Hi Ho Silver

Today marked the departure of the Silver B5 S4 that I’ve been working on for close to four months.

B5 S4 drives off
B5 S4 drives off

The car arrived nearly stock and left as a K04 charged Stage 3 car .

Midwest Turbo Connection B5 S4 K04
Midwest Turbo K04 Turbocharger

During the time here there was a long list of upgrades and maintenance performed on the car.

ComponentAdditional Parts/ProceduresPercent Complete
Fuel pump100%
Fuel filter100%
Brake Fluid Flush100%
Tie rod ends100%
JHM front axlesGaskets, axle bolts100%
Regrease front axles100%
Front brake lines100%
Brake Pad Wear Sensor Plugs100%
Front adjustable UCAUsed Fixed UCA100%
Front LCA100%
Front rotors and pads100%
Front wheel bearings & hubsDelayed
Front coil overs100%
Front swaybar endlinks100%
Front swaybar bushing/brackets100%
Rear rotors and pads100%
Rear coil overs100%
034 rear sway100%
Rear swaybar end links100%
Rear wheel bearingsAxle Bolt RemovalDelayed
Rear brake lines100%
Rear differential mount100%
Rear differential fluid100%
EngineVCG (Drv)100%
VCG (Pax)100%
Camshaft End Caps100%
Camshaft Seals100%
Camshaft Chain Tensioner Gaskets100%
Rear Main Seal100%
Timing Belt100%
Water Pump / Thermostat100%
Coolant Hardpipe O-rings100%
PS Fluid100%
Replace Snub Mount/Cage100%
Swap Alternators100%
Tune ECU software50%
Engine Oil Flush100%
Modify Airbox100%
Modify Brake Booster Hose100%
Install New Auxiliary Coolant Pump100%
Intake Manifold
New Intake Manifold Gaskets100%
Swap Fuel injectors100%
034 Spider Hose100%
Exhaust Manifold
New Exhaust Manifold Gaskets100%
New Exhaust Manifold Nuts100%
Remove stock brackets/rivets100%
Relocate AC Condenser100%
Trim Radiator Support100%
Check & Set Preload to 8 psi100%
Trim Turbocharger Inlets100%
PB5 Wastegate Line Kit100%
Paragon Oil Lines100%
Coolant Lines100%
Clean Oil Return Lines100%
Install Turbos100%
Replace Slave cylinder100%
Replace Clutch100%
Bleed Clutch/Slave Cylinder100%
Replace Throwout Bearing100%
Shift Rebuild Kit100%
Replace Flywheel100%
Regrease driveshaft joint100%
Driveshaft gasket100%
Transmission Fluid Change100%
Low Temp Thermo SWX 021 919 369 / O-Ring N 903 168 02100%
Repaired Instruments LCD100%
Assemble & Install Dual Exhaust100%

I never got to the wheel bearings as the driver side rear axle bolt proved to be very stuck and I concluded that a shop with an impact wrench would be the most likely place to get it removed.

Silver B5 S4 Stuck Axle Bolt
Silver B5 S4 Stuck Axle Bolt

Tuning was on the third revision, with the remainder to be carried out by the S4s owner when it was driven away.

B5 S4 Engine
B5 S4 Engine

In the meantime a backlog of turbochargers has grown in the corner of my garage.

BorgWarner RS6 - FrankenTurbo F21 - TiAL 605
BorgWarner RS6 – FrankenTurbo F21 – TiAL 605

Between the turbochargers and completing this engine build,

Istook Engine Clean Up
Engine Cleanup

and trying out the Mamba Wastegates, I have a number of options for future projects to tackle.

Mamba Billet Wastegates for the Audi B5 S4
Mamba Billet Wastegates for the Audi B5 S4