Project Nogaro – The Good

As I begin to assess this Nogaro S4 there are a number of positive aspects of the car.  First, and foremost, is the efforts to build it into a Stage 3 car have resulted in quite a few upgrade modifications having been performed.  Thus far I am aware of the following components having been replaced.

Part (Cost)

  • [No Name] Turbochargers ($600?)
  • Clutchmasters FX400 6 puck clutch ($800)
  • Fidanza lightweight flywheel ($420)
  • Bosch EV14 550 fuel injectors ($250)
  • K&N Cone Intake ($187)
  • Walbro 450 Fuel Pump ($157)
  • H&R Coilovers ($950)
  • Stabila Front Sway Bar ($229)
  • Borla 3″ Single Exhaust ($758)
  • 034 front billet aluminum subframe bushings ($150)
  • Audi R8 2.0 coilpack conversion ($479)
  • Vagautowerks coilpack adapter plates (?)
  • Custom instrument cluster ($80)
  • Depo clear code headlights with 6k HIDs ($700)
  • XS Power Bipipes ($140)
  • XS Power Diverter Valves ($110)
  • XS power k04 turbo inlets ($170)
  • Autobahn88 Silicone “Lobster Claw” (?)
  • Raxles Axles ($300)
  • CTS Turbo silicone accordion hose ($70)
  • RS4 Engine Mounts ($280)
  • OZ X-Line POWER 18″ Wheels ($1197)
  • Bridgestone Blizzak LM-60 Winter Tires ($1296)
  • EPL 85mm MAF ($250)
  • Audi R8 Oil Cap ($45)
  • Billet aluminum S4 shift knob ($65)
  • Alcantara shift boot ($50)
  • Autometer Boost/Vacuum Gauge ($75)
  • Podi Steering Column Gauge Pod ($40)
  • RS4 Replica Grill ($100)
  • ECS Tuning Short Shifter ($190)

Other Maintenance

  • Timing Belt, Serpentine Belt, Tensionser
  • Valve Cover Gaskets
  • G12 Coolant Flush
  • Pentosin PS Flush
  • Starter
  • Battery
2001.5 Nogaro Audi B5 S4
2001.5 Nogaro Audi B5 S4

I’d like to positively determine if the car has BorgWarner K04’s so I am in the process of pulling out the engine and transmission.

Prepping for engine pull
Prepping for engine pull
In position
In position

I’m almost there, I have a message into the prior owner to find out how the shift knob is removed!  Once I get that off I’ll be able to drop the shifter and be ready to attach the engine hoist.

The Odd:

Some peculiar things I’ve come across while preparing to remove the engine.  Lots of different bolts being used.  Lots of vacuum lines disconnected.   Wood screws being used to hold the bumper in place, yes that’s right, wood screws!

Driver side
Driver side
Passenger side
Passenger side

The driver’s side screw was easy to undo, the passenger side was a different matter.  The screw head was behind a plastic part, completely inaccessible.  I had to use a pair of pliers to back the screw out from the pointy end.  Bizarre.

Some previous owner chose to go with a single piece exhaust, having a Borla exhaust welded onto the mid pipes.

Borla one piece
Borla one piece

Really?  Because taking this thing off as a single piece is odd, and I can imagine putting it back on will be fun.  I’m thinking of taking a sawz-all to the pipe and finding a band clamp to hold the two pieces together.

BMW MAF + K&N Filter

The Nogaro project car came equipped with an unusual intake setup, a BMW Bosch MAF housing with the Hitachi Sensor epoxied into place, and a big honkin’ K&N cone filter feeding the MAF.

BMW MAF with K&N Cone Filter
BMW MAF with K&N Cone Filter

This Bosch MAF has grills on both ends, which seems to me to be a bit unnecessary.

BMW MAF Housing
BMW MAF Housing
BMW MAF Housing
BMW MAF Housing

It is a relatively large housing at 81.5mm in diameter on the inlet side and 83mm on the outlet side.  These readings may be slightly off due to being taken with the grills in place.

I was curious how this combination would flow in comparison to a typical S4 Stage 3 setup that I would use, so I pulled the EPL MAF off the shelf along with a stock airbox.  The EPL MAF has a 78.5mm inlet and 85.3mm outlet.

I first did a calibration run with a 400 CFM calibration plate on the flowbench.

400 CFM Calibration Plate
400 CFM Calibration Plate

Since I was interested in seeing how the MAF and also the K&N filter performed, I first tested just the BMW MAF housing.

BMW MAF Housing
BMW MAF Housing

Then I added the K&N filter to the MAF and tested it again.

BMW MAF with K&N Air Filter
BMW MAF with K&N Air Filter

Next I swapped over to the EPL MAF housing.  The EPL unit is sized to fit into the stock airbox and RS4 accordion.

EPL MAF and Stock Airbox
EPL MAF and Stock Airbox

Since this airbox does not have the benefit of being modified with the “Darintake” mod I chose to leave the intake snorkel off.  If it were included I would expect airflow to drop slightly from what was recorded.

Since the Darintake mod greatly helps with airflow through the airbox I did another run with only the air filter in place, simulating the effect of having the bottom of the airbox opened up.

Results:

Collecting the flow results and charting them produced the following:

EPL MAF vs BMW MAF
EPL MAF vs BMW MAF

A few observations about this data.

  1. The addition of the K&N filter to the BMW MAF housing did not alter the airflow reading in any appreciable way.  This was a bit of a surprise, indicating that the K&N filter is less of a restriction to airflow than the BMW MAF housing.
  2. The EPL MAF housing outflowed the BMW unit by a large amount, despite having a slightly smaller inlet.  I attribute this significant difference to the grills on the BMW MAF.
  3. The unmodified stock airbox dropped airflow through the EPL MAF housing by a great deal.  This reinforces the utility of performing the Darintake mod.  When this mod was simulated through use of the air filter alone the airflow jumped up becoming much closer to the EPL MAF housing alone, though not equaling that airflow.

Upon inspecting the BMW MAF housing closer it appears that the grills can easily be removed.  This leads to the opportunity to test the MAF housing with different grill combinations to determine the affect of the different grills on airflow.  It will also enable me to determine if the K&N cone filter becomes a restriction, relative to the MAF housing, at higher airflow rates.

Project Nogaro Begins

Lately I’ve been itching to take on some new projects with the S4.  As it happened I came across another local B5 S4 owner who had a project car that was being squeezed out by work activities.  Looking to hand the car off to somebody that would be equipped to undertake a project, I came along at the right time.

After a bit of correspondence I picked the car up and drove it back to my garage where it now awaits my attention to try and  move the effort along.

project_nogaro_1
2001.5 Nogaro Audi B5 S4
2001.5 Nogaro Audi B5 S4
2001.5 Nogaro Audi B5 S4