APR Motorsport X A4 Engine Build

Build-Up Log

Parts Listing

Pictures

Logs

Dyno Results

Base APR Motorsport X Engine Description

exhaust camshaft, ref.no.: 0301A1560-00 (for use with mech. Tappets),

o    opening duration: 256°

o    peak angle: 114°

o    cam lift max.: 11,0mm

o    lift at TDC: 0,6mm

 

intake camshaft, ref.no.: 0301E1480-00 (for use with mech. Tappets),

o    opening duration: 248°

o    peak angle: 112°

o    cam lift max.: 8,2mm

o    lift at TDC: 0,4mm

Additional Engine Enhancements

Motor Build Log

A moment of madness, a man obsessed, an action of auto enthusiasm....I don't know what it is or was...  but I am the midst of a project that many would consider complete madness and absurdity...  and they're probably right.   

This is a project I will likely never do again in my life so I thought it was worth documenting from beginning to end...

History/Background: I purchased my 1999.5 Audi A4 1.8T in July of 1999.  I chipped it (TAP 0.8 Bar) at 500 miles and was happy and content with that level.  A few years passed and I got the opportunity to drive Ed P's APR Stage 3 A4 while attending one of the APR BBQs.  By the time I left I had put down a deposit on a Stage 3 kit, and agreed to get their chip.  Long story short at 40,000 miles Stage 3 was in my car.  At 80,000 miles I added an air to water intercooler setup.  At a 110,000 miles on August 12th 2005 my car had the unfortunate encounter with a raised manhole cover.  The manhole cover caught the front crossover tube, bent it back and crack my oil pan.  I thought I had caught it in time, and there wouldn't have been any damage....and likely there wasn't any.  The car was towed to the dealer and the oil pan and pump were replaced.  On October 2 2005, 300 miles after getting the car back from the dealer and doing my really first WOT run, my engine grenaded.  When I say grenade... I mean grenade.

http://www.wseng.com/a4/pics/engine/rebuild/hole.jpg

http://www.wseng.com/a4/pics/engine/rebuild/shaft.jpg

http://www.wseng.com/a4/pics/engine/rebuild/hole2.jpg

http://www.wseng.com/a4/pics/engine/rebuild/debris.jpg

    

Engine Destruction:  Best I can tell here is what happened.  Cylinder 4's piston seized to the block.  The inertia and momentum in the system pried the bottom of the connecting rod apart and off the crank.  The rod then got hit by rotating crank, and bent into the block and impacting the RPM pickup gear.  The rod went through the block and also impacted the intermediate shaft, and breaking it.   The intermediate shaft then broke in 3 other places, and fell into the crankcase.  I believe the sudden release of energy led to the breaking of the connecting rod of cylinder 1.  The connecting rod on cylinder 1 swung around and put a nice sized hole in my nice new oil pan and out through the AC support bracket and waterpump.  Cylinder 2 also blew out through the block for some reason, probably due to the oil pump shaft pieces.  Cylinder 3 showed signs of cracking upon closer examination.

What to do...:  Well I had been planning to overhaul the motor and put in rods and pistons over the winter, but buying a new motor was not on the agenda.   My original manhole accident I filed with my insurance company as an accident.  They agreed and picked up the bill.  My motor blowing up they also agreed was due to the same accident.  They cut me a check for $4500 to buy a used motor and the necessary bits to get my car up and running.  Add that to my tax refund, a work bonus and my original plans... and I started thinking big.

Now I am a Program Manager.  I'm also an engineer so I know that projects never get estimated accurately, and there is always something.  I tried to add in an "unknown factor" in my budget.  I know about requirement creep, and I know about anticipating for the unknown.  But along the way I learned something else... it wasn't enough when I am the unknown.  I decided as I started to really get my hands dirty, that if I was going to do this I didn't want to go half way.  I didn't want to build a motor that also wasn't "finished"  (e.g. hot rods)  So what are the unknowns?  BLING pure and simple...  Oh wait and a few suprises along the way 

Build Story:

So here is the story and build log...for anyone thinking "oh that should just be __, ___, ___, and ___ and cost $___"

October 2, 2005 - Engine blew to pieces in A4

 108,503 miles on Odometer

December 14, 2005 - Purchased Passat 

After months of negotiations the car was finally delivered to me at 8pm.  

 http://www.wseng.com/a4/pics/engine/rebuild/passat.jpg

December 19, 2005 - Engine pulled from Passat

After purchasing an engine hoist, and a space heater I pulled the engine from the passat in 20 degree weather.  It wasn't too bad actually, pretty straight forward.  Here you see the engine after it has been stripped down, and prepared to be boxed and shipped.

http://www.wseng.com/a4/pics/engine/rebuild/engine-hoist.jpg

January 5, 2006 - Engine shipped to APR

 

January 21, 2006 - Engine pulled from A4

I pulled the engine from the A4 in order to take a closer look at it and the destruction.

 

January 23, 2006 - Kickoff meeting with APR on engine build and project goals

Decided to build an APR Motorsport 2.0L 8.5:1 compression engine.  In addition the head will be ported and polished with new valve guides installed.

February 4, 2006 - Polished intake manifold and prepared valve cover for powder coating

http://www.wseng.com/a4/pics/engine/rebuild/coolant.jpg

February  11, 2006 - Dropped off valve cover and coolant pipe for powder coating

 

February 25, 2006 - Parts back from powder coating

http://www.wseng.com/a4/pics/engine/rebuild/red_cover.jpg

March 7, 2006 - Begin detailing work on engine accessories. 

Using rust remover, degreaser, and paints from Eastwood, I prepared and painted the pullies, and engine accessories. 

 

 

http://www.wseng.com/a4/pics/engine/rebuild/painting.jpg

March 10-11, 2006 - S4 Strut Tower Brace

Following ModifiedA4s article, I machined up my 2nd version of the S4 strut tower brace.  I painted the A6 brackets in gloss black to match the bar.  In addition since I didn't have the pesky engine in the way, I installed the 5th bolt through the firewall.

 

March 13-18, 2006 - Airbox 

Began work on my custom intake system...  I'm hesitant finish it until I figure out what manifold I am going to use (and if the turbo placement may become an issue)

 

June 2006 -Gauges gauges and more gauges

I bought some new gauges... 

SPA Gauges:   (Boost + EGT and Oil & Fuel Pressure)  

Using a CF/kevlar panel I made up I replaced the center vent.   The SPA gauges have a lot of cool features.  Two alarm levels (four really)  One alarm will flash the LEDs, the other will trigger an external alarm.  I decided for the track having an audible alarm would be good.  So I went to Radio Shack after doing some research about what a specific tone would sound like.  

 http://www.wseng.com/a4/pics/engine/rebuild/gauges-3d.jpg

June 11, 2006 -Revised Intercooler Plumbing

I purchased a larger transmission cooler core to upgrade my existing air/water radiator to the largest possible size that would fit behind the stock bumper.

I also purchased a power steering core to help clean up the installation and to provide an additional cooling for the track.

I bought some extruded aluminum and a rivet gun to create a new mounting structure for the new setup. 

http://www.wseng.com/a4/pics/engine/rebuild/air-water-ic-rev3.jpg

June 2006 -Houston we have a problem

While trying beginning to assemble the AEB block with the new crank, the crank impacts the infamous oil pump/intermediate shaft.   The solution?  Use an AWM 2001 chain driven pump block.

July 2006 Fuel Pump Install

  • Walbro 255lph Pump
  • Banjo adapter fittings
  • Located in the fuel filter location

-Wired in the fuel pump...twice (stupid connectors from radio shack)

-Wired in accordance with APR Stage III+ TT details + modifications for A4 (writeup coming soon)

 

http://www.wseng.com/a4/pics/engine/rebuild/fuelpump.jpg

July 2006 -More wiring.

-Ripped out my VDO gauges and about 12 feet of wiring from 7 years of modifications.  

-Wired in my new SPA gauges.  

-I also wired in a digital tachometer I purchased.  I have the digital tachometer mounted in a new south steering column pod.  I drilled a hole in the back of the pod and installed a switch so I can turn the gauge off for around town driving. (see Tachometer Install Article)

 

I finally have nothing to do until my motor and manifold show up...

http://www.wseng.com/a4/pics/gauges-3e.jpg

August 24, 2006

OMG my manifold finally freaking showed up.  Originally supposed to arrive on June 7th, it shipped on July 31, got stuck in UPS hell, and finally arrived on my door today.

Manifold by Jay Thornton aka California Jay.  Purchased from Tapp Auto in Canada.

 

 

http://www.wseng.com/a4/pics/engine/rebuild/manifold-1.jpg

February 15, 2007

The motor is FINALLY here... after a long time it is here.  APR Motorsport Level X

  • AEB Head
  • Solid Lifter Schrick Cam setup
  • Stroked AWM block to 2.0L
  • Forged Crank
  • Forged Pauter Connecting Rods
  • APR spec'd Forged and Coated Pistons
  • APR oil squirter design
  • New OEM bearings and seals

 

 

February  2007

Evaluated the differences between the AEB and AWM block...time to go shopping again.

  • PCV System
  • PS Pulley
  • Coolant Pipe
  • Oil Cooler hoses
  • Coolant hose
  • AC Condensor Bracket (or is it)
  • Engine mount brackets
  • Dipstick funnel
  • etc
 
PCV System:
N90467301      Round Seal
06A103213F     Breather Tube
N90739901      Hose clip
06B133382H      T Fitting (3-way 1" T)
06A129101E      225 TT PCV 
                1" Heater Hose
 
Coolant System:
06b121065AC    AWM coolant pipe
N90365302      Seal ring
078133335A     coolant pipe nipple/Thermostat Housing
unknown         Hose Clamp                    
N0210742        Banjo Bolts-turbo to block    
N0138149        washer  
058198025A     AEB Valve cover gasket
4B0121055J     AWM Lower Radiator to Coolant tank and Thermostat Hose
032121142      Clip 
N90316802      Seal
357121140      Radiator Plug (plugs coolant sensor hole in lower hose)
Engine Mounting Hardware:
8D0199335Q     AWM snub mount housing
N0102706       bolts
8D0 199 305A   AWM Support Bracket Driverside
8D0 199 306AA  AWM Support Bracket Passengerside
 
Oil System:
06B121058B      AWM Oil cooler hose           
06B121058S      AWM Oil cooler hose                   
06B115611C     AWM Dipstick
06B103663B     AWM Dipstick tube
        
AC System:                
06B260885A      AC Compressor Bracket (Didn't work and returning)           
06B260849A      AC Belt
058260885C      AC Compressor Bracket
N90696701       Bolt
N90355801       Bolt
 
PS System:
n0138486       banjo washer -PS Inlet
n0138486       banjo washer -ps cooler ret line at rack
n0138494       banjo washer -ps line at rack
        
Intake Manifold:
n10080102      Intake M6 Manifold Bolts
06B129723AR     Intake Manifold Bracket 
                AEB Intake Manifold Gasket
             
Exhaust Manifold:
n90085001      Exhaust M8 Self locking nuts
n90357201      Exhaust M8 Washers
               AEB Exhaust Manifold Gasket
 
Accessories:
06B903141D     AWM Accessory bracket
06B105243D     AWM Vibration dampener
06B119145       Viscous Fan Pulley  (yes it was different.  AEB didnt align)        
n10302601       Bolts for fan pulley attachment      
n0147454       Fan Attachment bolts   
N90448801       PS Pulley Bolts
N0147135        Rear PS washer/bolt   
Misc:
8D0803123       Battery Hold Down  (gave my old one to the GF's car)        
8D0941509       Hazard Relay (gave my old one to the GF's car)    
06A109108K     AWM Toothed Belt Upper Cover
06A109147F     AWM Toothed Belt Middle Cover

March 2007 Progress

  • Completed the 2001 version of the S4 Oil Cooler Modification Placeholder for Article
  • Fabricated new mounting plate for catch can and fuel filter
  • Installed Fuel Filter relocation under coolant tank 
  • Fabricated custom aluminum coil pack cover
  • Manifold ceramic coated
  • Degreased engine bay and transmission bell housing
  • Engine is ready to go!

Some of the custom work that needed to be done

  • Ground down nub of oil block to allow for mounting/installation of S4 oil cooler
  • Threaded the passenger side engine bracket so it would take m6 bolts, in order to mount a heat shield
  • Cut and threaded Cruise control rod to proper length in order to mount on AWM accessory bracket
  • Drilled out RPM sensor mounting hole to use AEB RPM sensor in AWM block

 

 

April 1, 2007

Engine is installed in the car.  Thanks to Mark Pogers (MarkP) and Chris Reed (ModifiedA4) for the hand and laughs. Also installed:

  • RS4 passengerside transmission mount (from PureMS)
  • Stern driverside transmission mount (from PureMS)
  • RS4 Engine Mounts (from PureMS)

Hit a snag though... the crossover tube is different on the 2001, despite what I was told.  The snub post is not where it needs to be....another order for more parts

April 2, 2007

Packages out and packages in...

  • Sent off my stage 3 kit to Doug Foster (Dungbeetle)... glad it found a good home.
  • Received a "new to me" central locking pump to replace the one I put in my GF's car
  • Received some nord lock washers for my turbo install from Jon Tibbitts (Jon1.8T).

Parts on order:

  • 5/16" Hose menders/couplers (for fuel line and PS cooler connections)
  • 8D0199521AG AWM cross over tube
  • Zip tie clips
  • coilpack anchors
  • AEB AC compressor bracket
  • 2001 AWM APR Snub mount (wasn't need, just reused my AEB... a bit tight but ok)

 

April 7, 2007

Blog #5- Another few steps closer...Manifold back from coating

Cleaned up this week

  • Finalized wire and hose routings (zipties galour)
  • Parts arrived from Clair Parts (Barry comes through again)
  • Snub Mount transferred over
  • AC compressor installed
  • Manifold came back from Northeast coatings with the Satin Silver thermal coating
  • Turbine housing at Northeast coatings for the same coating
  • Received coupler fittings I ordered on Monday.  Fuel lines finalized
  • PCV system to catch can plumbing revised to provide more clearance.  Still need to finalize with BPV plumbing.

http://www.wseng.com/a4/pics/engine/today-4-7-07.jpg

May 16, 2007 Car Back from 666 Fabrication

Blog #6- Car back from fabrication
  • 3" exhaust from turbo to Cat
  • Cat relocated under car
  • 3"-2.5" tapered mid-car/post cat to APR 2.5" exhaust
  • Turbo/intercooler piping 2.5" Turbo-Throttle body
  • 90 Degree elbows welded on Air/Water Core
  • New Crossover piping (allows for Air/Air Core in series in the future-Track days perhaps)
  • PCV hardpipe to run across front of engine from catchcan
  • Airbox style intake idea was kyboshed... Now straight drop with 3.5" MAF integrated construction.
  • Ports on the intake are pointing in directions I would NEVER have imagined.  Will need 90 deg fittings (thanks Doug/Dungbeetle!!)
  • Cleaned out metal shaving from intake plumbing (glad I was coating the parts)
  • Sending parts to be powder coated.  Exhaust = Satin Silver Ceramic, Intake = Silver powder coating

 

June 25, 2007  Parts back from coating!  
  • Silver is different than the silver they did on my coolant pipe.  Maybe just the surface finish.  
  • Will likely have them redo the PCV pipe
  • Parts installed in car
  • Tried to use S4 injectors for break in (perfect sizing for 3.5" MAF.  No dice, wont fit  I didn't think they would but I was assured by some other parties they would.  Oh well back to plan A.

June 28, 2007  Prime the car for motor ignition

Blog 7- semi-big moment...
  • Pulled Fuel Pump Fuse
  • Pulled Spark Plugs
  • Cranked motor for 30 seconds to prime the system
  • Sounds normal (big sigh of relief since it has been almost 6 months since it was built)

July 8, 2007  American Le Mans @ Lime Rock Weekend

Blog #8- Everyone say a little prayer for me...
  • Work on 7/7/07 (was hoping to get lucky)

-Picked up 5 gallons of 93 octane
-Went to Autozone for $43 in "stuff"
-Finished installing and calibrating wideband Innovate LC-1 and gauge (in glovebox)
-Cleaned up Air/Water intercooler plumbing (hoses)
-Added a high level fill point to Air/Water
-Chopped off crossover pipe on passenger side with sawzall for more filter clearance.
-Notched frame for MAF sensor plug clearance
-Troubleshot the SPA boost gauge sensor fault (loose connection under dash)
-Installed injectors
-Primed motor again
-Installed spark plugs
-Installed coilpacks
-Ready to push car out of garage
Rained out...and have evening plans *sigh*

  • Mark P acted as a courier for injectors from Steve Gagne  (Thanks STEVE!)
  • Sunday = ALMS Weekend no worky on the car

July 10, 2007  Ordered Alternative Intake Pieces
  • Ordered hoses from Silicone Intakes.com (highly recommend them for service and price)
    • 3" 90 degree bend
    • 2.75"-3" Silicone Coupler (for running stock MAF )
    • 2.75"-3" 90 Degree Bend (turbo attachment)
    • Cheapo covered 3" Cone Filter
  • Ordered 3" pipe piece with 1" nipple from 666 Fab

July 14, 2007  Could it finally be that time...

Blog #9 The Beast LIVES!!!
  • Installed Donny Mak Original Stage 3+ ECU
  • Installed Stage 3 (orange top bosch) injectors -Porsche 944T injectors
  • Attempted to start car... wouldn't idle.  Checked codes Throttle body unplugged (oops)
  • Plugged in and we have ignition...The BEAST LIVES!

July 15, 2007  The break-in drive
  • Filled fluids and topped off.  
  • Conducted 40 mile break in drive.   less than ideal traffic, but what can you do.  Conducted a series of mid rpm accelerations and engine pull down sprints.

July 22, 2007  Waterfest Weekend
  • Been driving the car to work to continue the break-in, runs a bit rich at throttle.  Also runs out of MAP at high 5000 rpms
  • Trip to NJ shore and then Waterfest 13 @ Englishtown
  • Flashed ECU with standard Stage 3 code
  • Picked up APR R1 Diverter Valve

July 30, 2007  Reinstalled Turbo
  • Found I had an exhaust leak from the turbine housing (I left out a bolt oops)
  • Found intake hose to TB loose and possibly slightly disconnected.
  • Rerouted O2 Sensor Installation... read better when you have the front O2 sensor (brown) plugged in.
  • Reinstalled turbo with new hardware...Went for a spin and really romped on it   WOW!  It's like stage 3 all over again.  Full wastegate pressure (12ps)i at 4000rpms.  Boost starts building at 2400.   
  • The bad news I have an oil leak from the return line gasket *sigh*   Ordered parts from ATP

August 4, 2007  Running Well...
  • Installed new oil return gasket
  • Installed APR R1 DV, very smooth but because of BPV vs BOV functionality, it seems to delay boost onset by a little bit.  Will need to evaluate more.
  • Installed PCV return hose and T fitting (from B6) in preparation for emissions inspection

August 8, 2007 Fabrication
  • Created ICM mounting and heat shield

http://www.wseng.com/a4/pics/engine/motorsport/pics/eng-3.jpg

August 17, 2007  Passed Emissions
  • Yesterday 666Fabrication installed my rear O2 bung and sensor.   Drove home, cleared codes and ran readiness tests.
  • Passed CT emissions running APR Stage 3 Software.
  • Currently 70% complete with engine break in period (700+ miles to date on motor)

September 27th, 2007  Getting close
  • Completed 1000 miles of engine break-in
  • Compression (1-185 2-181 3-180 4-196) and Leakdown (1-100% 2-96% 3-95% 4-100%) tests complete.  Looking good!
  • Oil Leak Fixed 
  • Completed fabrication work (Small exhaust leak at weld, Cross over tube straightened, and exhaust hanger added).  Air/water radiator mounted

http://www.wseng.com/a4/pics/engine/motorsport/pics/fab_complete.jpg

  • Purchased and received a RS4 front bumper from Eric @ Supremepowerparts

Nov 2007-June 2009

Long story short….

  • Tuning
    • Contacted Tapp Auto for their AEB big turbo software and MAF setup
    • Tappauto AEB GT35 Tune
    • 1000cc Low Impedence Injectors
    • Mass Airflow Sensor SCT BA2600 with Cone Adapter
    • Best dyno 310whp @ 6000 rpms – 22 psi (rev limited to 6000) .  Still fun =)

..and then grad school
  • Troubleshooting rev issue in free time

Spring 2010
  • Fabricated Mount for Oil Filter Relocation Kit.  Perma-Cool Part # ____  ordered from Summit Racing
  • Purchased Maestro 7 Tuning Software

July, 2010
  • Pulled Motor for engine balance issue

October 3, 2010
  • Installed rebuilt motor. 
  • Engine work done by Bryan @ Center Machine Shop in Stratford, CT
  • Cams retimed

New parts added

  • Evolution Racewerks Competition FMIC (from Ringer-Racing.com)
    • Air/Water put into box for optional use.
  • Southbend Single Mass Flywheel with Stage 5 SS clutch.  Setup balanced prior to install.
  • Installed Al Honeycomb into MAF Inlet to help readings/idle.

<

2011-March 2012
  • Aug 23rd, 2011: Re-Registered car in CT.   Had expired due to lack of emissions in 2009.  Passed emissions with 2 readiness codes not able to be set.
  • Driving is greatly improved.  Maestro s/w released that works on smaller displays such as my netbook that made tuning easier.
  • Tried to get Dyno time at EPL.   Brushed off.
  • Decided to street tune:
    • Adjusted tuning down low to deal with a lean area of the curve around 3000 rpms.
    •  Logging showing no timing pull. 
    • Cranked boost up to max happy spot of 24-25psi.  (tried 25-27…need more eyes on air/fuel and gauges to determine parameters)
    • Redline increased to 7500rpms (starting to see signs of excessive PCV pressure)
  • Did some 40-100mph logs for performance comparisons.   Removes my wussy launching and granny 1-2 shift (but not my 2-3 or 3-4 )

Benchmark-2-2012.JPG

  • Replaced PCV valve (still signs of high PCV pressure at 7000+ rpms)
    • Time to add a vent/plumbing to valve cover. 
  • Installed remainder of black cloth Sport Interior that I purchased almost 7 years ago.  Goodbye grey seats

April 2012
  • New job in the “Kill-fun-ya” car state of California….  
  • Decisions
    • Keep car as dedicated track car or use in a kit car
    • Sell to a new owner…so it can live on
    • Part out

So what did this all take?  Well there were no Freebie values...

Engine and Parts Donor:

I had been looking around to all the usual sites to find a used motor that I could purchase.  All the ones I found were in the 1600 to 1800 dollar range.  I luckily had a friend refer me to a friend of his who had a client who had a son who ended up driving a Passat into a cable guard rail.   Did you follow that?  That wasn't a typo.  I had 4 degrees of separation in trying to seal the deal on picking up this wrecked Passat that still had a low mileage engine installed in it.  The car itself had 140,000 miles on it, but the engine had ~40k on it as it was replaced (I'm assuming after a timing belt failure).   It took until December for the deal to occur, but in the end I think it was worth it.  Besides the motor block, I was able to get replacement AC support brackets, power steering pump, and some other bits and pieces.  I also ended up selling and giving a lot of the parts away including:

Total cost  $1800 - $610 = $1190

Oh wait... I didn't need an AEB engine in the end....so $1190 for a new to me AEB Head, and core charge block.

Bill of Material/Ordered Parts:  (to be cleaned up and documented with parts in Log)

Engine Belts

Engine Cooling

Engine Exhaust

Engine Fueling

Engine Intake 

Stock MAF Intake for Break-in (Parts purchased from SiliconeIntakes.com)

Other intake

Engine Monitoring and Control

Turbo System

Driveline

Intercooler and Accessory Coolers

Other

Other Car Parts I Needed To Update:

Tools and Garage Upgrades:

Bling Materials and Custom Fabrication:

Total: