Audi S4  RS4 Conversion  DIY

99 00 01 S4  01.5   

The car is basicaly an A4 and like any German Car options cost extra so check vin numbers to see what was bought with the car at time of purchase.  I did not get the gps or the 18's but I did get a Lowjack which is allways good for Insurance and Loan Issues. Amazing thing about the Audi S4 is it has Side curtain airbags so it wraps around you.  Insurance companys dont figure the car for  Premiums  as much as the saftey.  It cost less to replace the car then the on going medical bills. So insurance is tolarable.  I did get Snow Tires   There is a special eddition with 2 tone leather.  Try to find one with low miles If you find one modded just check for recent work.  Mine was modded when I purchaced it had Bipipe, Chip, Diverters, Done at a speed shop, it had 40,000 and was in the garage when I got it.  Check paint at different angles and your good to go.   Engine noise is not  much 30 valves can make some noise but normal. Make sure you have your splash gaurds under the car Mechanics love to forget to put these back on (there are two).   Turbos Go if you dont Let them COOL.  Timing belt needs to be done when you buy it unless just replaced.  Rack and pinions go and I would buy one just to keep if you are planing to mod and do a lot of Drifting.  Along with Axles boots.   There are two models for the Rack and Pinion and Goes by VIN Number so 2001.5 is the cutoff for that.    But other than that really you can depend on The S4, and if you  drive propely these would not be Issues.  The car is fairly old now so add on parts are now tremendous.  Try to by  German Parts.    

Stages

Stages are up to what you want out of the car.   There are many options now for the S4.   You can take a S4 and convert it to a Rs4   Which is the Euro Version.  I recomend to do as much as you can at once. Look for Rs4 Parts.  For Example what they put on the Rs4.  Find the part number and install.   If you have K03 then tune the K03.  I have a tuned K03 car that is very fast.   Looking to do a 1000 hp Swap But tourqe rating are only slightly higer than my KO3 car so I am hesitant.  Torque will win a race HP only wins Bragging Rights.    

Tires and Wheels

Wheels need to be light for less upsprung weight. Diameter for Speed and Acceleration need to be 18 or larger For this year 19 are max for the Setup.  Tires need to have  a high speed rating, look at the conversion try to stay with stock sizes only going up in diameter.  Eg 16 to 18 ect.  Check the TireRack.com to see what size that year for width and profile and then look at the compound needs to be soft low number for Gripping.  Check tread design for road friction drifting tires for drifting Ect.  Check Side wall for Curb Protection.   Remember You Can lower your Car by tire Size and Profile with out changing the Suspention Travel.  Just the Ride Height.  

Old tires have been contoured to the Car they were on.  Tire pull can seem like an Alignment Issue.  Belive it or not you can reduce you times by changing tires and compounds.   So looks and performance are key.  But buy OEM or OEM style wheels they will hold the extra power.  Dont want to spin you wheels out of the rims and the car fall down!! .     Snow Tires need to be narrow dont buy a set that is wide. On ice narrow tires bite with the mass on a smaller surface area.  Therefore more grip.  I have been on complete Ice and stopped without a problem.

Suspension

There are alot of lowering Stiffining Options.  The best would be to Lower ride height and just stiffen.  H&R make a good front and rear Sway bar.  (Recomended is to stiffen the front only if not lowered)  Stiffens up the chasis and is a good modification.  If you want to change or be in control of your System there are Lowering Springs Coil Over Setups that Are Adjustable.  I think this affects alignment and will wear you tires out fast unless you use  a Shim Kit and Adjustable Control Arms.     Toe Camber Caster numbers are avalible, and S4 has a negetive camber from factory.  If you get Alinghened Make sure that you have a full tank of Gas and nothing in it.  Gas tank is on passengers side and weight needs to be accounted for.   Make sure they Joust (Pulling Car down in front) the Car well, and tires are even.  It will affect a 180 mph Car     Also avalible  are Strut mount bars, there are many and And with that is The Drive Train Stabilizer Bar witch will stiffen up the Trans components.  A must for Modded S4. They make front end kits which are nice I did mine when I replace my Rack and Pinon.  

ENGINE

There are differences like I said From the RS4.  With out a tear down, we have to watch how you lighten the Components To light is not Good.  A Light Spining mass Spining A Hevier Spinning Mass Cause an Unbalance. So becarfull how light you go and if you go light you Have to Go All Light weight.  There are Light weight pulleys, Light weight Pistons, Vavles and Crank.   This Engine is virtually bullet proof meaning it can take modifications, and be taken to the Track with out doing much. Timing kit is avalible on Only Buy German Parts  and is Recomended 65k 90k.  I would change when ASAP, or when you change the Intercoolers.  There is  a timing tool avalible.  Getting new Ignignitoin parts will allways be helpful on any application. New Coil packs Wires and Plugs Will tune up the 2.7 nicely.  Change Diverter Valves,and BiPipe Silicone intercooler hoses are avalible.  Again you get what you pay for so you need to cut the flashing Inside.

Intake

 You can make your own darin intake which is just a Cone air filter in the stock Air box.  You take a hole saw make some hole in the bottom attach a 35 degree bent short peice of Aluminum pipe and conect the air filter.  This is  diy darin Intake.  Look up s4 Darin Intake for more infro.  However a even better Setup is known,  They make kits that cost your hard earned money, but all you have to do is take  a picture of a Good setup, and fabricate it yourself.  The diameter of S4 Intake Piping from MAF is 3.5 inches Get some Bends In mandrel bent SS or Aluminum a Cone  air filter  weld on some Mounting Points (if welding use metal you can weld  Or use Rivets)  and it a custom Air Setup.  The silicone Couplings are also avalible in 3.5 inch.  So bolt it up and go.  Can add Decals To the intake to finish the look,  Go to FUZIONMODS.com for all Audi decals.

InterCooler

Two Options for the Inter Cooler.  One is the Front Mount IC Setup, and the Stock Side Mount Setup.   Remember Big Turbo Setup, Big Fuel Setup, Big Intake Setup, Big Exhuast Setup, Will egual big gains.  I see alot of front mount Intercoolers on Virtually stock setups So The Pressure Drop from the Inter Cooler Does not equal the Cooling Facter. Just looks Good I guess.  For most setups all you need is the Side Mount Setup Avalible Rs4 or Knock off.  Just watch you cant expect to get the same part as ECS or AWE, so  do the 3 P's and it will be the same.  Port Polish and Paint the Outside with Good high temp Paint.  I found some good silver paint after I work on them. Mounting holes might need to be made but its easy.

Turbos

Yes there are Twin turbos on the S4,   There are S4 Hybrids Rs4 K04 Turbos And the New Rs6 Turbos.  Depending on your setup and Driving needs.  All are relitive you need the whole Project to add turbos.  I see many people Swap the turbos with out the Fuel Package and it will run Lean.  You need to match the turbos to the car aplication.  S4 turbos are fine and can produce in the 300-400 range but torque wins races and Hp wins Bragging Rights.  So Bigger turbos is not allways good if you Lag and Power Range Changes.  Boost Controler are avalible. They work but I dont like the manual ones just let air out If I wanted  a boost leak I would Puncture a Hose.  Electronic Boost controlers are Great and You can get one with a TURBO TIMER this will allow the engine to cool.    Let your turbos COOL  Every time you Turn off Your Car.    You need to let the center Cartridges cool be for you turn off.  Cool for 2 minutes or so and I can touch the  top of the engine.  S4 has great cooling Abilitys if you leave the car runing.  Not to long It is not good for the CC though.   If adding any turbos you need a lot of RS4 parts so be aware of fitment issues.   Turbo upgrades are easy just pull the motor or you can get from the front pulling bumper or swap when you drop the trans there is room.    It can be done in a weekend under that shade tree.  Just  fuel the beast  with all the extra modifications it will run lean.

Computer

Yes the S4 computer is Programable with the right Software. Lemming works Software lets you change you paramaters. Codeing Fuel Ect. Giac and Apr make chips for the s4, .  Giac make a chip you can set to race gas or set it for A trip to the Dealer less Hp.  The computer  can be accesed by a USB(Laptop) to ODB2 cable VAG-COM is the software that will let you Check Fault Codes and Change Controls.  The Cable is avalible on ebay as well I got mine and It worked well I can erase DTC codes and the annoying CEL light.   Dont just add a computer with out adding any mods,  computer will run to the best of you setup meaning If it you dont have a custom intake Exhuast and turbos no need to go stage three.  Get a stage one chip and Tune it that way.  So I can hook up my Laptop to my S4 Do A run with an air filter, Do a run with A intake Setup and Compare the Numbers.  Its is easy.  That is USB To ODB2.    It will graph the results and you can see air moving over the Maf.   Compare the Results and Bend or Replace or Remove now we can see what works and what does not.  It is like having a tuning shop in the palm of my hands not to mention that if something engine wise went wrong you can read the codes.

Clutch

There are different stages depending on driving Style and HP Ratings.  Tremendous amount of Clutch options now.  I counted 21 for Unorthodox, South bend, Clutch Masters For a stock Pedal feel Luk is the only one.  Sachs makes a kit and is similer to the Rs4 version.   The Clutch disk is the same part number For the S4 and Rs4.   Clutch type material vary from Carbon kevlar to Ceramic Copper Composites.   Rs4 Clutch is  a direct bolt on.  Along with a light weight flyweel will be a great setup holding Up to 350 HP.  There are sprung and unprung Disks, Unsprung is Like a on and off switch with no give.  Break in periods for clutches vary depending on material.    Back to a Sachs with Stock Disk and  I am running a findanza flywheel had it balanced.   Findanza has a replaceable Surface disk. 

Exhaust

I dont like the Popping you get from aftermarket Exhaust.  If you spend the money for a tuned exhaust it will be less but there.   Tuned Exhaust is Supposed to mean that on  both Pipes the Exhaust notes are the same therfore Tuned.    Exhaust will open things up and Down pipes can be made Piggies.  Or they are avalible  now and again,  several companies  sell catbacks.  High flow Cats and The exhaust is done depending on the tone you want.  Loud or What the F was that.  S4 turbo exhaust note in like Ripping canvas.   But puting an exhuast will probably trip the Cel light Because more airs is flowing out.  Which can be addressed by getting Wide range O2 sensors and A Hitachi Maf sensor, RS4 MAf, or O2 spacers. Avalible   stock up on Sensers now because prices allways change.  I dont run an exhuast on my S4 due to all the problems with the LAW.  I want to try one of those electric cutouts see if I can work something.  Dump it after the first muffler. I will see  But other than that she will run corectly when just cruisin  no light on dash.  Headers are avalible but not needed you get what you payfor so watch welds and guage thickness.  I dont have headers the stock flow fine if The 3 p's are done. Port Polish and Paint ceramic coating.  Headers do work and are needed for turbo upgrades.

Brakes

There are big brake kits for the S4 but different model years are compatible I cant say which ones but you Can add say A8 Calipers And Brackets.  Again Need to research but that is what companies are doing and sell you the Adapters.  Hey all this power you need to stop Right.  Good investment.   You have to buy bigger wheels to fit over your bigger brakes dont  try to put 17teens on a Big Brake setup.  Need 18 teens to fit that is why I started with the tires in write up. If anything Get some Drilled rotors need Ceramic pads for the content. They last longer less dust and no squel.   Tremendous amount of rotors options.    Drilled and Slotted will eat Brake Pads.  Thats why there are different componds to the pads.  Match the Pads to the Rotor Aplication.  When buying Stock rotors try to get OEM for the Steel and Coating.  This will cause Less rusting.  Stainless steel lines are avalible and will fix a spongy brake pedal due to soft brake lines.  However when buying  Stainless Steel Brake lines Look at the End Fitting to make Sure they are Stainless also not that Pot Metal yellow tinted Garbage.    Stop tech has a good product and reputaiton.  Not worth risking you life to some Chinese Made Brake Products.

Transmission

Six speed manual gear box is the only.  Change the fluid and add some support and you should have no  problems this Gearbox shifts well and is allways in synch with the next shift.   They make a short throw shifer for the S4 that will shorten your shifts making it easier.  DTS Bar is a great upgrade. They have higher Top Speed Gears Now as well as Rebuild Kits, DVD's and Manuals.

Fuel

Fuel deliver is just as important a Rs4 fueling kit is need if upgrading turbos.  It includes gaskets for higer compresion and injectors.  Fuel pump and Regualtor should also be canged.   This cannot be over looked if upgrading turbos will make you car run lean.  Race gas can be made and Used with the Right Chip.  Look up Race Gas I cant say how  but  Tolulene is  a Octaine Booster.   Have to Calculate Percentages.  NOS is not needed but anything that will get my engine to its turbo power range is great in my opinion.  Just be carefull how you set this up again do the research.  To diagnose Fuel Pressure Problems add a Fuel Psi Guage in a pod or in the Dash.  You can see right away when something Fuel related is wrong.   If gauge reads low or no fuel pressure  Fuel Pump,  Fuel Regulator,Vac Leak, or Line Clog.     To Check Fuel Injectors Turn Car on Disable Ignition Coils and Turn the car over If your Fuel pressure Drops Significantly or more then the Proper Drop.  Most of the time its a leaking Injector that is Causing a malfunction.

Meth Injection

This mod really is the secret and will tie every thing together like i was saying it is all in stages these Mods all work together   One will affect another all have to be tuned.  So this mod will chemicaly provide intercooling.  Its injection  it is lke a Super Charger for the turbo.  It will allow for more oxygen for combustion keep temps down.  Which means less detination high ocataine ablilitys and timing can be ajusted for say RACE GAS.  Recomend for race aplications only do not recomend for street use because if you have goton this far in modding your S4 is Streetable But Barely.     

Addons And Cleaning

 Motor Flush.  I did mine a 5 minute motor flush I followed the Directions and this will clean sluge in the engine.  It is called 5 minute motor flush and Yes I only let it run for 5 Minutes Hence the name Do not Rev the engine.  I added when the engine was only slightly warm add 1/2 and at 2.5 minute mark add the other 1/2.  SLOWLY. Only add while engine is off and NOT HOT.   Do not dump the whole bottle in at one time Please.   Take some oil out then Mix the two to add This is the Secret.    Like a miricale my Oil pressure light Went of and I was making more power the valves were no longer sticky and my acceleration engine wise was smoother.  PLEASE becarefull with this and follow all directions on the bottle.   Transmission fluid is also a detergent.   You need to get all the flush out so A rinse of SYNTHETIC ONLY oil is needed it cost alot for all the oil but is worth it. PLEASE watch high mileage cars as sometimes Sludge is the only thing holding it together.  If High mileage you need to do the FLUSH SEVERAL TIMES.  Then add a oil additive.  But Allways rinse oil out with fresh oil it is expensive, never use regular oil,   S4 has turbo lines that oil will not drain out of.  It is expensive but far less then The STEALERSHIP.   My car only had 40,000 when I bought her so I did once.  My oil pressure light comes on when oil is lost its viscosity.  S4 dont have Sludge problems. So it could also be a bad Pressure Switch or Bad Oil Change.  I didn't want to mess with the oil pan under the shade tree so I just cleaned it internaly.  Check you oil pressure first to make sure pump is good and lines are clear.  Pick up tube should be replaced but after Flushing It was fine.  Dont flush to much it is not a oil change deal,  Only a precaution or fix to a sluge problem.   

When Chaninging oil make sure you use a High Flo Filter not a  Fram or Extra Gaurd, any filter other than A Mann is Garbage.   The aftermarket Filters are smaller and restrict oil.  I had a shop put a Fram Extra Guard on there and lets say- Words were Exchanged.  When you say your a Foreign Repair Shop I expect you would know a detail like that.     You can tell a lot about a shop buy just an Oil Change.  Never Again.

Seafoam can be added to the brake booster line, or to the gas or oil.  I like to add it to the booster and watch the smoke show.  This is normal it is cleaning all the contaminants, and the s4 has pre cats and cats so 4 areas to restrict air flow do the seafoam and clear it out.   The results were noticable.    Please be Carefull Follow the Directions to the T they do vary.   This is a one time deal.  When added it will break up contaminants and send them out the exhaust.        

 Use a Vaccum gauge first to detect any Vac diagnosable Problems.  Sticky Valves  will show a Drifting Neele or Fluctuating Needle when using a Vac Gauge.  I show Strong   19-20 psi for standard Stage One Vaccum at  Idle. No jumping and Strong positive pressure when Reving or Accelerating.

Boost Guage was not A stock item on the S4 so adding it is key to see boost levels.  They make a pod that goes on the Steering columb but it hinders Guage viewing.  So You can add one right in the Vent, which is the vent boost mod.  They also make a kit but as with the writeup you can DIY.  Just pop the vent out cut the vent fins and install.  Make sure you get combination Vac Boost Gauge.   So you can tell right away without hooking up any test Guages what the problem is.     Before ODB and computers a Mechaninc Had his   Knowledge a  , Vac gauge,  Fuel gauge, Compression gauge with that you could fix and diagnose any problem.  Now you need 50k in Snap On tools and a good Computer that does ABS Just to Do a Brake Job.     Thats when Sex was Safe and Cars Were Dangerous.  Now well you get the point.

Rear Spoiler, is avalible painted unpainted it is just two sided tape Looks nice when compleated.

Body Kits the mods are  endless.

Navigation  Kits are avalible  aftermarket is getting better and more stock looking.  However you need the Gps Head unit the Wiriing for the Gps Reciever, Gps Reciever  and Rear Unit.   There is a Euro Version that might work or might not be compatible. So beware.  Also I have seen A6 units of the same year Shaved down on the sids to fit in the stock wiring harness.