My JHM Stage 1 Install with some twists

B6/7 S4/RS4
#1

Hi Everyone,

Short intro, from South Africa, been an active reader on AR for a year or two, maybe three, and my 1st name is Rudi.

Now, I know that there have been a few RS4 Stage 1 Supercharger build threads over the past few years on AR but I figured given that mine is a RHD with a few things done differently compared to SAR’s in the UK it make sense to make another RHD built thread.

I started talking to JHM about 2 years back but only pulled the trigger late December 2015 and the package arrived in January 2016. I also included the JHM Oil Cooler line upgrade, the 3R Series lightweight flywheel and clutch and combo, 034 Engine, Torque and Transmission mounts.

To be honest, when all arrived and I started unpacking everything I was to say the least a bit overwhelmed when I realized that I somehow had to fit all those parts to the car. My initial plans were to outsource that to a shop to do the build for me but in the end decided against it and just knew that this was something I had to do myself.

Some history on the car, 2008 Misano Red with around 41k miles on the clock. Prior to the Stage 1 build I replaced all the control arms, Back & front rotors, brake pads and also installed a KW adjustable spring kit which allowed me to retain the DRC system. This was done in December 2014. During 2015 I re-covered the Recaro Buckets and did a few other small things. So basically the next logical step for me was to go the supercharger route as I have made the decision that the car is a keeper.

I also fitted 2.75" DP’s and exhaust and literally drove the car from the shop to my garage, parked it and the next day, March 27, the stripping started. I mainly worked over weekends and the install took me just about 4 months from start to finish. The installation has just been completed and the 1st start was about a week ago. So still have to sort out one or two small things with the AC re-gas one of the outstanding items.

I had the help of a buddy that came over to assist with the things where an extra pair of hands were needed but apart from that the rest was done by myself.

Also a big thank you to the guys at JHM, Jake & Dru which were extremely help-full through-out all of this.

So lets get the ball rolling and I will probably post the build over a few days, apologies in advance if I leave some things out or post things out of order etc. but give me a shout and I will try to fix.

Oh, by the way, the Clutch still needs to be done but I will need a shop to assist with that I just don’t have the facilities to do that at the house.

First things first, the package.

All neatly packed with plenty of protection.


http://i1175.photobucket.com/albums/r630/rudivn/JHM%20Stage%201/DSC02095_zpszbhyd4zl.jpg


http://i1175.photobucket.com/albums/r630/rudivn/JHM%20Stage%201/DSC02099_zpshpcbkm2w.jpg


http://i1175.photobucket.com/albums/r630/rudivn/JHM%20Stage%201/DSC02097_zpsng2ojsk9.jpg


http://i1175.photobucket.com/albums/r630/rudivn/JHM%20Stage%201/Charger%20Contents_zpsbpcm2rso.jpg

Stripping Commenced
Bumper was pulled off lights removed, so far so good no problem. Made a point to Bag & Tag every bolt.nut & screw I removed and that paid of big time when it came to assembly time.


http://i1175.photobucket.com/albums/r630/rudivn/JHM%20Stage%201/DSC02117_zpsiiyfamah.jpg

Next was Lock carrier removal and well, fluids were lost, she was bleeding different colors fluids from places I never new existed. :o Lesson learned, next time drain some of the stuff off beforehand and keep some containers handy.


http://i1175.photobucket.com/albums/r630/rudivn/JHM%20Stage%201/DSC02121_zpsae2eza9a.jpg

OEM pulley removed and ready for the new JHM lightweight one, what a huge different in weight. The new pulley was so light it didn’t even registered a reading on my scale. ;D


http://i1175.photobucket.com/albums/r630/rudivn/JHM%20Stage%201/DSC02134_zpsu5g3yvwl.jpg

Old pulley

http://i1175.photobucket.com/albums/r630/rudivn/JHM%20Stage%201/DSC02138_zpswgi9gipm.jpg

New Pulley

http://i1175.photobucket.com/albums/r630/rudivn/JHM%20Stage%201/DSC02139_zpsp13mexhw.jpg

And first of the new parts bolted to it’s new home.

http://i1175.photobucket.com/albums/r630/rudivn/JHM%20Stage%201/DSC02140_zpsvrkjkfa7.jpg

Next up was the new check valve install between the manifold and the oil seperator, figured that whilst I am busy let’s replace the PCV, what a ball ache, just couldn’t get that sucker off and had to pull the intake manifold which remind me, forgot to mentioned that I also had a CC done about 180 miles prior to the Stage 1 install.

Damn, almost midnight down here so it’s way past my bedtime, been a long day, will pick it up again tomorrow.

Goodnight everyone.

#2

Holy crap that motor is clean!!

#3

That’s what I am sayin!

#4

Haha first thing I thought as well, when I saw the photo’s.

#5

Great looking build. Nice clean motor sevearal of us here installed the same great JHM kit so if you need help let us know. Excited to watch this come together

#6

A red RS4 with only 41K on her…I just jizzed in my pants! Nice build thread

#7

made me want to take the front end off my car and clean it

#8

Guys, thanks for the replies and comment’s, much appreciated!

Where was I, Ok, the check Valve, well nothing new their you have all seen that before so that went on without any issues and as mentioned I installed a new PCV as well whilst the manifold was off.

Aaaarghhhh!!!, have to cut this short, work calls, will pick it up later again >:(

#9

guess you are friends with SAR now…since he was I believe the first to do a RHD stage 1 install. Any idea how he’s doing?

#10

Yes, we exchanged a few emails and he is doing well. Car is still running strong and is in the shop now for a full re-paint.

#11

With all the parts, SAI pump, Driver side RAD etc all removed I decided to tackle the motor and torque mounts and get that out of the way before doing anything else. Oh boy what a job! Torque mount is a breeze though. Engine mounts ain’t no fun when you have to do that lying on your back with limited space to move arms and hands.

Got that heavy lump supported

http://i1175.photobucket.com/albums/r630/rudivn/JHM%20Stage%201/DSC02151_zpsheinwqjw.jpg

New mounts in

http://i1175.photobucket.com/albums/r630/rudivn/JHM%20Stage%201/DSC02162_zps8mjjysnj.jpg

Torque Mount

http://i1175.photobucket.com/albums/r630/rudivn/JHM%20Stage%201/DSC02164_zpsrk4fin75.jpg

With those things out of the way it was time to start some, almost to scared to say it, hope no-one from that other Audi site see this, well, to do some cutting :o
Marked the area out and pulled the trust old grinder closer and did as instructed ;D

Cut out done!

http://i1175.photobucket.com/albums/r630/rudivn/JHM%20Stage%201/DSC02167_zpssbhbsf4l.jpg

Primed and Re-painted

http://i1175.photobucket.com/albums/r630/rudivn/JHM%20Stage%201/DSC02202_zpsbnvldrws.jpg

#12

With that done it was time start bolting on some new bits. Started with the biggest of the 3 pieces that make up the charger bracket. Quality is top notch and fitting was spot on every hole lined up perfectly.


http://i1175.photobucket.com/albums/r630/rudivn/JHM%20Stage%201/DSC02178_zpsp7sy6ese.jpg

All went well until this moment, and for lack of knowing any better thought I have been shipped a wrong bracket.

Where are the holes??

http://i1175.photobucket.com/albums/r630/rudivn/JHM%20Stage%201/DSC02180_zpshenuvxvr.jpg


http://i1175.photobucket.com/albums/r630/rudivn/JHM%20Stage%201/Bracket%20to%20Upper%20Oil%20Pan_zpskxinjnzt.jpg

Send a mail of to Jake who confirmed that they have seen a similiar case once before. I couldn’t find any explanation for it so off I went to get the correct size Drill & Tap to get those holes put back where they belong. Must admit I was shit scared drilling into that block. glad to report that all went well tapped the holes and I was back on track.

Tapped holes

http://i1175.photobucket.com/albums/r630/rudivn/JHM%20Stage%201/Missing%20Holes_zpskoslawns.png

With that out of the way I fitted the rest of the brackets pulleys and finally the blower.

Brackets on and torqued down.

http://i1175.photobucket.com/albums/r630/rudivn/JHM%20Stage%201/DSC02203_zpsz3glrq0m.jpg

Looking good!!

http://i1175.photobucket.com/albums/r630/rudivn/JHM%20Stage%201/DSC02208_zpsdk5quys0.jpg

#13

Next on the list was the AC dryer re-location. And this is where mine differs quite a bit from SAR’s. As we all know by now on the RHD cars we cannot move the Dryer under the right-side fender as per JHM’s instructions. SAR decided to move it to the left-side fender and in the process he also got rid of the front vacuum reservoir that is hosted there. I didn’t want to go that route for 2 reasons. Firstly I really didn’t like all that extra hoses that got added so that alone was enough reason for me too look at another solution and secondly all my flaps etc. was still working so i also didn’t want to fix something that ain’t broken.

I decided to look at the possibility to relocate the AC Dryer to behind the left-side Aux Rad and removed that to see whether that was a viable option. The new location would also mean a less and shorter hoses and that’s exactly what I was looking for. Once removed I took some measurements, hold the Dryer at different positions and I came to the conclusion that it might be possible.

RAD removed

http://i1175.photobucket.com/albums/r630/rudivn/JHM%20Stage%201/DSC02163_zpssdhjnsj6.jpg

Once I identified the new resting place for the dryer, and according to me there is only one place it can go, I sketched up a drawing of the new dryer bracket, transferred it to a thin flexible plate, which was then cut out and used as a mock up. That allowed me to bend and shaped it to fit its new resting place, mark and drilled out the holes and once happy with everything dropped it of at a shop who laser cut the new bracket for me. Finally got it powder coated and it was ready for fitment.

New Dryer Bracket

http://i1175.photobucket.com/albums/r630/rudivn/JHM%20Stage%201/DSC02285_zpsdadzckr2.jpg


http://i1175.photobucket.com/albums/r630/rudivn/JHM%20Stage%201/DSC02287_zpscbfhuxeg.jpg

Really worked out well as I could use existing OEM bolts and mounting points to secure the bracket, no drilling of new holes in the body or chassis was necessary.

New Bracket mounted

http://i1175.photobucket.com/albums/r630/rudivn/JHM%20Stage%201/DSC02293_zpsnxzigujq.jpg


http://i1175.photobucket.com/albums/r630/rudivn/JHM%20Stage%201/DSC02294_zpshouvoquv.jpg

Test Fitted Dryer

http://i1175.photobucket.com/albums/r630/rudivn/JHM%20Stage%201/DSC02295_zpsyomm2myw.jpg

New fittings Installed

http://i1175.photobucket.com/albums/r630/rudivn/JHM%20Stage%201/DSC02310_zpsutvvs0sx.jpg

#14

Time to get all the AC hoses mocked up so next on the list was something I was not looking forward too namely removing the big AC alu pipe running from the evaporator to the IN port on the AC Dryer. SAR went through the same ball ache and the amount of parts that needed to be removed is almost enough to consider diching the whole idea. Both ECU’s needed removal as well as the brake master cylinder. SAR removed the complete brake booster but after reading his write up I opted to pull just the master cylinder. Can’t really tell whether that’s easier, still a shitty job.

Pipe that need removal

http://i1175.photobucket.com/albums/r630/rudivn/JHM%20Stage%201/DSC02322_zpshqszvn9e.jpg

Master Cylinder removed

http://i1175.photobucket.com/albums/r630/rudivn/JHM%20Stage%201/DSC02324_zpsppgyxef6.jpg

Culprit finally out

http://i1175.photobucket.com/albums/r630/rudivn/JHM%20Stage%201/DSC02325_zpsv0r97czh.jpg

Having the hoses made up was quite a lengthy process and took about 5 - 6 trips to the shop to get all the lengths worked out and fittings crimped. With that sorted I could put everything back and get the hoses hooked up.


http://i1175.photobucket.com/albums/r630/rudivn/JHM%20Stage%201/DSC02350_zpsa5xkusgo.jpg

Left Side RAD re-installed, clearance to Dryer look good

http://i1175.photobucket.com/albums/r630/rudivn/JHM%20Stage%201/DSC02332_zpstpbrx01g.jpg

#15

With the AC finally sorted I turned to finishing up the rest of the install and got all the spider pipes fitted, plugs swapped out with the ones supplied by JHM, super charger belt installed which are all the same stuff as per all the other installs. With that all done lock carrier was installed and all the wire looms tidied up and zipped tied out of harms way. Next up was the new JHM oil cooler lines.

#16

Very cool! Thanks for the great pictures and step by step process. Best of luck on the rest of the install.

#17

Awesome work! Really enjoying the updates!

#18

Uau thats a lot of work! :clap::clap::clap::clap::clap::clap::clap:

#19

WOWWOW WOW wow WOW. Great work great updates and what a great job with the reciver dryer that looks really nice. This is a very fun read. Thanks for all the hard work to show just what your going through. Karma points for you Im very interested to hear whats next and excited to see you get this back on the road and hear your thoughts

#20

Thanks, much appreciated!

Thanks, I will try to keep them interesting!

Absolutely, but it will be worth it in the end.

Thank you sir, much appreciated, Yes, I am really happy with how the AC dryer turned out. That spot was made for it!