Good day AudiWorld community: (this is my introduction, so it will be long, but I sincerely appreciate all knowledge, advice and experience, and look forward to sharing my own down the road)

I've followed the Audi Forum Sites for about two years now looking for a B6 A4 1.8T Avant Quattro. And, now I've got it. I just recently got 2002 A4 Avant Quattro (manual, I couldn't not) with almost 130k in what is the Sport/Ultrasport for 2002 (I don't believe they had a difference then, but just a "Sport" model). It has the brushed aluminum interior trim and red lowered stock suspension.

Now, the fun begins - I want to continually upgrade and maintain this car to be a fun and sporty daily driver. As of now, I'm not planning on tracking it and I know I've got maintenance costs, so I'm looking for a balance of comfort, power and control while balancing the budget. I plan to buy parts that are okay to buy used through the Audi Forums and new ones through recommended dealers. I plan on doing as much of the work as possible myself, with the assistance of friends with the knowhow, and then timing belt, clutch, etc. through trusted mechanic. I'm not looking for all the answers here, but direction. I got this car to enjoy the process of research and using my own hands and do have experience in construction, tools, and cars.

First off - yes the car has high miles, but I have had two separate trusted mechanics look at it (one that just did the timing belt service) and both were very impressed with the cleanliness of the car and engine. Plus, I would seriously consider replacing the engine down the road, when I have more moolah and if I have everything else tuned in how I like. Items I've been told need to be addressed are upper control arms and muffler. Below I outline my interests in improving and repairing the car and request that you feel free to address all, some, or one with any advice and assistance (including the order in which certain upgrades should be made, like when to install cold air intake and intercooler).

1) Suspension and handling - So I'm going to do the upper control arms myself and it was mentioned/recommended I address the suspension at the same time. 2002 Sport came with a pretty low stock suspension and I must admit, I haven't noticed problems with it. Am I crazy that 130k on the original sport suspension still performs admirably (or maybe it was replaced at some point)? The car recovers well and is not bouncy. While coilovers may be down the road, I'd rather spend money right now on improving horsepower and known issues I'll have to deal with in the next year or so (i.e. clutch, to sport clutch?). As such, I could get a used Ultrasport suspension for a couple hundred or just replace the control arms and wait on suspension till I'm ready to fund a full upgrade.

That being said, I would like to decrease the body roll a bit. Could I achieve this through upgraded sway bars? If so, recommendations (H&S seems quite popular, or just newer stock?)

2) Horsepower - I'm not trying to hoon, but want a little more pickup out of the 1.8T (which I got for that very reason of being able to do). I'll need a muffler sooner than later, might as well upgrade exhaust right? What recommendations on exhaust modifications (still legal in most states) to get horsepower? And, of course, balance of performance to money spent?

Intercooler and cold air intake? What point should these go in?

Other horsepower improvement recommendations (prior to chip)?

Finally, I do, as of now, plan a ECU chip/modification. This probably will not occur for a year or two, but is the idea.

3) I recognize that with greater horsepower, I'll need to upgrade items on the car to be safe and handle it. Brakes of course (or so I'm assuming) will be a must. Any recommendations? I would like to go with slotted Brembos or something, but haven't delved into that research yet.

Other upgrades to help the car be safe and handle more horsepower?

I'm also considering do a sport clutch and speed shifter when it's time. Opinions on this?

4) Appearance (with a little performance) - In the next year I want to add 17" or 18" wheels with a somewhat lower profile tire (and keep the 16" with snow tires). I know the 2002 Sport suspension is lower than later B6 and B7 sport suspensions, does anyone know if this will be an issue with 18s? Should I look into getting a slightly wider wheel as well? What other issues will I face with larger wheels?

I really like the overall look (hence getting a B6), but plan to change to an aftermarket lower front and rear bumper.

5) Current radio issues - My Symphony II goes in and out. It seems to go out more often the longer the drive (which makes me think Amp). I've done research and read check the wires and, then, it may be the Amp. I've found some wires in the driver door that were worn and taped them, but it's still occurring. I'll check the passenger door next, and then under the dash. Any opinions on this? Also, I got the radio keys, but they don't pull the radio out (there's scratch marks around the radio key inserts, which makes me think someone messed around with something other than the right keys and broke the releases. Any other way to get the radio out without taking apart the console?

That is all I can think of for now. Excited for more correspondence. Thank you, Forrest

Oh yeah, I currently live in San Diego, but will be moving back to the Carolina's later this year. I can get some pictures together later.

 

Some thoughts to consider based on my knowledge, but certainly not intended as recommendations, just food for thought. Everyone's personality, needs, and desires are very different

1) Suspension: I find the stock sport suspension (I have an 02 with the low low ride height as well) to be more than anything I need on the road. Any more and one could be tempted to drive too agressively with others on the road. My A4 is used primarily by my 17 year old son, but this tempts me as well. I am a firm believer in responsible driving when other knuckleheads are around. So, I would simply replace the shock inserts unless you are "tracking" the car. Also, I have no specific knowledge on upgraded anti-roll bars for our A4's, but the comment above applies.

2) Horsepower: again, for me this is not in the cards based on the above mentioned primary driver. But, a quick summary (others please corect).
a) There are several companies that offer a couple stages of flashes. These can get you into the 225 hp range with the stock turbo. Cost is something around $500. APR seems to be the most common although there are others. Stick with the ones you read a lot about and don't be tempted with someone that does not specialize in VAG cars.
b) Upgraded turbos are next. The first and mildest is the K04. With injectors, I think you can push 250 (others help here). The next step would be the GTR Eliminator which again with injectors pushes this up to the 275 range (others again help here). All of these come with unique flashes.
c) As far as intercoolers, don't believe you will see any improvement until you get to the GTR turbo as the pressures the K03 and K04 run aren't enough to overpower the stock intercooler except on maybe the hottest days.
d) Cold air intake: It really already has one. The air enters through the grille. If you are talking low restriction intake, there are varied opinions on whether this really helps the A4 and I don't have one

3) Brakes: maybe it's me driving my other cars (a 27 year old Nissan sports car and a Benz SUV), but I think the brakes on the A4 are stellar. If you look at stopping distances, they are up there with the best. So for street use, I think they are more than adequate. If you are tracking the car or driving on the street like you were on the track, that is a different conversation.

4) Appearance: My sedan has 17 inch stock wheels, so I am surprised you have 16's. Maybe the Avant's option were different. With the low low stance and 17's, I think the look and stance of the car are a good balance of aggressive and "street". Any lower (opinion here), and I think this or any car looks, hmmm, contrived. 18's? Not sure if they will fit without spacers or not.

5) Radio going in and out could be the door harness, but if the CD works fine, then it is the antenna booster. I have this problem and just can't drop the $300 or so on a new booster. So lots of CDs and cassette adapter for the ipod, and all drivers enjoy music.

My 2 cents...

 

Lyle is on the money with everything but I'll elaborate on bits.

-Power: you won't get anything without a chip. Just the chip puts you at ~215-220, chip + injectors ~230-235 and so on. Car is just as driveable but a fair bit faster so it's warmly recommended.

-I ran 18'' OCZ Ultraleggeras on stock sport suspension. The ride was awful. There just isn't of a lot of tire on a 18'' rim to dampen the road. I'd stick with 16 or 17'' and just put a whole bunch of pressure on track days (42+ psi) to prevent the sidewall flexing. 16'' rims will actually perform better on track because they're lighter, so long as you put in proper pressure. You won't have any problems with stock sport suspension and the 18'' rim so long as the tire is 235mm or less. If you lower the car, you might run into problems with tires rubbing but that depends on tire width and ride height.

-2002 sport is lower than Ultrasport. All 2002 sport suspension cars come with 17'' rims, slightly different design between sedan and wagon. Are you sure your rim is 16''?

-Cold air intake is a complete waste of money and time.

-Brakes: I'm still stock but lots of people updated to B5 S4 or B6 S4 brakes. It's not cheap but it'll give you better stopping distances. Bear in mind stock A4 brakes aren't bad.

 

This is fantastic information (less overall work needed (i.e. balance the budget), but still get results. Thanks guys.

Suspension - Great news. I wasn't sure how much suspensions wore down over time and if 130k required a replacement (in my old Land Rover I was getting shuddering and replaced them before 100k, but I also did off roading). Lyle - when you mention shock inserts, are you just referring to the shocks/struts? Like get a set of Bilsteins and stay with the Audi Sport springs? As discussed, the 2002 sport is low, and I definitely don't want to go any lower. I'm not looking to have overhanging fender lip, but would like a little clearance between the tire and fender.

The nose picks up when accelerating from a stop, especially pulling out into traffic in a turn, so I was hoping to decrease that and body roll. I know that a firmer suspension will of course work with that, but I didn't know if sway bars or any other "simpler" (cheaper) parts/ways could be done.

Wheels - Sorry, forgot to mention it has aftermarket Borbet wheels (well three and one other similar looking, what may be a stock wheel). The tires are 205/60 R16, so I believe the wheels are 16. The car had been in Montana, so maybe they had put on smaller wheels for the extra "dirt road and snow" clearance. Anyway, I do like the look of a larger wheel, but also want to keep a reasonable ride. As I mentioned, I'll probably keep these with snow tires and get 17"s (sounds like 18" just get ridiculous?). What about increasing wheel width a little to get it flush with the car?

Horsepower/Performance - Nice to hear that Audi stock systems are already impressive, I knew they were good but wanted to make sure I installed the proper upgrade items to protect the engine and car while I was increasing horsepower and torque on everything. I had heard from others that they thought cold air intake and/or intercooler should be installed before chipping. I'll happily do some more research on the subject.

I'm not looking to make the complete jump with injectors and bigger turbo for now. Maybe once I get used to/or bored with the chip upgrade.

Brakes - This is good news, I can think about upgrading down the line.

Exhaust - I'll need to replace the muffler anyway, and would like to upgrade the exhaust. I don't want a rice-burner noise, but look for a little more of the deep rumble. Any air flow/horsepower improvements I can get while replacing the exhaust? Items I should look for or into? Recommendations? Once again, not trying to go crazy but improve performance and sound slightly.

Radio - I think it is wiring or amp because the radio goes out with the tape cassette as well as the radio the same. (The CD player has an error 3, jammed I believe, and I got the keys to pull it out, remove the faceplate and fix it as I read around here, but the keys don't work on pulling the radio out, I think the clips have been broken by someone before. Anyone have other ways to get the radio out?).
When I said I checked the door, I meant door harness (just had a brain fart at the time). I checked the drivers side and found some wiring that had been clipped and taped, I retaped it, but the Brown (radio ground wire I believe?) had a clip on it which maybe isn't working, so I guess I'll take the whole thing apart and check. I'll also check the passenger door harness. Would any wiring under the dash possibly be involved?
I was wondering about the amp because I had read that elsewhere and it seems that when I drive for work, while the radio cuts in and out sometimes regularly, just before two hours of driving it cuts out and won't come back on till I park the car for the night, or a while at least. Any further feed back on this would be great, as mentioned I travel for work.

Thanks for the input and information. It's a blast!

 

1) Yes, just the "red" part. Again, done no research on sway bars.

2) I'm not from snow country, but I believe most people's snow tires are mounted on 16's. Clearance is one reason. Maybe whoever sold the car didn't keep the original tires or offer them with the car? Don't know. Anyway, the stock 17's are 235/45's. I think they are plenty wide "looking" for a small 4 door sedan, but that's my opinion.

3) I have never looked into cat back exhuasts. Would start with HKS as I am familiar with them on my Nissan plus I think they don't go with the buzz bomb sound that sound like you and I share an opinion on, especially on a near luxury German sedan.

4) Yeah, sounds like you have a wiring problem. When I had similar issues with the door harness, I ended up deciding to replace it as splices just didn't seem to last very long based on my reading. I would just belly up and replace the harness, and you should have several years of trouble free operation.

 

What are your opinions on getting S4 stock shocks with 40k miles on them (will just leave the stock springs on) for $150? Trying to decide if it's worth the update since there are some local or just put that money into everything else.

 

Not smart enough to know how they would differ, but keep in mind my comment below that I plans no mods to the A4 because my son is driving it and the only mods I have made to my 26 year old Z are upgrades to bits that needed replacing which are generally not more expensive than Nissan parts. So, I don't pay a lot of attention to anything that involves modding the car...