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  1. #1
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    Daniel's S3 rebuild

    Well i brought this car a few months back, on impulse of someone i knew. Its has been quite a big financial mistake. The car is on just over 106k miles so you would not think it would have been too bad. I had to replace the dual mass flywheel with a new clutch not long ago. i replaced the cambelt, and waterpump. Changed the pick up feed, cleaned sump, changed rocker cover gasket etc. But the other week i was driving back from a 300mile journy, when i pulled over and stopped i heard a new kncoking noise. Took it into Jabba sport to have a look, they said my worse fears that it was bottom end. so i took the car home and dropped the sump to fined it had scored the crank (engine out job!) SOOO i brought the car for £3000 spent a £1000 when i got it on parts. Now i have to rebuild the engine so i guess i got shafted here but OHHH well i have fallen in love with the Audi. Trying still to sell my Mk4 Golf gti 1.8t but no one wants it.
    Anyway i have decided to do the work all myself as i always fined when i take a vehicle to a graged they either brake something or something break shortly afterwards. and i have been to a few diffrent garages. So its going to take me a very long time but i am giving it a go. well here are a few photos of the car being more and more stripped ready for the engine to be removed.


    Car at Cheddar gorge working!



    Was going to take the engine out today but i got the wrong tool off ebay for undoing the prop shaft, which is very anoying. Phoned up audi today tho and ordered some new parts:
    Crank
    Main Bearings
    Thrust bearings
    both crank seals
    oil pump and tensioner
    cam chain tensioner
    stem seals
    big end shells

    Now i am looking for some forged rods that are drilled, anyone advise any to me??? i am getting my block bored out to 82.5 and also needing some over sized pistons and rings but yet again dont know of a good make???

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  3. #2
    camscockle20vT's Avatar
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    Hi dude, where abouts you from? As a sponsor on here badger5 should be able to help. Also a few people on here that will probly be along shortley to help out.

    Good luck with the build.

  4. #3
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    Quote Originally Posted by camscockle20vT View Post
    Hi dude, where abouts you from? As a sponsor on here badger5 should be able to help. Also a few people on here that will probly be along shortley to help out.

    Good luck with the build.
    Well i am from Lincolnshire, yes i may need some help with what parts are best too put in as i have no idea but i want a strong engine. I also what to get around 300bhp out of the car, so i am wondering what is the best set up turbo wise etc.

  5. #4
    Benjiman46's Avatar
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    Where about's in Lincolnshire are you mate?? I'm in Coningsby through the week so could lend a hand if you're close!

    As for rods mate, check these out... Everyone raves about them. Get rifle drilled ones though.. Well worth the little bit extra.

    IE Con Rod 1.8T 144x20 | Shop VAG 1.8T | Backdraft Motorsport

    Ben

    1.8 litre porsche eater!

    R-Tech Terrorist Squad - 265bhp & 275lbft

  6. #5
    superkarl's Avatar
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    nice looking car. shame about the damage. do you know the cause? obviously its hard to tell but any signs?
    good luck with the build.
    theres so many options for power, search for build threads and you can choose the option best suited to you/your budget.

  7. #6
    <tuffty/>'s Avatar
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    Bill @ Badger 5 normally keeps drilled rods in stock and can get you pistons... JE 82.5mm will do the job (83mm will take you to a 1900 if you wanted to go that far)

    <tuffty/>
    Silver 2001 AMK S3. Silver alcantara interior... now with added powarrrrrrrr, torques. VAGCOM + KII-USB. >> My build thread...

  8. #7
    Sam_'s Avatar
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    CTS also have deals on them:
    VWVortex.com - *** IE Connecting Rods Specials @ CTS Turbo ***

    Not sure how the pound/$ is at the moment though. Then you have the duty lottery.
    Handling mods++. GTX30 soon-ish. Hiding parts from the mrs since 2011. Build thread

  9. #8
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    I am not far off spalding, and yes i have seen a few people use those rods. will be ordering some tbh and i will get the drilled ones as i do a lot of town driving. with the bottom end damage looks like i got contamination in the oil.
    Anyway got a phone call off audi today, i have to wait a week for the crank to come from Germany so it will give me some time to clean engine bay etc. I got my engine out today after work, i had a little trouble getting the exhuast off the turbo but i got there with some help. So what sort of price am i looking at for getting some over sized pistons and rings?


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    Mate just check Bill @ badger5 i think he stocks the IE rods they seem to be the finest:

    Integrated Engineering Tuscan 144X20 Rods 1.8T, FSI, 16V, early 8V Audi VW

    Pistons

  11. #10
    actualeddie's Avatar
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    Might as well get a stroke kit. Wish I had a spare car, so i could dismantle mine

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    i hear you mate , same here

  13. #12
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    well i got the head off the car today after work and it was what i would say a very depressing moment. Pistons are dented from exhuast valves and i found a crack on the head. WHAT DO I DO, the thing i dont get is i had the cam belt changed only a few thousand miles ago. they must have set it a tooth out the ****ers. Anyone got another head that i could buy please????

  14. #13
    superkarl's Avatar
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    ooooo not good.

    its a good opportunity to upgrade to a large port head though. AGU or AEB. ebay as always. look for a golf breaking etc

  15. #14
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    Quote Originally Posted by superkarl View Post
    ooooo not good.

    its a good opportunity to upgrade to a large port head though. AGU or AEB. ebay as always. look for a golf breaking etc
    what work will be need changing the head with a big ported head? same manifold, exhuast manifold?

    cheers

  16. #15
    superkarl's Avatar
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    yeh the same manifolds can be used they're fine.
    with the AEB head a little tab needs machining off, so if you can opt for an AGU.
    its a well worthwhile upgrade! if my engine was apart i would DEFINATELY be getting one.

  17. #16
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    Quote Originally Posted by superkarl View Post
    yeh the same manifolds can be used they're fine.
    with the AEB head a little tab needs machining off, so if you can opt for an AGU.
    its a well worthwhile upgrade! if my engine was apart i would DEFINATELY be getting one.
    i will keep a look out for one then

  18. #17
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    That's not damage from 1 tooth out! That's had a Cambelt snap at some time and either a new head or rebuilt head fitted.

    Fit an AGU or AEB head. Everything will just bolt straight up to it. I think you'd be best of getting a good used AGU engine for around £400, rebuild that, then you'll have higher compression and large port head.

  19. #18
    superkarl's Avatar
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    yeh i was just about to say, you'l need pistons, a3 and golf pistons are slightly higher compression so considered a bit of an upgrade.
    so like beachbuggy says, get hold of a full engine for cheap, there are some bargains out there too

  20. #19
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    Quote Originally Posted by beachbuggy View Post
    That's not damage from 1 tooth out! That's had a Cambelt snap at some time and either a new head or rebuilt head fitted.

    Fit an AGU or AEB head. Everything will just bolt straight up to it. I think you'd be best of getting a good used AGU engine for around £400, rebuild that, then you'll have higher compression and large port head.
    so an AGU head i can keep the same cams in with a APY engine?

  21. #20
    superkarl's Avatar
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    Quote Originally Posted by Dan s3 audi View Post
    so an AGU head i can keep the same cams in with a APY engine?
    yes everything is transferable, you can use agu cams, or apy
    its wise to get it built with new exhaust valve guides if its a high mile one.

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    agreed as Beachbuggy and SuperKarl, just get yourself a good AGU head, and while your at it get a stroker kit since your doing all the work yourself.. i think youll be happy it mate.

    impulse being isnt good i know i did it once on my previous A3 didnt go as well should i say.

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    wathching this thread with great intreast as it looks like ill be doing the smame sort of rebuild well done so far matey looking good

  24. #23
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    Quote Originally Posted by superkarl View Post
    yes everything is transferable, you can use agu cams, or apy
    its wise to get it built with new exhaust valve guides if its a high mile one.
    There is a good AEB head on ebay, so what needs to be machined is it somthing i could do myself? And are exhuast valve guids stem seals??

    Well i wont be getting a strocked kit i am going to get the black re-bored to 82.5 but looking at pistons i dont understand all this diffrent compression ratio stuff. can someone help me out on this one? Cheers

  25. #24
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    This came out off cylinder two notice anything wrong with it? lol

  26. #25
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    Oow bendy lol.

    Hows the block?
    Driving the most secretive S3 on ASN

  27. #26
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    block is getting re-bored tomorrow not too sure what bore to get 82.5 or 83

  28. #27
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    i fur going 83mm u might as well get a 2.0 tfsi crank and some 2..0 tfsi forged pistons :D

  29. #28
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    i have already brought a new standard crank from audi. i just did not know wether you had to change the valve springs if you went to 83 bore

  30. #29
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    I just want to add........ Well done !

    More balls than me taking on a job like that. :-)

  31. #30
    superkarl's Avatar
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    id go 83mm, its the safest bore you can take the block too, and gives you a nice official 1.9cc engine.
    compression ratio wise, it depends what you want to do with the car, i mean if you want to slap a big turbo on it then going a lower compression ratio is an ok idea, if not, id be wanting as close to stock as possible if you're keeping the stock turbo.
    stock comp ratio is 9:1
    i've only ever seen quite low aftermarket pistons at 8:1, which wouldnt be so great if you are keeping the standard turbo.

    here is an aeb head, with the relevant tab machined off (threaded hole, looks fresh) post number 1890:
    W3STY's Progress Thread

    and yes the exhaust guides are stem seals.

    what was the spec of your car to have bent the rod like that?

  32. #31
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    Well i took my block into a local engine tuneing place. Ordered some wossener pistons 82.5 £495 for a set not too bad me thinks, once i have them i will take them to the engine place where they will bore to suit. So now i need to decide on a turbo.

  33. #32
    superkarl's Avatar
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    Quote Originally Posted by Dan s3 audi View Post
    So now i need to decide on a turbo.
    a big one

  34. #33
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    Quote Originally Posted by superkarl View Post
    a big one
    why settle for one.... ;-)

  35. #34
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    Do it right and do it once, GT30
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  36. #35
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    Smile Hi Daniel, I am embarking on same job! Can I contact you please? Nice work by the way

    Quote Originally Posted by Dan s3 audi View Post
    Well i took my block into a local engine tuneing place. Ordered some wossener pistons 82.5 £495 for a set not too bad me thinks, once i have them i will take them to the engine place where they will bore to suit. So now i need to decide on a turbo.
    Daniel

    Thanks for posting this. I am embarking on the same job. Can we hook up. I am from Weston Super Mare. we ARE OBVIOUSLY BOTH MAD, for doing this. i think you have more to give than me having already done it, but i promise to help the other way round in the future!

    Thanks for posting all this!

    my contact details are 07970 268819

    My name is Nigel Banks

 

 

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