cost.Dully noted. Definately removing the SAI and would like to remove the upper O2 sensors as part of a modified downpipe assembly too. Going to take the Turbo's in to a local shop tomorrow and see what they have to say about their condition.

With the various frustrations encountered here and there, I have to say the direct swap effort for the tranny itself once the turbos were removed was one of the easiest I've ever done. Even with the stout 385lbs, I was able to extend the arm on my hoist and lift it up and in to place quickly and bolted everything including the TQ up in less than 1/2 hour.

[ttboost]

We discussed the EGT removal at great length, and decided that the rewards were greater than the penalties. I ran with no EGTS for the last 6 months I owned my car, with no issues. Tim, I think you meant rear O2's? You cannot remove the "upper" or front O2's. And for the record, EVERYTHING is easier with the engine and transmission out of the car. PM me your email Tim, and I will send whatever pics I have...

[DHall1]

Tim,

Since you're going to all this extent on the high miler if you want to update any wear items while its out...LMK. Randy had exhaust manifolds come apart at 150ish. I have all the bolt on stuff from the 55k engine here. Fuel injectors too.

Its going to take me 10 more years to reach that mileage on either one of mine.

[Bigglezworth]

Tim,

Since you're going to all this extent on the high miler if you want to update any wear items while its out...LMK. Randy had exhaust manifolds come apart at 150ish. I have all the bolt on stuff from the 55k engine here. Fuel injectors too.

Its going to take me 10 more years to reach that mileage on either one of mine.This is the 'low mileage' Daytona unit (125K).... ha Everything appears to be in good order except for the usual rusted out fasteners that shear off and require drilling/tapping to correct. The exhaust clamps were so rusted out, their shank was half the thickness of new...

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I have contemplated keeping the 'high mileage' Mugello beast (235K) around for $hits and giggles simply for reassurance to many an RS6 owner that aside from the obvious tranny/DRC fiascos the car can go the distance with proper maintenance. That coupled with the wierd status of being the owner of the highest mileage beast on NA soil. That aside, I'm in the midst of getting a third beast here in a month or so, and that will likely see me move the Mugello on to some other owner to continue setting history with.

[Bigglezworth]

Confirmed both turbos are in decent condition and even though I have everything apart and the time is optimum, going to elect to reinstall without any bearing or seal overhaul on either ($550/ea.). Sourced out some replacement fasteners/studs to swap out the originals on the turbos, picked up some aluminum plate to create my own SAI block-off plates, and will be looking to modify the coolant pipe that snakes around the passenger side valve cover so that I can easily remove passenger valve cover should I need to at a future date. Going to also drop by a speed shop and look at what options exist for remote oil filter kits.

[RAUDI]

Also, had another frustrating thing occur today when one of my specialty allenhead wrenches stripped out inside the head of the one header bolt that is tucked up way inside..... Can't get the wrench out now either. I think I will need to use an actuall puller to extract as bang and wrenching hasn't been successful to date... CRAP!

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I did see this last week. I looked right over this last part of the post and read the rest of the thread. That's funny. In fact, I was using your pictures when I was describing to someone how well most of our cars are standing up to corrosion. The worst things that get it are the exhaust. How goes your progress?

[Bigglezworth]

The hulk is back in the bay and all bolted up. Going to spend tomorrow hooking up all the suspension, brakes, ECU, fuel, sensors, etc. Also going to get started on repairs to seal up both intercoolers that are clearly leaking. Would be nice to have it all buttoned up and out the door for the end of the weekend, but at this point my body needs to take a breather and enjoy the last few days off for Xmas break prior to heading back to the office on Monday. Solo work is time consuming and tiring to say the least.

Mentioned a few posts ago that I was looking to modify the Frankenstein coolant pipe that snakes around the back of the engine and along the bottom of the valve cover on the passenger side. Wanted to introduce a flexible connection that would make flexing it out of the way to do a valve cover gasket a host easier. Had all the modifying parts in hand and took things to an aluminum fab shop.

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After a lot of discussion, opted against modifying for two reasons. The silver solder connection(s) would be comprimised as soon as the welding of aluminum flare fittings was undertaken. Being as I didn't have fittings that could slip over the existing pipe, I would need to weld vs. solder. I certainly could have had the solder connection(s) welded also, but that just started to increase the price to the point it simply wasn't worth it. I don't have any friends that do aluminum welding, so ended up leaving things as is.

I also wanted to relocate my oil filter with a remote kit, but at this point have shelved that idea also as the fittings for all the current 'kits' are not suitable for an Audi.... Again, something that can be fab'd, but more important to get the ride back on the road vs. an ornament in my garage.

I did however spend a couple of hours bashing the hell out of both piggy pipes to gut the precats. Damn that metal was hard! All cleared out and ready to release a bit more back pressure. Should be somewhat noticeable with a decent tune.


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Also blocked off the SAI ports out the back of both heads with some block-off plates that I fab'd up quickly and put in an aluminum coupler for the oil cooler similar to the Bufkin one sold on eBay all the time.

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[Beardown1]

Nice work Biggz. I am a few steps behind you. I am planning to do the same to my precats......did you use an air hammer and chisels to clean it out?

[Bigglezworth]

Nice work Biggz. I am a few steps behind you. I am planning to do the same to my precats......did you use an air hammer and chisels to clean it out?Too deep down inside for an air chisel to be effective IMO. You might find otherwise. I used good old arm and hammer....

[Amulet-S6]

Bigglezworth, Thanks for sharing the photos.

Happy New Year to all!

Feeling really fortunate to have Quattro this time of year. Out and about in 7" of fresh snow and 4* temperatures, topped to offer assistance to several motorist yesterday. Dedicated winter tires are such a good investment (in colder climes)

Keep Smiling (& flossing:) Jim

[4everRS]

You need longer chisels. I also needed 2 chisels for mine. The first one got all kinds of stuck.

Keep up the good work Tim.


Too deep down inside for an air chisel to be effective IMO. You might find otherwise. I used good old arm and hammer....

[Bigglezworth]

You need longer chisels. I also needed 2 chisels for mine. The first one got all kinds of stuck.

Keep up the good work Tim.Non air-tool removal was beneficial to offset a tiny bit of the Xmas donut I have around the mid section...

[Bigglezworth]

Took a break with car stuff for the entire last week and only got back to final assembly this weekend. So many parts affected with an engine removal. Seems each time I turn around, something else needs to be reassembled. ha. As part of reassembly, I'm cleaning a bunch of things up, sealing small oil leaks, general tidiness. Wanted to make reassembly of the oil/tranny cooler a little easier by undoing the fittings from the oil cooler housing itself. Couldn't do this while it was on the car as the fasteners were seized on way to tight and though that some clamping with soft jaws in the vice would make things easier. Blasted the lines with a host of liquid wrench and started on things after a couple of days sitting. Fitting broke loose and started to work out after some back and forth. To my dismay once the hose was entirely removed however, I noticed so were all the threads on the nipple.... DAMN.

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Refrained from trying to remove any of the other fittings obviously and did some soul searching to figure out what I would do as a remedial effort. Putting a new fitting in would require aluminum welding which I would need a qualified trade for as I can't locate anyone locally that does silver soldering. There was still ample threads left on last half of the nipple, but with this being a flared tube fitting, I couldn't just lop off the damaged end as that would compromise the sealing of the line. I thought about milling the end off and retapering to accept the fitting, but that was really only a logical solution if you could align the cooler with the milling machine and all the spagetti hanging off each end quickly killed that idea. I then elected to lengthen the fitting on the end of the hose. I was able to chase out all the damaged thread material from the original coupler and purchased a second coupler to which I cut off a 5mm portion to provide the required extension. Some careful mig welding and voila!. Add some proper anti-seize compound for dissimlar materials and line repaired.

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[G2]

Very clever. Hope it holds for the long haul. If not maybe weld another male threaded section on the oil cooler?

[Bigglezworth]

Repair effort has been working fantastic for the past 2.5 weeks. Glad to have the wounded warrior back in action tearing up the roads. I can't remember the thread where I made mention about reversing the aux rad backflow valve and running it between the T-stat pipe and the coolant resevoir, but I did in fact do that here on my end after removing the aux rads and confirm it's performed exactly as well in action as it does in theory.

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