04 Audi S4... going 4g and rwd...

[BoostforBreakfast]

My name's Matt. Here is the story of my S4:
Bought it in 2010 from a guy in SLC without seeing it personally after test driving a similar s4 locally. Awesome car. supreme handling, stunning interior, smooth pulling 4.2L v8, gotta love the 6speed paddle shift awd!. Flew to SLC and picked it up. It was everything I expected and more.... for the first month.... Then a timing chain tension took a crap...
Oh, did I mention that the timing chains are on the BACK of the engine? Audi has 4 or 5 different 4.2 designs and they designed this one to be stuffed into where a 1.8/2.0 4cyl or a 2.7 v6 is supposed to go.
I bought this car to NOT work on... it was to be my daily (well, my wife's while I was away on hitch) while I got my and my wifes many other projects together. So I was pissed and let it sit in the driveway for almost 6 months before taking it to a supposedly good shop to fix it (as I didnt want to deal with it). It still had the temp tags on it!
So it sits as this shop half torn apart for almost 4 months while the mechanic messed around with it. Long story short and $4k later, I get the car back misfiring and barely running and while I was away my wife takes it to her uncle's house (who is a head mechanic for Peterbilt) and he gets it running before I get back from hitch... for free. Awesome guy. I get the car back a week before my wedding. My wife and I take it to our wedding. so far, so good... we get back home and a week later the car dies in the middle of the damn road on the 4th of july. THAT WAS THE LAST STRAW. Turns out to be a fried ECU, but I already made up my mind.... OUT WITH THE DAMN 4.2!! I pulled it out and sold and so the car has sat in my driveway for almost a year....

As I can never make up my mind, my plans have gone from a twin turbo destroked 6.0 Lq9 (not enough room), to a high compression ls7/t56, to a 2jz/4l80e rwd combo... Well I just picked up a 1g TSi with electrical problems for damn near nothing and was looking around on the forums and now have decided to yank the 6bolt (probably build it) and toss a 4l80e behind it, and throw that in the S4....

I'll get pics up tomorrow of what I'm dealing with.

 

[Bud92gsx]

Subscribed.I want to see this when done.

 

[BoostforBreakfast]

Ok, so now some pics:
The S4 when I got her

and now out with the crap 4.2!!!

Gone!

The wife wishing it a fond farewell in the back of the z71....

at the new house

looking so lonely

The 1g sitting in the backyard with its yardmates

I'll start ording parts on friday.

Oh, And my wife keeps reminding me of the weight of the s4 (and she had her heart set on a 800+whp 2jz set-up) so I guess I'm going to fully build it.
Plans:
Stock stroke 6bolt
Probably Manley 300m Rods
9:1 JE pistons
Probably send the head to All Motor Mike to get heavily worked
Dont know on cams yet
I'm liking the Hx52 for a turbo (I used to run one as a single on my diesel)
FIC 2150's
Bills 4g to Chevy trans adapter kit
4500-5000 stall converter
rwd 4l80e w/ shift kit and controller
On e85
I would like to run an AEM EMS so I can integrate an Ethanol sensor so I can run on 91 if need be without busting out the laptop

 

[Bud92gsx]

What turbos are on the v8 are they ko4s

 

[DSMnoobsause]

They were non turbo.

 

[BoostforBreakfast]

the v8 was N/A. The B5 S4 had the 2.7v6 with the twin Ko3's (iirc). The B6 S4 went to a 40valve 4.2l v8 with 340hp. The Twin turbo 4.2l came in the 03-04 (iirc) RS6's

 

[ThunderChild]

Ms3 has fuel and boost table blending

 

[BoostforBreakfast]

ms3 is an option. I've dealt with both MS and the EMS. I will have my hands full integrating everything as I would still like the factory gauges to work along with a/c, ps, etc. The Audi's body computer can be accessed via VAG Com (yea... make the jokes now, ), so this will be interesting

 

[BoostforBreakfast]

I was actually looking a b5 s4 before this one.. (I should have got it). A few people have swapped the 2.7tt into the B6 s4 chassis with great success, but I like to do something different and off the wall. The S4's suspension and steering is absolutely beautiful.... but they need to get their priorities together with their electical system and simplify their engine designs.

here is a pic I found of the BACK of the S4 4.2

 

[ceedawg]

I was actually looking a b5 s4 before this one.. (I should have got it). A few people have swapped the 2.7tt into the B6 s4 chassis with great success, but I like to do something different and off the wall. The S4's suspension and steering is absolutely beautiful.... but they need to get their priorities together with their electical system and simplify their engine designs.

here is a pic I found of the BACK of the S4 4.2

Jesus look at that timing chainWTF Looks like four chains there I'd say. Wow! Glad my MB is not like that. However im sure the Audi gods are screaming there heads off about this swap! Looking forward to seeing this build. Think I would have gone 2jz with her though because its a heavy car. This should be a blast though.

 

[91stocker]

Not enough room for an ls even with the false fire wall removed eh?

 

[BoostforBreakfast]

I could fit an LS, but It would be a nightmare to run twins( or even a single) with p/s and a/c and a full exhaust. I have a 94' Lincoln Mark 8 that will get a built TT LS when I'm done with this. Mustang to lsx mounts and bam!
My wife will probably end up DDing the audi when I'm done and we will take it on trips to colorado so I would like all the creature comforts of having an audi

 

[91stocker]

I hear that, but a heads/cam ls1/ls2 will make 500whp n/a. Hell heads/cam ls7 will make 650whp n/a. How much power you looking to make with a 4g that will be dd'd?

Sorry, you can delete this if its cluttering up your build thread.

 

[KAOI]

I was actually looking a b5 s4 before this one.. (I should have got it). A few people have swapped the 2.7tt into the B6 s4 chassis with great success, but I like to do something different and off the wall. The S4's suspension and steering is absolutely beautiful.... but they need to get their priorities together with their electical system and simplify their engine designs.

here is a pic I found of the BACK of the S4 4.2

Jesus christ. DSM guys complain about timing jobs with our engines.... imagine doing this....

 

[horizontalkev]

Suddenly DSMs seem like simple to work on cars

 

[teejayDSM]

Why get rid of AWD though? With as much as trans/rear would cost it would probably be the same as getting adapter/flexplate made up. Plus I'm sure the car has sensors for the drivetrain, would be easier to keep gauges and such stock.

 

[Alex7747]

Im a BMW guy and my brothers an AUDI guy. I can't wait to show him this build he's going to be like WTF.

Nice build, can't wait to see this finished

 

[sheffester]

I have done timing chains on a 4.2 s4 when i was at audi. They arent bad once you get them apart. The 4.2 non fsi is a dog of a motor, so the 4g will be much better. Lighter motor too.

 

[Doubleot]

Like it! Keep us updated!

 

[BoostforBreakfast]

I'm looking for around 450 whp on 91 and 650+whp on e85. As far as the keeping the AWD, I may in the future go back to AWD as I still have the stock 6spd Tiptronic paddle shift auto in my garage. But the ECU controls the transmission.... and it will go ape shit without an audi engine... not to mention I'll be replacing the factory drive by wire. I will use the factory rear end as I want to keep the nice, smooth ride. a used 4l80e can be had for less than $600 and I'll just rebuild it (guys are running 4l80e's with a simple shift kit at over 700whp with no issues). As far as like a cammed Ls2 or Lq9.... I like boost..... and adjustability.

 

[BoostforBreakfast]

sorry, havent updated this in a while:
Got a good deal on a fully built 2.3 stroker to fit in the audi and get all the kinks out while I build the 2.0.
Engine Specs:
8.3:1 wisecos
Eagle rods
4g64 crank
H11 headstuds
Fully ported 1g head
Si +1mm valves
Si dual valve springs
Kelford 280 cams
HKS cam gears
5 angle valve job.

Engine already dyno'd 703awhp with a hta3794. I also got my Bill hincher 4g63-to-sbc adapter plates. Also ordered R&R pro aluminum rods for the 2.0L. Looking around for a good th400 or 4l80e right now. Will be running an s366 at first

I'll get pics tomorrow

 

[luisgil]

Can't wait to see pics of the 4g63 inside that engine bay.

 

[GofaST4life]

Wow! This is interesting.

Pictures!

 

[CrackedDSM]

You really should post this on the Audi forums. I remember a solid 4+ years ago someone 4G63 swapped a 1.8t A4 and they completely lost their shit over it. If you were to post that you were 4G63 swapping an S4 I think their heads would collectively explode.

 

[BoostforBreakfast]

Ok, here are a couple pics I have right now:

And I picked this up for the wife: