Enjoying my 01e conversion

[mdegracia]

After several unplanned mishaps, including burning a hole in the turbo oil feed line from the starter lug; premature solenoid failure; and a mystery driveline vibration, I am finally at a good point to safely update the group on my 01e conversion. The clutch (AMD 3+) engagement is getting better with each day of use.

For anyone who's planning on or is in the process of doing this conversion, here are a few notable mentions:

1. Starter power connection - verify the oil line is not touching the power terminal. There is little to no room to see clearances and little room to bend/adjust the line.
2. Bench test the starter for flywheel mesh/engagement
3. Pressure test your wastegates and make sure they both open at the same pressure, adjust spring pre-load as needed
4. Bleed slave cylinder before raising the engine assembly into car
5. Replace the plastic tee in the boost line with a brass unit
6. Torque steering rack bolts and clear firewall drains

New additions:
SRM K24 turbos
Devils w/m
034 spherical upper control arms
BMW E39 filter relocation
Innovate SCG-1 gauge
All new seals and gaskets top to bottom
60lbs EV14s and 3bar MAP (pending my dyno appointment with EFI in June)

At the moment, I am running EFI's base 01e tune and just spring pressure for boost. Ran the car at Watkins Glen in April for a HPDE class and was pretty happy with results. I am really looking forward to getting the car dialed in with EFI in June. Stay tuned for the dyno update.

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[mrdave]

Nicely done. I'd love to see the dyno results of what you have there.

Also, now that your 6sp is dialed in... time to sell?? :jlol:

[lswing]

What's the sale price:hihi:

Nice work, thanks for sharing the info!

[mdegracia]

Haha, no! No intentions of selling, way too much time invested. :mech::w::mech:

[s8prtotype]

Did you put in a pump or 5 bar FPR? Also, injector part number?

Was actually wondering what the K24's would do on this platform.

What tranny set-up did you use?

With all this said i have stevekens kit on the way, and EVERYTHING will be cleaned up. Will be a completely different car once it's done. :)

[Avus-RS6]

Congrats and welcome to the club!

[GreggPDX]

I'm about to start my conversion, can you elaborate a bit on point #2? How did you know the starter engagement was correct?

[mdegracia]

Thanks!

I replaced the in-tank pump with a 450 Walbro and no change on the FPR. Not sure on pn for the injectors, they are FoMoCo units, EV14s with adapters.

Running the 01e with 0.56 6th gear. I would recommend sourcing your own axles (front) with either Genuine cores to send to Raxles or GKN if you can find them. Note - Axle application is dependent on what axle flanges/cups are on the transmission. Mine came with the tripod flanges which made it very difficult to source the appropriate axles and service parts for the tripods are not typically available.

[mdegracia]

For the starter engagement, first install the two shims that Steve offers. Next, using a power probe to actuate the solenoid and inspect the mesh at the flywheel. As a final check before installing the motor and transmission back into the car, send power to the starter to verify proper engagement and turnover. I did not do this and had horrible engagement (think chevy v8 starter noise! puke:). Coincidentally this is when I burnt a hole in my oil feed line, so everything had to come out again anyways.

Long story short- typically there are two ways to skin a cat...except when it comes to working on the RS6. On the RS6 there is only one way and that's it!

[GreggPDX]

Thanks, that helps. Another random question, are you still running with the DRC? If so, did you leave them hooked up when dropping the subframe? I see some people just drop the subframe with all of the front suspension intact, but I don't want to deal with opening up the DRC and recharging.

[P1054]

I see you went with the BMW E39 filter setup. Great call, looks like you used about the same design as mine! I don't think you'll be regretting it...

Also, enjoy the 6-speed. It's worlds better than the automatic. I'm really really wanting to get another RS6 and convert it....

[Aronis]

Very nice!

:)

[bethridg]

and a mystery driveline vibration
Any details or root cause? I initially had a driveline vibration after the 6MT swap that showed up at 120mph+ but was fine anywhere below. Let the car sit for a week and now the vibration comes in around 60mph. Ruled out brakes, tires/wheels, axles and trans/motor mounts. All signs point to the propshaft center support bearing and possibly the cv joints. Considering rebuilding the entire propshaft.

Keep us posted with your impressions of that clutch. I'm running it (~6k miles) and I think hahnmgh63 will be too.

Also REALLY interested in your tune. I'm currently running Daz's 6MT tune but need to go a different direction now.

Congrats and enjoy the added smiles-per-mile.


Another random question, are you still running with the DRC? If so, did you leave them hooked up when dropping the subframe? I see some people just drop the subframe with all of the front suspension intact, but I don't want to deal with opening up the DRC and recharging.

I didn't touch the suspension when I dropped the subframe. Just unbolt the lower control arms from the subframe and let the suspension, upright and wheel hub assembly hang. But be mindful of the headlight autolevel switch on the drivers side front lower control arm so not to break it.

[mdegracia]

Yes, I don't miss the 5at one bit!

Regarding the vibration, mine comes in at 50mph and stays through to 70mph. Pretty sure it's the crappy reman front axles that came with swap kit. I was able to source a new gkn axle for the left from worldpac. Im still waiting on ecs to get me the right axle. Vibes definitely reduced after replacing just the left one.

[JSRS6]

Can we get some more info on the bmw filter relocation?

[mdegracia]

See pics for some more info...

[JSRS6]

That's perfect thing to replace my SAI pump with!

[JSRS6]

Do you have any associated part numbers?

[mdegracia]

Yes. P1054 is who initially pulled this together. See parts list below:

P1054
January 11th, 2015, 20:52

Sure thing!

Parts I used:

<tbody>
Spin-on adapter
Canton Racing Products 22-595
$ 82.92
Amazon.com


Oil filter housing
BMW E39 oil filter housing
$ 60.00
Gresham Auto Wrecking


Hose and fittings
Russell - 2x RUS-660503, 4x RUS-610045, 1x RUS-63216, 2x RUS-660883
$ 155.81
Baxter Auto Parts


Custom plugs for filter housing
Custom machined by me
$ -
Me


Filter
Mann HU-938/4-X
$ 10.79
Tony's Auto Parts

[mrdave]

How large is the E39 filter compared to stock? I've never really liked the relatively small oil filter on these cars considering the performance level of the engine.

[mdegracia]

I'd say the e39 filter is close to twice the size. It's just a very convenient design.

[P1054]

Yes, it's definitely substantially larger. Not to mention much more convenient to change. And to top it off, the filters are less expensive! All around a win-win.

[s8prtotype]

On the injectors, it seems they're only good for like 600hp is what I'm seeing online?

This is saying they're not really 550's

https://www.facebook.com/PerformanceFuelInjection/photos/a.174356292674007.34770.164255713684065/557908707652095/?type=1&theater

[hahnmgh63]

Closest I could find at 3Bar was:
0280156167 (Blue RS6) - 380~400cc
0280155968 (Big Green) - 415
0280155892 (225TT 1.8t) - 386cc

These are one of the newest Bosch designs (EV14) that everyone is using with the 5v 1.8t motors which should match our combustion chambers well.
http://www.bosch-motorsport.com/media/catalog_resources/Injection_Valve_EV_14_Datasheet_51_en_2775993867pd f.pdf The EV6 (RS6) injectors are compatible with the right EV12 & EV14 injectors. My Turbo just went out in the TT (K04 also) so of course I'm upgrading the daily driver as 225 + downpipe/exhaust, & tune (probably around 260bhp) aren't enough. I'm going with a modified K04 (Frankenturbo) and 550cc injectors, bigger MAF, and new tune. The mod has been out for the 1.8t for almost 5yrs and everyone is running cooler EGT's and about 290~300lb/ft of TQ and about 280~290bhp at the wheels, all from a 1.8t. Like the RS6 (very similar motors actually), the Rods are the limit and everyone says stop at 300lb/ft unless you replace the rods.
http://www.usrallyteam.com/content/products/injector/Bosch_Injector_data.xls

[hahnmgh63]

Some more interesting Bosch reading:
http://www.bosch-motorsport.com/media/catalog_resources/Injection_Valve_EV_6_Datasheet_51_en_2775912459pdf .pdf
http://www.bosch-motorsport.com/media/catalog_resources/Injection_Valve_EV_12_Datasheet_51_en_2775957003pd f.pdf
http://www.bosch-motorsport.com/media/catalog_resources/Injection_Valve_EV_14_Datasheet_51_en_2775993867pd f.pdf
Although you can get a little higher flow rate from just running a higher fuel pressure regulator. Either way you need a custom tune to go with it. Costly for the dyno time but you can probably get more power fairly easily compared to off the shelf tunes with lower EGT's but of course at a cost to the tuner for his time & dyno. I may go this route down the road with AMD, I they've done hours and hours of this on just about every Audi including the RS6. I think AvusRS6 car has had a bit of work on the Dyno at AMD, not just an over the counter tune.

[mdegracia]

On the injectors, it seems they're only good for like 600hp is what I'm seeing online?

This is saying they're not really 550's

https://www.facebook.com/PerformanceFuelInjection/photos/a.174356292674007.34770.164255713684065/557908707652095/?type=1&theater

I will grab the injector part number and post tomorrow.

[mdegracia]

Part number on the injectors is 0280158298. These are EV4 and need the EV14 adapter for the RS6 wire harness.

https://www.fiveomotorsport.com/bosch-ev14-0280158296-16-hole-nozzle

[s8prtotype]

This looks tempting?!?

http://www.amazon.com/GooDeal-Injector-Adapter-USCAR-Chevy/dp/B00ZH1G0IS

[s8prtotype]

Also... this is the best price as the ford part number crosses with the Bosch part number...

http://www.newegg.com/Product/Product.aspx?Item=9SIA9Y43VT7755&nm_mc=KNC-GoogleMKP-PC&cm_mmc=KNC-GoogleMKP-PC-_-pla-_-AT+-+Fuel+System+-+Performance-_-9SIA9Y43VT7755&gclid=Cj0KEQjw94-6BRDkk568hcyg3-YBEiQAnmuwklnlbL2H6Z7Z2i3AXNx60XsH02LEuVKZpiQ_EO3n fvMaAmxf8P8HAQ&gclsrc=aw.ds