Engine Rebuild: S4 2005 B6 BBK (South Australia)

[Paragon360]

Hey Folks,

New to the forum and a first time poster.

I have a 2005 S4 which needs an engine rebuild. I'm wondering who I should take my car to for the job? I've recently moved from VIC to SA so am not linked in with SA workshops that can and want to do it.

Any suggestions would be massively appreciated.

Cheers,

Matt

 

[jnrdavo]

I don't have any personal experience with any of them, but here is a list that I found, most have good reviews that you can reach out to and check out.

Lonsdale Engine Worx — Lonsdale
A highly rated engine rebuilding service with strong reviews and modern machining capability. Suitable for full V8 rebuilds.

Southcott Engines — Wingfield
Experienced engine rebuilders with a reputation for quality machining and reconditioning.

Advanced Engines — Salisbury South
Well‑established workshop with experience across petrol and diesel engines, including performance builds.

Bullet Race Engineering — Green Fields
Performance‑focused engine builders with strong machining capability. Known for high‑power builds and precision work.

Chris Milton Engine Developments — Prospect
One of SA’s most respected engine builders, known for high‑end machining and performance engines. Excellent choice for complex V8 work.

 

[Alister]

FWIW cost is going to be significant relative to the value of the car.

Make sure you go in 'eyes open' on the costings plus contingencies before committing to the rebuild, as for many the exercise would be considered uneconomical.

 

[Paragon360]

I don't have any personal experience with any of them, but here is a list that I found, most have good reviews that you can reach out to and check out.

Lonsdale Engine Worx — Lonsdale
A highly rated engine rebuilding service with strong reviews and modern machining capability. Suitable for full V8 rebuilds.

Southcott Engines — Wingfield
Experienced engine rebuilders with a reputation for quality machining and reconditioning.

Advanced Engines — Salisbury South
Well‑established workshop with experience across petrol and diesel engines, including performance builds.

Bullet Race Engineering — Green Fields
Performance‑focused engine builders with strong machining capability. Known for high‑power builds and precision work.

Chris Milton Engine Developments — Prospect
One of SA’s most respected engine builders, known for high‑end machining and performance engines. Excellent choice for complex V8 work.

Thanks for this jnrdavo.

 

[Paragon360]

FWIW cost is going to be significant relative to the value of the car.

Make sure you go in 'eyes open' on the costings plus contingencies before committing to the rebuild, as for many the exercise would be considered uneconomical.

Thanks Alister.

What contingencies should I keep in mind do you think?

I understand the cost factor would normally be prohibitive but over the last few years I've replaced the clutch, dual mass fly wheel, full German suspension kit replacement, new aircon, the engine is pretty much the final major thing to attend to.

Cheers,

Matt

 

[Alister]

Hi Matt,

Things like clutch and flywheel (which you've already replaced by the sounds of it) would have definitely been on the list, and would have also been one of the more expensive items otherwise likely needing replacement.

I'm no engine builder, but there's bound to be a bunch of other (relatively) smaller items that can still very much add up through the rebuild process. Things like electrical/ignition components (spark plugs, coil packs, various engine sensors, wiring harness issues) etc all spring to mind. But there is also bound to be other components that will either need or be recommended for replacing (water/oil/fuel pumps, timing chain components (chain, guides, tensioners) etc). Given the car is circa 20 years and there is a bunch of plastic and rubber components that become brittle/fragile with age, there will for sure be a list of bits.

Given the difficulty of working on the bigger engined models such as the BBK in the B6 S4 there will be a lot of things that just make sense to replace whilst the engine is out of the car as otherwise access later is problematic.

Not wanting to scare you off from going down this path but it'd very much be worth talking to someone who has gone down this path before with a B6/B7 S4.

 

[Pickles]

Thanks Alister.

What contingencies should I keep in mind do you think?

I understand the cost factor would normally be prohibitive but over the last few years I've replaced the clutch, dual mass fly wheel, full German suspension kit replacement, new aircon, the engine is pretty much the final major thing to attend to.

Cheers,

Matt

G'Day Paragon, I'm not familiar with the engine specs of your S4, but I congratulate you in looking after your car, which you're obviously attached to.
Is your S4 a V8?...If it is, even more reason to keep it. (I love my V8s!)
Anyway, I wish you well, in finding someone who is familiar with the engine in your Audi, so that the job can be done right, the first time.

 

[Paragon360]

Hi Matt,

Things like clutch and flywheel (which you've already replaced by the sounds of it) would have definitely been on the list, and would have also been one of the more expensive items otherwise likely needing replacement.

I'm no engine builder, but there's bound to be a bunch of other (relatively) smaller items that can still very much add up through the rebuild process. Things like electrical/ignition components (spark plugs, coil packs, various engine sensors, wiring harness issues) etc all spring to mind. But there is also bound to be other components that will either need or be recommended for replacing (water/oil/fuel pumps, timing chain components (chain, guides, tensioners) etc). Given the car is circa 20 years and there is a bunch of plastic and rubber components that become brittle/fragile with age, there will for sure be a list of bits.

Given the difficulty of working on the bigger engined models such as the BBK in the B6 S4 there will be a lot of things that just make sense to replace whilst the engine is out of the car as otherwise access later is problematic.

Not wanting to scare you off from going down this path but it'd very much be worth talking to someone who has gone down this path before with a B6/B7 S4.

Thank you Alister. Great detail.

I've had two quotes back and it's just not going to be viable to rebuild the engine, upwards of $30K. I've just begun sourcing a replacement engine and will get the timing chain done on it, assuming that it hasn't already been replaced, before installing.

 

[Paragon360]

G'Day Paragon, I'm not familiar with the engine specs of your S4, but I congratulate you in looking after your car, which you're obviously attached to.
Is your S4 a V8?...If it is, even more reason to keep it. (I love my V8s!)
Anyway, I wish you well, in finding someone who is familiar with the engine in your Audi, so that the job can be done right, the first time.

Cheers Pickles.

Yep, it's a V8. There's nothing more satisfying than the sound of the naturally aspirated engine!

 

[Alister]

Thank you Alister. Great detail.

I've had two quotes back and it's just not going to be viable to rebuild the engine, upwards of $30K. I've just begun sourcing a replacement engine and will get the timing chain done on it, assuming that it hasn't already been replaced, before installing.

That cost is well and truly at the upper end of what I would have expected. Either way, uneconomical to repair unfortunately.

Be careful with the replacement engine too - make sure you buy from a reputable seller and that there is some sort of warranty on it as that too could end in tears.

My recommendation would be to sell the existing car 'as is' and source something else. Could result in a lot less headaches and cost.