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  1. #1
    Westy's Avatar
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    Few jobs for this weekend.

    Been compiling a little list of things to do to the car this weekend (Friday/Saturday) and been collecting a few parts.

    - Swap post cat lambda sensor with a known working one to finally work out whether I need a new cat or not
    - Remove rocker cover and inlet mani to be cleaned and painted matte black
    - Replace cam adjuster gasket and rocker cover gasket
    - Finally fit turbo to charge pipe Forge hose after being messed about by an eBay seller
    - Fit short shifter
    - Clean injectors
    - Remove alarm and replace batteries before they leak

    Next up will be the suspension but that all depends on whether I have to pay out for a new cat or not.
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  3. #2
    Chugger

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    Have you bought the replacement alarm siren unit? Been thinking of doing mine as it doesnt work at all
    57 A3 2.0 TDI Sportback (140)

  4. #3
    Westy's Avatar
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    Quote Originally Posted by sportstractor View Post
    Have you bought the replacement alarm siren unit? Been thinking of doing mine as it doesnt work at all
    No way mate it cost a fortune. I'm having a crack at this:

    ALARM NOT WORKING-TT-
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  5. #4
    Westy's Avatar
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    Ok scrap fitting the forge turbo to charge pipe hose as Forge are out of stock!
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  6. #5
    fran-s3's Avatar
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    Quote Originally Posted by Westle View Post
    No way mate it cost a fortune. I'm having a crack at this:

    ALARM NOT WORKING-TT-
    I got a replacement one of Ebay for 35 delivered - it's 4 years old... Mines started doing the '3 beeps' .... Hopefully not to much of a horrible job to do.

  7. #6
    Westy's Avatar
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    Quote Originally Posted by fran-s3 View Post
    I got a replacement one of Ebay for 35 delivered - it's 4 years old... Mines started doing the '3 beeps' .... Hopefully not to much of a horrible job to do.
    Mine started beeping over a year ago but then stopped, it's back again. I've ordered the batteries from Maplin so I'll have a crack at fixing my exisiting alarm first.
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  8. #7
    finesse's Avatar
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    mine beeped then stopped beeping lol, I guess it was being as temperamental as the car

    what makes you think your lambda or cat are going? cats are about 400+

    how are you cleaning the injectors, s3dave style?

  9. #8
    Westy's Avatar
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    Quote Originally Posted by finesse View Post
    mine beeped then stopped beeping lol, I guess it was being as temperamental as the car

    what makes you think your lambda or cat are going? cats are about 400+

    how are you cleaning the injectors, s3dave style?
    I'm down on power (about 20bhp from VCDS logs) and i've diagnosed the lambda sensors. The post cat sensor is supposed to have a fairly stable voltage to it unless the cat is damaged. My voltage is all over the place. I did the same test on S3 Baby's car and his voltage was fairly stable so we're going to swap sensors to determine whether the sensor is shageed or the cat.

    My current cat recently passed MOT so I'm not sure what to do at the moment. Fork out a fortune on a downpipe and sports cat, or go de-cat and put my current cat back on each year for MOT.

    S3 Baby and I have purchased one of the cleaners to do our injectors so If you do make it to mine on Saturday we can do yours too.
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  10. #9
    finesse's Avatar
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    sounds like a plan

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    Quote Originally Posted by Westle View Post
    Mine started beeping over a year ago but then stopped, it's back again. I've ordered the batteries from Maplin so I'll have a crack at fixing my exisiting alarm first.
    I did mine just before Christmas - easy to do and solved the problem.

  12. #11
    Welly's Avatar
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    Quote Originally Posted by Westle View Post
    My current cat recently passed MOT so I'm not sure what to do at the moment. Fork out a fortune on a downpipe and sports cat, or go de-cat and put my current cat back on each year for MOT.
    I'd be going with option number 2. It's quick and it's easy. Fitting a 3" downpipe is NOT easy. At all.

    Annoyingly my MOT reminder just came up - next month.... Eeeeeek.
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  13. #12
    Westy's Avatar
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    Quote Originally Posted by Welly View Post
    I'd be going with option number 2. It's quick and it's easy. Fitting a 3" downpipe is NOT easy. At all.

    Annoyingly my MOT reminder just came up - next month.... Eeeeeek.
    Option 2 is cheaper but I will need to get the post cat sensor mapped out to avoid a dash light appearing! I might wait till i've been to Bills for some diagnosis on the problem before I start throwing cash about.
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  14. #13
    Westy's Avatar
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    Also adding the following to this weekends job list:

    - de-baffle charge pipe silencer. (mainly in preporation for a B5 3" TIP, so I can enjoy even more noise )
    - Paint the charge pipe matte black. (After seeing Sandips thread where he'd pained his I thought I'd do mine)
    - Dremmel some of the fittings off the charge pipe. (The charge pipe is going to get it this weekend!)
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  15. #14
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    Quote Originally Posted by Westle View Post
    The charge pipe is going to get it this weekend!
    Haha, I got a real good sense of satisfaction when i did mine, surprised me how the baffle is made up aswell really, seemed to be fishing out lots and lots of broken pieces

  16. #15
    Westy's Avatar
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    Quote Originally Posted by wibble111 View Post
    Haha, I got a real good sense of satisfaction when i did mine, surprised me how the baffle is made up aswell really, seemed to be fishing out lots and lots of broken pieces
    I've looked at doing it once and decided it looked like too much work but as it's coming off for all the other jobs I'll bash the sh!t out of it. I cant wait to get cracking now. Next week it's going to Bills for diags and RR and it might get treated to a 3" TIP and filter if it doesn't need a new cat. Getting the old girl in good shape now
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  17. #16
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    Westle i wouldnt waste your time with the charge, id just wait for the forge item.
    Driving the most secretive S3 on ASN

  18. #17
    Westy's Avatar
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    Quote Originally Posted by Dani_B19 View Post
    Westle i wouldnt waste your time with the charge, id just wait for the forge item.
    I probably wont waste my money on a new charge pipe to be honest mate. I'll make to with hacking and painting the original
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  19. #18
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    The only problem with de-baffling is, it leaves a larger void, it goes from the turbo outlet size, to a large void then back to the turbo outlet size, i dont think it really does the turbo anygood. If your doing it id say weld a piece of pipe in to make sure its a smooth transition .
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  20. #19
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    home made pressure testing?


    ALDI - Sunday Special Buys 13th March 2011

  21. #20
    Westy's Avatar
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    That's a bit over kill mate!

    Yeah I know what you're saying Dani, I may re evaluate it but there are a fair few people running it like that at the moment. Surely even with the bafles in there the air is still getting through the holes and filling that chamber?
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  22. #21
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    If anything, and it is nothing, the holes in the baffle will be more of a 'restriction', which it isn't because its constantly flowiing pressurized air.

  23. #22
    Westy's Avatar
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    Quote Originally Posted by superkarl View Post
    If anything, and it is nothing, the holes in the baffle will be more of a 'restriction', which it isn't because its constantly flowiing pressurized air.
    So basically what your saying is, removing the baffles won't be a problem
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  24. #23
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    I don't think it will no, can't think of any reason against it. What's the baffle made of?

  25. #24
    Westy's Avatar
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    Quote Originally Posted by superkarl View Post
    I don't think it will no, can't think of any reason against it. What's the baffle made of?
    Not sure, all I know is that it'll be smashed out by the end of tonight
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  26. #25
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    haha good luck. few pictures would be good too mate

  27. #26
    Westy's Avatar
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    Quote Originally Posted by superkarl View Post
    haha good luck. few pictures would be good too mate
    I will be taking pics of every one of the jobs i've metioned above to put on this thread.
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  28. #27
    Westy's Avatar
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    Here's a coupple of pics from my weekends work. S3baby has the rest on his iPhone so I'll post them up when I get them.

    We spent from 18:00 - 00:00 Friday night then 07:00 - 16:30 on Saturday to get everything done.

    I managed to get everything painted I wanted to except the charge pipe due to a little issue with putting a hole in it! I decided I didn't want the bracket on it anymore so we heated up the weld with a blow torch and removed the bracket. Unfortunately this left a hole in the silencer and I had to go and get it welded up.

    I got the quick shift fitted which is a wicked mod and really tightens up the feel of the box and reduces throw.

    The injector clean was also a huge success and it has helped make my car run smoother, start better, and idle better.

    On the Saturday Finese turned up just as we were finishing putting my car back together. New rocker cover gasket, cam adjuster gasket, inlet mani gasket, and throttle body gasket. We took a little look at Finesse's car for him and he also needs his rocker cover and adjuster gaskets changed. We cleaned his injectors for him and did the N249 bypass and replaced his FPR hose.

    One thing we did find out was that it's very easy to forget to plug the sensor connectors back in once removing all that lot. I had a brown trousers moment when I went to start my car and it was running like a bag of crap. Turns out it will run like a bag of crap if the TB isn't plugged back in!

    Anyway here are the pics I have. I'd like to say a big thanks to S3baby for all his help and also to Finesse for supplying a big box of Krispy Kreme donuts



    Last edited by Westy; 14th March 2011 at 22:07.
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  29. #28
    s3dave's Avatar
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    Looking good mate, well done

  30. #29
    Westy's Avatar
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    Oh yeah ignore the huge chunk out of the battery cover, I need a new one.

    Going to paint the charge pipe tomorrow night.

    I've now done about 100 miles since changing the gaskets and there isn't 1 drop of oil seeping out now so i'm well chuffed I just seem to be loosing power every time I do a log. Down to 189g/s now about 235bhp! Not good.
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  31. #30
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    Which short shifter did you go for? I keep meaning to get hold of the R32 one.

  32. #31
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    Very nice Westle, good work!
    > S3 225 (03) - OEM+
    > 205 GTI (90) - Limited Edition Miami Blue with full leather - 1 of only 300 made
    > Clio v6 255 (05) - Lethal Weapon

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  33. #32
    Westy's Avatar
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    Quote Originally Posted by wibble111 View Post
    Which short shifter did you go for? I keep meaning to get hold of the R32 one.
    I got this one:

    https://compbrake.co.uk/Parts-by-Car...l?review=write

    It's got a really nice feel to it.

    Quote Originally Posted by Funky_Junky View Post
    Very nice Westle, good work!
    Thanks matey. I'm not one for keeping the engine bay that tidy as I prefer to enjoy driving the car instead of looking at it but it has neatened things up a touch. Doing charge pipe tonight.
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  34. #33
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    Pics man, pics lol.
    Driving the most secretive S3 on ASN

  35. #34
    Westy's Avatar
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    My mans here now I'll get the pics off his phone once we get his bumper back on
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  36. #35
    Dani_B19's Avatar
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    Night time car work ftw haha.
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  37. #36
    Westy's Avatar
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    First up we rigged up a light so we could strip the car outside and use the garage for spray painting and cleaning.



    And so we began to remove parts:



    Fuel rail/injectors off and coil packs out:



    Rocker cover off and inlet mani off:



    Injectors in the bath:



    Mani masked:



    Mani painted:



    Rocker cover painted:



    TB painted:



    Ooops! The hole I put in the charge pipe by removing the bracket:



    Ran out of paint for the charge pipe so it needs another coat or two:



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  38. #37
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    Very nice mate, mine will look like that soon but wrinkle effect. Did you get pics of the rocker and cam gaskets mate?
    Driving the most secretive S3 on ASN

  39. #38
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    Respect to you and the boys westle! In the dark is harrrrdcore tinkering haha.

    Can't believe how tidy and clean it is under your manifold havin fitted the catch can.
    What's next on the agenda then?

  40. #39
    Westy's Avatar
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    Sorry dani we didn't get any pics of the actual gasket change. The rocker cover one is self explanatory, it fits over all the studs. The adjuster gasket is the fiddly one but it's just a case of sliding the old gasket out and the new one in.
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  41. #40
    Westy's Avatar
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    Cheers Karl. I love the old late night mechanics. Me and S3baby have been out there one night a week for the last 4 weeks. Tunes on, a cold beer and ASN on the laptop just incase

    Anyway I have loads of jobs left:

    Alarm batteries as I didn't get time
    Ball joints, drop links, top mounts
    Shocks and springs
    FMIC

    I'll try and get better pics and instructions for my next jobs.
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