After many months of planning, saving, buying/selling, and many more months spent with the Audi Service Manual, piles and piles of parts, and some torque wrenches & plastigauge in my garage - This motor is mostly together.  2000 Audi A6 2.7T, Sport Package, Manual Transmission, 75K miles.

Drivetrain

• APB Block, 82mm bore
  ATQ Heads fully built, new guides and lifters, polished cams, mildly ported and all Supertech Valvetrain (Inconel, Nitrided SS, Spring Kit)
  3L Crank, re-balanced
  Wiseco 8.5:1cr Forged Pistons
  Pauter X-beam Rods
  ARP Main Studs
  034 Bearings throughout
  Eurospec Non-Stretch Head Bolts
  Heavily Ported Stock Exhaust Manifolds (enormous PITA.  No wonder VAST used to charge so much to do it)
  Heavily Ported Stock Intake Manifold
  Stock Throttle Body
  Nefmoto Software and Tuner Pro
  CM Stage 4, 6 puck disk.  Machined OEM Flywheel
  Deatschwerks 320lph in tank pump mounted inside stock gutted pump
  JHM RS6R Turbos
  ARD '05.5 AR Aluminum TBB, 2.125" Bi-Pipes APR Bi-pipe, 4 bar map sensor, 5120 Mod
  ARD 3" Downpipes
  DIY 3" to 2.5" catless mid-pipes
  DIY Dual 2.5" Exhaust (2x Magnaflow 10426, 2x Magnaflow 11226)
  ARD 95mm MAF tube/K&N open air element
  Bosch Racing EV14 Porsche 997 650cc Injectors Bosch 980cc EV14 running E85
  SRM SMICs
  Innovate LC-1 Zeitronix ZT-3, STE PPD
  DIY PCV, Air/Oil Separator
  DIY Oil Cooler Unnecessary
  EFK, switchable between Manual and Auto
  etc etc

Chassis

• Koni Sport Shocks w H&R Sport Springs.  Fronts - Sleeved, Rears - 4 grooved height settings
  B5 S4 rear calipers with B7 S4 rotors. 034 caliper spacer
  Porsche Cayenne 17Z Front Calipers over D/S 330mm Volvo V70R Rotors.  18Z Centric ceramic pads
  Hotchkis F/R Sway bar Kit
  034 Street Density Control Arm Kit w Adjustable Uppers
  034 Street Density Engine and Transmission Mounts
  JHM DTS
  18x8 Hartmann R8 Reps
  034 Snub Cage/Mount

Tuning - Just a nefmoto lurker/learner/beginner, I've played with files that already ran, but this will be the first attempt at tuning a setup starting from scratch.

ARD provided all the numbers needed to get the injectors dialed in.  Tuning for the MAF and all else will be new territory.

I hope to hear any and all your criticism and advice.

Tuning started with a stock M-Box file.  Car has a Hitachi Maf now installed.

First Steps

• KISRM changed from stock 0.120435 to 0.134850 for change in displacement
  KUMSRL changed from stock 0.00107200 to 0.00114400 for change in displacement
  Coded out rear 02 and EGT sensors per S4Wiki
  Set Fuel System correction maps to 1
  Added rudimentary launch control at 4000rpm, and raised rev limit to 7500.
  Removed speed limiter
  Tweeked TVUB for new injector latency values
  KRKTE ended up at .04995 on stock MAF initial tune

Just a few more parts and ceramic coatings.



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THAT is badass. Also I am a fan of low CR builds.

A couple of updates to the build:

• Transmission/starter are now mounted to the motor
• Piston size listed above as 81.5mm was mis-typed. Pistons are for 82mm bore (which is actually probably pretty close to 81.5mm since they are Forged from 2618 alloy).   I'm crossing fingers and beheading chickens in hopes that I don't end up with the same issues Julex had with his Wiseco's.  
  
• ARD Bi-Pipe is a new design using a metal TBB boot, bolted to the TB through the stock holes, and V-banded to 2.25" bi-pipes with meth bungs.   Seems to be a nifty product, so I'll post pics once it arrives.
  
  • Intercoolers are now on hand, made by SRM.  Time will tell on performance, but for now, they sure do look nice....and big
  
  The d/s turbo oil inlet seems to have a sealing issue and it looks like the problem is potentially several issues so the oil line, bolt and the banjo fitting will need to be replaced.   $100 +
  
  I started looking into the Induction Motorsports Oil Line Kit $200 shipped
  then quickly realized a kit like this could easily be diy'ed with something like:
  
  -
  
  • 4 x 12mm banjo to AN -4 fittings, steel - $50
    8 x 12mm copper crush washers < $1
    12" PTFE Braided AN -4 Hose - $10
    20" PTFE Braided AN -4 Hose - $10
    3' of High Performance fire sleeve - $15
  
  I couldn't find specs for the K series turbos, but it looks like Borg Warner recommends AN -4 for their other turbos so I will assume this will work. 
  

Installed the motor/transmission today. 

Engine fired up within 10 seconds, which seemed unusually quick - Lines were purged in September.
 
I'll be running the stock maf while I fine tune injector constant, and seat the rings.

Two things I was pleasantly surprised by today:

• No leaks anywhere... yet.
  SRM intercooler fitment.  They installed in 5 minutes a piece, and there is plenty of room in the oil filter area for the sandwich plate, and possibly the high capacity filter.

One thing that sucked: Bleeding the clutch.  It was just more a pain in the ass that it should have been for some reason.  Still doesnt feel right either.  I'm starting to wonder if the master cylinder went out.

Here's a couple camera pics during the install.

Worked on the ride a few evenings this week, I've got just about everything on the car ready to roll out.  Car starts and runs great.  Ended up with some coolant dripping down near the oil cooler, but it looks like it was just building up on the block due to me not cranking down the coolant bleeder bolt.

Clutch issue I mentioned just turned out to be this: http://www.audizine.com/forum/showthread.php/234720-Clutch-Slave-Cylinder-Install-Tips-and-Bleeding-101-by-JHM.  Front end of the car was too high when bled.

So far, after logging idle and part throttle while parked, I am seeing basically 0 STFT.  Fluctuates between about 2 and -3 on both sides-not simultaneously, but mainly stays at 0.   KRKTKE is 0.04995 with Bosch Racing 650cc/min injectors, and idle is smooth as butter. 

Car sounds very tame with a pair of Magnaflows (pn 10426 and 11226) per side with 2.5" mandrel bent tubing - 3" downpipes and no cats.   

I'm dying to take a test drive, but the brakes aren't quite done.

Just waiting (story of my life, right?)  on a pair of new front brake lines.  I'd originally planned on using banjo fittings, but I always felt for the Brembo setup, that the banjos could ratchet themselves loose under the right conditions, so I decided to go with 10mm to AN3 adapters at the calipers, then back to 10mm at the end of the hardline from the ABS, with a foot of AN3 in between.   Seems to make the most sense, and keeps the lines well away from anything the could rub, snag, or twist them oddly when steering lock to lock.

I will have a set of the JHM Rear S4 SS brake lines for sale, as the A6 rear lines are much shorter.  15" of brakeline back there is just way too much.   I guess the lines are run a little differently between those cars.   The S4 has a second section of rubber hose.


   

Looking very neat! Great job. I guess those injectors are another ev14's? What TVUB did you end up with?

Thanks for sharing, I'm waiting for same injectors for my rs4 ASJ, also figured KRKTE around 0.05 +/- from other EV14's comparison, though calculated is smth like 0.045.