With the B6 S4 hitting its 10th birthday and the countless posts on motor issues, failures, scored cylinder walls, warped blocks and just plain high mileage. It’s good to know there is an option. If you have been in the B6 or B7 S4 world, you know the complexity of these motors and that you can’t rebuild them like a standard motor.
If the 4.2 S4 blocks being aluminum wasn’t a big enough issue, the paper thin walls are. Much unlike a standard motor, you can’t just bore the cylinders as there isn’t enough wall thickness and if that wasn’t enough the walls are aluminum, they require a much different hone process then standard blocks.
Here is the good news. I thought I would post a few pictures of what you can do about it. JHM has a solution.
http://jhmotorsports.com/RandD/B6S4/sleeved_motors/JHM_Sleeved_B6-B7_S4_Short_Block-Closeup.jpg
http://jhmotorsports.com/RandD/B6S4/sleeved_motors/JHM_Sleeved_B6-B7_S4_Block_Top.jpg
http://jhmotorsports.com/RandD/B6S4/sleeved_motors/JHM_Sleeved_B6-B7_S4_Block_Bottom.jpg