Which years did the S4 have the Aluminum version of the 2.7 block? I believed it was 00-02, but I'm not sure. Some sources list it as an iron block, but I thought I was told Alum.
Considering swapping blocks with my 2.8, building out the bore/stroke, and over blowing this since the S4 seems to handle 400+ modifications due to bottom end ruggedness. Am I off-base with this assumption? (yes, I'm considering a customized S/C kit to accomplish this, expecting a large bill for it too.).

I don't see any reason why this can't be accomplished. As always, custom tuning and programming is gonna be the biggest expense. Also, keep in mind that boring the cylinders out will inevitably weaken the head and reduce the maximum safe boost levels. I'd consider stroking and reducing compression.

You might be right on that. I was thinking of returning the setup to a 2.8 spec so that I could run it with the current hard EC parts in my 98.
OH YEAH.. and the weight difference of about 100lbs or so should make a front to rear weight ratio shift towards 50/50, like my old 944.
Hey..you ran the G1 setup with the IC right? How did the hardware hold up on the PES system? I think that would take some of the PITA out of developing a custom one-off/since the blower has to be larger or at least diff from Tony's Eaton unit to handle the air charge required to boost the block enough. I like the PES system, but it is apparently not flexible enough to handle the range of power I want to produce.

It's solid, reliable and I expect it to last longer then the engine (knock on wood).
As far as boost levels go, the Eaton M62 unit that PES uses in the G1 and G2 kits will max out at about 10 PSI due to high s/c RPMs. It's just not capable of turning fast enough to supply more air. If you want more boost, your best bet would be the M90 unit or another brand altogether.

I don't believe the 2.7T was all-aluminum. The 3.0 is, however.

You may want to ask on the B5 S4 forum, if you haven't already.

Good luck,

Rich

> like your stock driveline will be at it's limit.

3.0 has alumnium block

Aluminum doesn't like the S content.

Not going with stock, either level RS6 Tip/ A8 tip/ or stock 5/6 speed manual is going to be the replacement to sub for the current tip mode. I can upgrade T/O bearings, and clutch components to handle it well.

But the diff/CV arms and joints, bearings and mounts are all identical (tolerances to stress) to the S4 and they stress those cars to 4-500 hp sometimes without breakage..
Thanks for thinking of that though..

The M-90? Do you think that this could be fit to the G2/1 kit? or am I dreaming of how easy that would be?
Please get back to me with this if you can..

LOL...
Hey thanks for that clarification. So the current S4 block is what? the 2.7 transplanted and updated?
Damn all those plans...lol.
Thank you.

The M90 is thicker and wider, but not longer, which is good because the M62 barely fits between the firwall and the front of the car. I think M90 could be made to fit in the same spot, although it would require some fabrication of new mounts and possibly new collector plate.