6SpeedOnline - Porsche Forum and Luxury Car Resource - 2005 Audi S4 w/ Brembo Brakes, Bilstein PSS9 Suspension, Milltek Exhaust

When life gives you lemons, make lemonade.

Its an old adage we've all heard probably half a few hundred times in our life. But this B6 S4 Cabriolet owner took it to heart. When this S4 came to us, it had a broken timing chain tensioner that needed to be repaired as our main mission. This also seemed like the perfect opportunity to start investing in some upgrades at the same time.

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Part Installed:
Audi S4 4.2 V8 Quattro Milltek Cat-Back Exhaust - Resonated
Audi S4 RS4 2004 - 2008 H+R Sway bar front 32mm
Audi S4 RS4 2004 - 2008 H+R Sway bar rear 22mm
Audi A4/A6/A8/S4(B5/B6/B7 Chassis) Camber Adjustable Upper Control Arms
Audi S4 Front (B6, B7) 6-piston 355x32 2-Piece Big Brake Gran Turismo Kit by Brembo
Audi A4 Rear (B7)/ S4 (B6, B7) 4-piston 345x28 2-Piece Big Brake Gran Turismo Kit by Brembo
Audi S4 B6,B7 Coilover kit - 2003 - 2007 - Bilstein PSS9 4door, Avant and Convertible

We started by rebuilding the top end of the engine and replacing all of the timing chains, tensioners, and guides. While the engine was out, we upgraded the clutch in anticipation of installing a supercharger at a later date.

Engine Tear Down and Rebuild
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Getting the engine out
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Engine tear down
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The broken follower that caused the engine to jump time
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Where the follower was
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The new follower
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The new and shiny Stern mounts
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The clutch upgrade, fresh out of the box and ready to rock
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Everything back in

Once the engine was ready, we went ahead with a Brembo GT brake upgrade package and Bilstein PSS9 coilover suspension.

Sway Bars, Coilovers and Control Arms
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Front and rear H&R Sway Bars
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Old versus new
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Installed

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The old
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The new goodies
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Old versus new
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All in

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Brembo Big Brake kit
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Old brakes
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New Brembos

To wake up the sound of the 4.2l V8, we installed a Milltek header-back exhaust.

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We also installed a set of VMR wheels to neatly finish out visit number 1.

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So much got done but this car isn't even finished yet! For the car's second visit, we are going big on style and will be installing an Audi TTS flat-bottom multi-function steering wheel, an Oetinger front bumper, custom LED DRLs, B7 A4 tail lights, RS4 grilles, and an Escort Passport 9500ci radar system. We are really excited to see the end result. It will, without a doubt, be something special and unique.

To keep up with this build, check out our gallery here!