Intro and RS4 w/ Carbon Clean

B6/7 S4/RS4
#1

Hi Everyone,

I figured I should do a quick introduction since I didn’t in my last post. I have been a long time car nut, be it from playing with Hotwheels to picking up my first project car, my senior design project, known as FSAE, my Audi(s), or helping friends with their cars, I’m daily wrapped in cars. If any of you are familiar with FSAE, you will know that I’m a mechanical engineer, a fresh one at that since I just graduated in May and am now pursuing my masters. Now back to the cars. The first car I picked up was a Datsun 260z with the intent of swapping a skyline motor into, a RB25det to be exact. I’m still working on the car, but college and Audi’s have slowed progress down. I bought a 2004 s4 back in 2013, as some of you know, it recently went to the grave yard. Hopefully someone was able to pick it up for a good price and put that motor back into another car. I now recently own an RS4 and last week did a carbon clean on it, so I will go over that later on too.

Here is a picture of the Datsun as it sits. It doesn’t look to crazy from the out side, but is a little different under the hood.

http://drive.google.com/uc?export=view&id=0B0yQvTxhcHpYNFVFYXI0UU5uNzFDNDJqYXNDOVpPZVBfQy1Z

Here is the engine that I put in it, don’t worry this is just the beginning.

http://drive.google.com/uc?export=view&id=0B0yQvTxhcHpYUmZBUC1Mc0p2T3FUSVJ0QUNrRTRFaE5tTmZV

The next car project that I was majorly involved in was FSAE, this is a undergraduate program for engineers where we get to design, build, test, and race a car. It is an extremely fast pace program at my school where we have 1 1/2 years to do all of the above. I was personally responsible for the engine team, where we got to make a custom exhaust, intake, cam sensor, do all of the tuning, basically everything besides build the engine block and turbo. We ended up turbocharging a 2014 KTM 450sxf engine, unfortunately, I couldn’t say how much power it made, but it was around 70hp, mind you this was with a 20mm restrictor before the turbo. All in all it was a fun project, and I learned a lot from it. Below is a photo of the racecar.

http://drive.google.com/uc?export=view&id=0B0yQvTxhcHpYd2U3RmpZYlB5NTg

The RS4. This is, in my opinion, the pinnacle of the of the Audi 4’s. Mine is a little higher in mileage around 100k, but still drives great, and even better now that I did the carbon clean and a couple of other things here and there. The car has the alcon/stasis BBK with the Mono 6 pots. It is also sitting on stasis CO’s. I’m not sure of the exact type, I believe there were a couple different coilovers they sold for the car, correct me if I’m wrong. I haven’t put the car in the air to see what it has. I will let the pictures speak. For those that are curious as to how I did the cleaning, I used brake cleaner, a brush, and a cheap harbor fright media hopper with fine walnut media to clean the ports.

Before:

http://drive.google.com/uc?export=view&id=0B0yQvTxhcHpYRDQ5amEyY2N1YU0

After:

http://drive.google.com/uc?export=view&id=0B0yQvTxhcHpYUVN3N2ptUGMtLTA

And a little sugar on top or should I say bottom:

http://drive.google.com/uc?export=view&id=0B0yQvTxhcHpYVlVlcWpkUXhpNnM

I also installed some JHM spacers while I was in there. I pulled some data, from before I did the clean, but I need to go pull some now that I have cleaned the intake. I will post a comparison once I get some time.

For the bad. When I had the intake off, I also changed out the sensors for the flap position. I know keep getting a EPC, and MIL, because of the flap positions. I have been looking around in VCDS to see if there is a way to calibrate the sensors. I’m sure the values that they are sending the computer is different than what the other sensors where sending, so it seams like this would affect the ECU. Does anyone know if there is way to correct for this? Could I have installed the sensor wrong? It seems kind of hard to install it wrong though. Any input on this would be appreciated.

This is just the start of this car. I have a lot planned for it and will try and keep you guys updated with things I do to it. It is hard since I’m working full time and doing graduate school full time though.

#2

The rs4 is a great car. You already had a 4.2 so you know the wonders of the V8 and with the extra RPM it really helps make the car a hole new animal.

the carbon didnt look to bad but you did a nice job cleaning it. The heat reflecting tape looks nice to you really took your time with that. There has been a lot of good sharded data from the gains with the JHM spacers its always interesting to see how much each car has picked up with the addition of them. From your other posts your no stranger to JHM so you already know there is a nice line of parts for the RS4 that JHM makes.

Post the codes your getting for the intake flap sensor. That should have some good information to let you know what is the next best direction for how to fix it.

You can do an output test to see if the flaps move. This should help give you some idea on if everything is functioning properly.

#3

Thanks Justincredible. I took a while to clean the intake and apply all the heat reflective tape.

The only code that I’m getting currently is:

Address 7E8: 1 Fault Found:
P2015 - Intake Manifold Flap Position Sensor (Bank 1): Implausible Signal

When I do an output test I can see both actuators moving, so I’m lead to belive that it has something to do with the sensor, I’m not sure if I have it rotated wrong, which could be a possibility, but the bently manual doesn’t say anything in specific about how to install the sensor. Correct me if I’m wrong by bank 1 is the passenger side and bank 2 is the driver side, or do I have that flipped.

#4

I cant see that you would have it installed wrong that should be obvious. As for bank one yes that is on the driver side. The range fault is a tough fault due to the fact that something could be wrong or not moving properly.

#5

JI,

Since I was only getting the code for bank one put the front clip into service position and pulled the sensor off. I decide to compare the old sensors that I had to the new one. To do so i checked the resistivity between pin one and three, which from the manual are the 5v and ground. I placed all the sensors so they were fully rotated to one direction. When I measured the old sensors I got around 200 ohms for both of them. When I measured the new sensor I got a reading of around 400 Ohms. I then put an old sensor back on and so far this week I have yet to have any codes come up. When I had the other sensor on the code would come back within an hour of me clearing the code. So at the moment I am pretty sure that it was a faulty sensor that I got. Thanks again for your input. I will keep you guys updated with anything else that I do with the car. It will most likely be injectors like you mention earlier. When I change my plugs out there was some whiting on some of the plugs, so i would not be surprised if they are not flowing to well.

Regards

#6

That can be such a huge pain when you get new electronic units and they are bad. That can really cause more issues and delay getting the car up and running. Great job troubble shooting this and getting the car up and running again.