View Full Version : My B5 S4 Journey...
MiniMental
05-10-2017, 08:13 PM
I have one for my passat on UKP so figured I will do one for my S4 here also.
Car: 1999 S4 Avant in Ming Blue, 124k on the clock, good service history etc. Completely standard except 18” RS4 Alloys (Also have the Original S4 ones)
Know Faults:
1) Bodywork is tatty in places and needs tidying up/redoing particularly front and rear bumpers and tailgate. Shell/bonnet/doors is pretty much immaculate. Alloys also need a refurb due to curbing.
2) Rear suspension arms and both sub frames need a bit of love. Getting quite flaky in places
3) Front callipers (Lucas 4 pad system) are both missing the anti rattle springs, this is doing my head in and new ones seem tricky to source. I have found some £45ea from VW however.
4) Boot Load cover spring has gone so it’s all floppy and loose. Going to have a looksee..
5) Headlight washers don’t currently work, some people delete them, I want them working. Have traced this to the pump. Has voltage but isn’t spinning.
6) Suspect original Diverter valves are leaking, boost seems to disappear far to quickly when changing gear. I know that’s the idea but if you just lift off slightly it drops the boost until you hoon it again. They are the original plastic ones...
7) DID LCD in cluster is dead, I know these can be repaired so will removed cluster at some point and send it off.
8) Driver’s seat is rocking. Found guides cheap enough on eBay so will get that sorted.
9) Driver’s seat also has a split on the bolster where it’s worn through, needs repairing or replacing. Any suggestions?
Done so far:
A lot of history and receipts of stuff done over the last 8 years. Very good history and last owner of 8 years was an enthusiast.
Fixed detached rear washer pipe by glovebox
Fixed central locking in passenger door, deadlock bar had come off the cam in the rear of the key barrel.
I’ll keep updating this thread as I go. Any help or advice always appreciated, whilst no where near a novice, I’m new to owning petrol cars so will take some re-learning in places.
I’m going to colour code the car with Orange (FF6600), Callipers, all hoses, fog light surrounds, interior alu trim( wrapped so I dot ruin it) etc etc. I think orange will go nice with the navy blue colour of the car. Will start by getting callipers powder coated and rebuilding them with new seals etc.
Watch this space....Aidan
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54 Passat Wagon PD175
99’ Audi S4 Avant 2.7 QTO ;)
spartacus 68
05-10-2017, 08:57 PM
Worth replacing headlights with single unit with integrated indicator. Standard halogen 55w bulbs were shocking, regardless of upgraded bulbs. Did B5 S4 come with xenon headlights as option?
If you're getting bumpers and alloys resprayed, then look at rear window spoiler and get it painted at the same time. Doesn't look much but I think it makes a difference.
MiniMental
05-10-2017, 09:18 PM
Worth replacing headlights with single unit with integrated indicator. Standard halogen 55w bulbs were shocking, regardless of upgraded bulbs. Did B5 S4 come with xenon headlights as option?
If you're getting bumpers and alloys resprayed, then look at rear window spoiler and get it painted at the same time. Doesn't look much but I think it makes a difference.
I’ll bare that in mind, I may get tailgate done as well but was debating getting it all smoothed out properly and wrapped instead.
My Headlights are OEM Xenon so would rather not lose them, unless I can find some Xenon all in ones? Not sure if they exist... They are very bright, will get my drill and autoglym kit on them, then they’ll be good as new in no time.
54 Passat Wagon PD175
99’ Audi S4 Avant 2.7 QTO ;)
spartacus 68
06-10-2017, 11:51 PM
I’ll bare that in mind, I may get tailgate done as well but was debating getting it all smoothed out properly and wrapped instead.
My Headlights are OEM Xenon so would rather not lose them, unless I can find some Xenon all in ones? Not sure if they exist... They are very bright, will get my drill and autoglym kit on them, then they’ll be good as new in no time.
54 Passat Wagon PD175
99’ Audi S4 Avant 2.7 QTO ;)
Stick with them! Headlight lenses probably just need refreshed. Roof rails I'd go brushed aluminium, but hey that's just me! :cool:
MiniMental
07-10-2017, 12:01 AM
Stick with them! Headlight lenses probably just need refreshed. Roof rails I'd go brushed aluminium, but hey that's just me! :cool:
I actually thought about buying some new headlights and separating the lenses off them and swapping them.
54 Passat Wagon PD175
99’ Audi S4 Avant 2.7 QTO ;)
MiniMental
09-10-2017, 04:23 PM
Well, got the front bumper on properly. Was sagging by 1/2” at each wing. Jesus Christ those clips are hard to get in! Managed in the end though so front end looks straight now :) happy days!
Is this car a subframe off or engine out job to reach the turbos? Tried to find them but didn’t have much look lol.
54 Passat Wagon PD175
99’ Audi S4 Avant 2.7 QTO ;)
MiniMental
12-10-2017, 05:59 PM
Well, another job tackled and another one added to the list.
My new headlight washer pump came today. Easy to see why the old one was dead.... New one was £13 off eBay and took 2 days to come.
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So on with it, headlight out, also had to remove three bolts from the lock carrier so I could pull it forward. Just gave me enough room to squeeze pump out. Difficult with big hands haha.
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I then found that old pump had a flat male connector and new pump had a notch on it. So trusty Gerber soon sorted that out
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After:
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All fitted in nice :)
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And then onto the new job on the list....
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Found once they were working that the outside nozzle on passenger side has also split, I imagine due to frost, so I’ve ordered one, again from eBay, (a German one) which set me back £18 inc postage :)
That’s it for now. Also can’t get the load cover out. The release button has broken inside.. when I get a new one I’ll cut it out I think. Haha.
I have also found some brake rattle springs for the front callipers! VW told me there were 4 left in their database at a grand old price of £45+vat each!! (I need two)...ECS tuning is about the same with import costs so I did some research.... turns out RockAuto (www.rockauto.com) have them. I have ordered a set which were £9.50 for BOTH springs and £25 priority shipping as I’m not waiting four weeks... still cheaper than one spring from here.
Result!
54 Passat Wagon PD175
99’ Audi S4 Avant 2.7 QTO ;)
spartacus 68
15-10-2017, 08:07 AM
Good job. One we get into cold temperature territory keep the screen wash additive topped up with additive to avoid a repeat. Haven't had a bad winter as such for about 5 years or so.
MiniMental
15-10-2017, 02:32 PM
Good job. One we get into cold temperature territory keep the screen wash additive topped up with additive to avoid a repeat. Haven't had a bad winter as such for about 5 years or so.
Cheers. Yeah I will be doing. Was hoping new washer unit would turn up yesterday but no dice. Will be tomorrow now....
My anti rattle springs didn’t fit... evidently it seems my Caliper doesn’t take them. I’m going to put the spare set of discs and pads on today and see if that helps as the spare set are Brembo and have soft backs on all the pads etc where the fitted ones don’t.
My Older HP2 Caliper
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Newer HP2 Caliper meant for the springs
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I’ve got a shot at a B6 S4 front upgrade if I can find some funds... 345mm Discs, calipers, pads etc and I’ll be looking to do the 300x22mm rear upgrade before Xmas as well if all goes to plan.
Cheers
Aidan
54 Passat Wagon PD175
99’ Audi S4 Avant 2.7 QTO ;)
MiniMental
17-10-2017, 07:43 PM
Done some more tinkering over the last couple of days,
My shiny new washer unit turned up,
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So I changed that yesterday, what a PITA that was, lost my temper a bit trying to get tee piece out of hoses...
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Other than that it wasn’t difficult to change really, I will say a flexible 1/4 drive extension is a must, bumper bolt also needs removing so you can slide it forward 5mm for wiggle room to get the unit out.
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Fortunately, being an Avid fish tank reefer guy I happened to have SS jubilees and a few 3/8” tee pieces lying around so managed to get it sorted there and then. System is now all working with no leaks just as it should be. Happy days.
Today, I did some more investigating as I’m sure I have a boost leak, tightened up all the from boost hose connections I could reach, some were quite loose actually, haven’t found a way to reach the two short outlet hoses off the turbos as it started raining. Think I still have. Small leak, watch this space..
I also investigated a smoking LHS exhaust manifold and found a small leak from LHS rocker cover and maybe one of the caps...
Along with this I suspect I have a leaky sump gasket so I’m intending to get a full kit for valve covers, camshaft caps/seals, chain tensioner seals etc to try and rectify this when I do it’s 5k mike oil service at the end of the month. Sump looks straightforward to drop with minimal messing about so may as well. I’m not sure if the sump leak is oil running down the block from the covers.... Good news is, oil still looks new, nice and gold, either way, I’ve vowed to change it every 5k miles/12mnth and that’s what I will be doing regardless.
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My two babies all dirty from the sandy storm weather yesterday....
I do love how easy the S4 is to take apart. No rust anywhere, everything Anti-seized with silver anti-sieze. It’s a beautiful thing to work on a car this old that’s obviously been treat right. Wholly different experience to my Passat.
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Aidan
54 Passat Wagon PD175
99’ Audi S4 Avant 2.7 QTO [emoji6]
MiniMental
27-10-2022, 12:31 PM
I do still have this. It gets better all the time.
Major differences/work since last post all them years ago:
- Serviced a few times
- Timing Belt, WP & TStat done along with a full head reseal on both banks
- Full Decat, 3” Downpipes into 2.5” Non-Resonated dual system (basically straightpiped) fitted.
- Bilstein B12 Full suspension kit fitted
- Facelift brakes fitted front & rear
- Wheels refurbed and lots of bodywork done
- Full Ivory Recaro Electric interior fitted which took my a long time to find and is going for reconditioning in the new year
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Scott K
02-11-2022, 12:15 PM
That looks great. Just need the armrest covered.
MiniMental
03-11-2022, 11:48 AM
That looks great. Just need the armrest covered.
It’s on my list. I’ve got a quote to have the entire interior reconditioned next year including the arm rest recovered and the seats re panelled and properly matched where the leathers cracking/flaking.
Will be superb when done [emoji41][emoji41]
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MiniMental
03-02-2023, 09:40 PM
Well, been a while since I posted so figured I’d stick up what I been on with. It all started with a cracked wheel, MOT Expiration and realising I needed front pads…
Lurched spontaneously into a brake upgrade this week, sourcing parts from all over Europe it seem haha and figured today I would do a quick first test fit since I’d rather do it now than scratch the calipers once they’ve been refurbed and PC’d.
Decided I’m going Signal Orange with Purple Brembo logos and Purple brake hoses front & back [emoji108] Also have a 300x22 rear conversion coming.
Got the ML55 disc centres bored out last night to 68mm which now fit perfectly.
Retaining my current 3mm spacer they fit with about a rizla thickness of clearance. Think I’ll go back to the 6mm I use when I put new pads in the stock brakes. Or maybe a 5mm.
Problem is I’ve never seen hubcentric spacers that thin. Not that I’ve ever had an issue in 5 years of using them. So will have to do until I sort some new wheels out in summer.
But other than that, they fit and look stupendous [emoji1787][emoji1787] I know plenty run them on these cars but it’s a learning curve for me.
Absolutely love it. Gonna look superb and hopefully brake superbly too [emoji123][emoji123][emoji123]
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MiniMental
20-02-2023, 08:25 PM
Good progress [emoji2956].
Had the calipers powdercoated and rebuilt them myself. Ordered all the parts over the last month or so and finally ready to fit them this morning.
So..https://uploads.tapatalk-cdn.com/20230220/52d6b288835bcb5bb97843024186d1d5.jpg
All four corners stripped, any steelwork I can reach cleaned up a little and overpainted. Should help keep it tidy till I get around to doing it properly.
New brakes all fitted up, just a few niggly bits left to do and the hydraulics tomorrow.
Weirdly, the caliper bolts for the passenger side are about 1mm too long and catching the disc. Can’t decide whether to grind a bit off the end of them or get some 16mm washers to go on them.
Other than that all fitted up and looking superb IMO.
All the brake pipes have cracked off the original hoses bar the front right so will sort that tomorrow hopefully, then I can install the new braided lines on all four corners and bleed the entire system through with shiny new fluid [emoji108][emoji108]
No other niggles at all. It all fit straight on [emoji41][emoji108]. Proof that planning it out works.
Many thanks to MTEC Brakes for quick custom machining of rear discs. They arrived just after lunch [emoji123] and major thanks to Jake at helperformance.com for correcting my rear lines and posting them back out with no extra charges! What a superb company.
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MiniMental
21-02-2023, 11:20 PM
Hoses done and its all mostly bled. Bit of an incident blowing the damn fluid res to bits [emoji849]. Second one I’ve done on this car now [emoji2357] Oh well, another on order for tomorrow.
Anyways, lines all on and have brakes on the pedal. Little bit springy but I’ll finish bleeding tomorrow morning while the tyres are getting fitted [emoji2]
No brackets anymore so good old cable ties to the rescue along with a little solution to protect the hose [emoji851]
Then just a service and a wash!
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MiniMental
22-02-2023, 10:37 PM
Well, didn’t wanna be busy on the born on day, but wasn’t left with much of a choice.
It’s now done. [emoji108]
Service done, found oil cooler nut was loose so hoping that has cured at least one leak [emoji1787]
Wheels and car cleaned, new brake fluid res installed along with four new tyres.
Brakes tested. Yes. It stops. [emoji1787] [emoji15] Hopefully it’s a little less aggressive once the coating has worn off the discs. Should be fine haha.
Finally ready for its mot.
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MiniMental
23-02-2023, 10:12 PM
Clean sheet for another year [emoji3526] Christ I love this car. I’ve missed driving it so much!
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MiniMental
02-03-2023, 09:27 PM
Finally got round to washing it [emoji18]
All clean. I love this car.
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MiniMental
25-04-2023, 07:41 PM
Well,
First show of the year was this month and it was superb! Managed to get the B5 numbers up a little also.
I think this is the best “Julie” has ever looked to date
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MiniMental
15-06-2023, 09:16 AM
Been a busy month this far. But a productive one.
Front bumper and tailgate have been off for paint, and I’ve put a much better condition bonnet on.
AC Dryer replaced
AC Clutch Replaced
AC Pressure Switch Replaced
AC Orifice Valve replaced
Radiator replaced & coolant flushed & vac filled
Left top front arm replaced
Alternator fully rebuilt
Tensioner pulley replaced
Serpentine belt replaced
Badges are off for a spruce up
Just need to finish buffing the paint and get the aircon pressure tested and recharged and hopefully we’re all good for the summer and Vorsprung International [emoji123][emoji123]
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Crasher
15-06-2023, 01:35 PM
The paint looks lovely, we have a 94 S2 in at the moment and a pervious owner owned a body shop, he must have spent hundreds of hours blocking and buffing, utterly flawless
MiniMental
16-06-2023, 11:36 AM
The paint looks lovely, we have a 94 S2 in at the moment and a pervious owner owned a body shop, he must have spent hundreds of hours blocking and buffing, utterly flawless
Ta bud. It’s getting better all the time. Not my doing though, I have a good mate near me who’s been sorting my bodywork for me over time. He also has a Ming Blau B5 Avant. 2.8 Supercharged. 1 of 2 in the U.K. that we know of.
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An S2 I do love. With the price of them I’ll never own one unfortunately though.
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MiniMental
07-07-2023, 08:04 PM
Panels all back on and just about finished, few niggles need sorting but nothing major.
Badges have been “revamped” to match my colour scheme/callipers as they were very tatty..
Aircon has died again, suspected evaporator failure. Knew I shoulda changed it when I did the heater matrix back in 2020 but hindsight’s a bitch I guess. I’ll change it after Vorsprung.
Just niggly bits and a damn thorough clean required top to bottom, outside & in now.
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FrenchAudi
08-07-2023, 08:48 AM
My aircon didn't work properly when I bought the car, and the evaporator burst at quite a low pressure when I was testing the system some time ago.
We drove for years in much hotter countries than this without aircon, so it doesn't bother us too much, but I bought a new evaporator with the best intentions, which is still on a shelf with a gearbox filter kit.
How long did it take you to take out the heater/aircon assembly? I don't suppose there's much difference between LHD and RHD.
MiniMental
08-07-2023, 03:56 PM
My aircon didn't work properly when I bought the car, and the evaporator burst at quite a low pressure when I was testing the system some time ago.
We drove for years in much hotter countries than this without aircon, so it doesn't bother us too much, but I bought a new evaporator with the best intentions, which is still on a shelf with a gearbox filter kit.
How long did it take you to take out the heater/aircon assembly? I don't suppose there's much difference between LHD and RHD.
From memory it took around 90mins until I had the heater matrix out and on the floor. Then another 4hours or so to reassemble.
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FrenchAudi
08-07-2023, 04:50 PM
Thanks. I'll think about doing the job:o
FrenchAudi
08-07-2023, 04:55 PM
BTW, I grew up in Barrow until about 1948, and after wandering the World, moved to my father's village near Devoizes in 1969.
MiniMental
22-07-2023, 01:14 PM
Well,
That’s phase 2 of paint done.
Have to say a massive Thank you to James Barnes for doing the work, especially the challenges that appears along the way.
Thank you mate. I owe you big time.
Jules is lookin better than she’s ever looked in my 6yr ownership and I’m ecstatic. [emoji41][emoji108]
Can have a rest from it for now and look forward to fixing the Last bits when show season has ended along with aircon repairs round 2.
Front Bumper [emoji736]
Tailgate [emoji736]
Rear bumper [emoji736] (Phase 1 in 2020)
Replacement better condition bonnet [emoji736]https://uploads.tapatalk-cdn.com/20230722/9b25a76991f4de9c8be4a4b22aab61bd.jpg
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