My silver S3 from South Africa

[Sidey]

Hi guys, I am from South Africa and purchased a 2001 8L S3 3 weeks ago, so thought I would start a rides thread.

2001 Audi S3 Quattro

99000km
FSH from agents
Black leather
Sunroof
Bone stock and only 1 owner since new

Few things to sort out but for the price I paid I could not let this one slip away.

Before I collected the car I had already bought some parts for it.

Audi TT pedals
EVO digital boost gauge
Gauge pod
BMC filter and K&N cleaning kit
Forge type DV
Pioneer AVH-P4350DVD

Some pics of the car itself

 

[gingergoolies]

looks really nice and clean!! look forward to seeing more pics of its progress!
got any other mods planned?

 

[Sidey]

looks really nice and clean!! look forward to seeing more pics of its progress!
got any other mods planned?

Thank you, I will update shortly.

Performance mods ill do the usual TIP, intake, FMIC, DP and exhaust, software.

 

[Sidey]

Got cracking on the boost gauge install.

The universal pillar pod really is a piece of s**t and does not line up with anything.

So thought id trim it down as much as I could and then id fibreglass it to the shape of the pillar trimming.

Got carried away with the trimming a bit and was left only with the cup piece.

Used some tape to hold it in position to get the right angle and temp fitted it to the car.

Got some brackets and epoxy from builders to fasten it to the pillar.

Found some fabric at chamdor to match the rooflining. Made the holes for the screws and the wiring.

After lots of pulling and swearing and sticking and and and....we have this.

Fitted the gauge last week, not lots of space in the S3 with all the wiring and electronics.


First had to clean all the leaves away to get the the grommet

Fat people never get off easy with this type of job.

And all done and fitted.

Best pic I could get at night time.

 

[Purdy99]

fair play, that looks really good! keep up the good work!

 

[guzzy_431]

Good work coming along there bro, loving the auto gauge it looks neat. What sort of BHP gains are you wanting to acheive? in the tamed beast?

 

[Sidey]

I am redoing the suspension on the car at this stage, not really happy with the ride.

Purchased some goodies this week.

Koni STR.T struts for front and rear.

Apex Coils.

Powerflex bushes , all thats missing is the powersteering rack mounting bush and the dogbone mount bush, they are on order and will have them in 2 weeks.

Front control arm bushes
Rear trail arm bushes
Rear Tie arms bushes
Front ARB bushes
Rear ARB bushes

 

[Sidey]

Good work coming along there bro, loving the auto gauge it looks neat. What sort of BHP gains are you wanting to acheive? in the tamed beast?

Im new to the quattro world, so I know there is quite some drivetrain loss, but 280whp will be fun.

Not new to the 20v world though, this was my previous car that I sold to buy the S3...

 

[Sidey]

This past weekend got cracking on the suspension, Did not get as far as I would have liked to, but working on quattro is a bit more challenging than normal fwd cars and takes time.


Fitted all the rear bushes, So will do the fronts next and then fit the shocks and springs.


Must say im going to have a very colourfull car with orange shocks, yellow springs and purple bushes :lol:

Some parts I have purschased.
Balljoints
Front control arm bushes solid TT
Febi shock mountings
Stabilizer bar links
Thermostat
Anti Freeze
Turbo gasket

So onto the suspension,
Rear Tie bars revomoved

Pressing old bushes out in the vice

New powerflex bushes lubed up with copper slip and inserted

Bars fitted back with lots of swearing

Rear sway bar bushed installed

Rear trailing arm bush (Original)

Oem vs powerflex

Fitted (its not damaged in the pic, just dirt)

 

[s3dave]

Excellent progress mate..:icon_thumright:

 

[Sidey]

Replaced the thermostat and then decided to replace the turbo gasket, because it was leaking quite a bit, which was suppose to be a short 1 hour job turned into a nightmare of a 10 hour job.


The turbo was replaced recently and instead of it having the OEM bolts, it had studs with nuts, so had to remove the complete manifold to get to the turbo gasket.


Here you can see the gap on the left where it was leaking

So had to strip a s**t load of stuff in the engine bay to get the manifold out, and with the quattro system everything is in the way and struggled my **** off getting to the bolts.

I was left with this, got some new gaskets and bolts and nuts today, so will put it all back together tonight.

[/quote]

New bolts/copper nuts/nordlock washers and vasbyt inserts

One insert in

Gasket now flat and tight

New OEM DP gasket

So one of the bolts on the exhaust side on the turbo was fecked, so to be able to get it out I had to strip it all off again :bang:


Hence my status on Facebook being

After removing KO4 turbo on quattro twice in 3 days, I think I am now qualified to be a Gynecologist!

SO new studs fitted and all is back again.

 

[MIGGZ]

Always awsome, neat and pro work done by you! And it helps that you got a looker of a car!

 

[Sidey]

Did a sump service on the S3 the past week.
New oil was purchased (Indy oil 5W40 Full synt) and two filters and new pickup with pan sealant.
Motor was flushed and oil pan dropped, was expecting to find a sludge filled oil pan with blocked pickup, but to my surprise its actually damn clean.

Oil pan inside

oil pickup

Internals looking nice and golden.

New pickup fitted.

Sump cleaned.

Sealent applied and fitted.

 

[Sidey]

The clutch is also on the way out, major vibration from the DMF and rattle noises from the Cylindric slave.
So the past Saturday Gizmo, Daniel and I tackled the job of dropping the box and fitting the new setup :crazy:


New DMF, pressure plate and clutch plate

OEM bolts

Slave, OEM rear crank seal, OEM stretch bolts for mounts and dogbone mount, OEM oil seals for transfer case that needs to come off

Last Thursday night I got cracking on stripping parts off the car to remove the gearbox on saturday.

Gizmo and Daniel rocked up at 9am and we got going on the gearbox right away, about 2 hours later the transfer box was separated from the gearbox and the gearbox was out and clutch assembly removed.

New OEM rear crank seals was fitted while everything was off.

New transfer box O-rings were also fitted, atleast now I know why mine was leaking, stuffed seals.

Long *** powersteering line that needed to be removed.

Gizmo tightening up the flywheel :lol:

Dougi looking like is gonna get butsexxxxx

Gearbox was soaked in cleaner and then pressure washed.

Old clutch setup pics, the DMF was completely nackered and had plenty of play on it.

The complete job of dropping the gearbox and fitting it back into place took us around 4 hours with lots of screwing around and joking and a case of beers. Was a great workshop session and I would like to give a big thanks to the guys that came to help.

 

[MIGGZ]

lmao dude i hate dropping boxes with my whole heart! but at least its done now, good work boy

 

[Sidey]

lmao dude i hate dropping boxes with my whole heart! but at least its done now, good work boy

Agreed boy, its the job I absolutely hate the most.

 

[Gizmo20VT]

Its done and dusted, was expecting it to be harder with transfer box and prop, so forth.

 

[Dougi]

Hi im here now and it was fun fitting the clutch!

 

[MIGGZ]

welcome dan-son!!!! remember spell check :Flush:

 

[Dougi]

Thanks dude, ill try.

 

[Sam_]

Nicely done. Hats off to ya. Think my DMF is ******** too. Judders pulling away sometimes

 

[Dan-Jnr]

Top work doing all that yourself. I wouldn't know where to start with dropping the gearbox.

 

[Sidey]

Thanks for all the kind words guys.

Collected my goodies to service and redo the CV shafts yesterday. Will do that this weekend and then assemble the car.

 

[Sidey]

So lost a bit of motivation to fix the S3, but after 5 weeks of being non mobile its running again, and driving like a dream with all the new bits and bobs.


So first onto the CV's.
They were completely stripped, cleaned and repacked with new grease.


Cleaning process

Nice and clean

No signs of wear

Repacked with grease

Shafts cleaned and sanded and received a fresh lick of paint

Before

After

Powerflex dogbone mounts

Poweflex bushes and new Solid bushes in control arms

Top shock mounts have seen better days

Rear colourful smartie box suspension

Powerflex Steering rack mount installed

New CV joint heat shield

 

[Sidey]

Did a joey mod on the headlights too. Came out quite awesome, need to pop around to NeVaG to get the lenses proper polished up.


Headlights before, lenses all pitted

Stripped

Lenses sanded down, wet sand 300/400/600/800/1000/1200/1500/2000

The drill attachment I used that works like *** together with plasti-X

Insides masked off and painted

Pics of the results to follow

 

[Sidey]

My boy Tiaan popped through one saturday so we could drill and re-tap his dogbone mount holes as the previous owner farked it up proper. So pics of the broken S3's :lol:

And onto the pics of where it is at now, had wheel alignment done yesterday and the car is a dream to drive now.

 

[MIGGZ]

i was wondering yesterday when will there be an update! looks sick dude i love it

 

[Sidey]

Bought a Forge 007 a steal.

 

[<tuffty/>]

Bought a Forge 007 a steal.

Won't be needing that red spring!! lol... to pre-empt the question, just use the green spring and one shim... seal the shim in using a bit of grease or a little sealant as this reduces the piston volume and improves response... only need a green spring to hold it 'shut'

<tuffty/>

 

[Sidey]

Won't be needing that red spring!! lol... to pre-empt the question, just use the green spring and one shim... seal the shim in using a bit of grease or a little sealant as this reduces the piston volume and improves response... only need a green spring to hold it 'shut'

<tuffty/>

Thanks Paul, Been reading a few threads on the forum about what spring to use but that clears it up nicely.

 

[Purdy99]

Amazing stuff! fair play to bud!

 

[Gizmo20VT]

Thanks Paul, Been reading a few threads on the forum about what spring to use but that clears it up nicely.

Update your timing chain noise! Might be usefull in future for another user

 

[s33nyboy12]

Update your timing chain noise! Might be usefull in future for another user

???????? share with the rest of us????????

 

[Sidey]

I'm quoting and posting this from one of the other forums I frequent.

I replaced turbo gaskets and when I started her up she sounded too good, no more gaskets blowing, real nice and smooth, until you rev it up, sounded like a TDI with marbles in the head.
Sounded identical to this
Audi A4 1.8T Cam Chain Tensioner (CCT) Failing? - YouTube


So after some troubleshooting etc, it was narrowed down to the Cam chain tensioner, Message was sent to Wikus at GW delarey and some new parts were collected yesterday (4k later )........OH how I love my S3 :lol:

New Chain Tensioner
New Chain
New Tensioner Gaskets
New tappet cover Gasket


As per the above post


Fitted the new chain tensioner and seals, but the noise is still there :bang: But will get to that now later in the post.
Was too happy to fit new tensioner seals and cover gasket as it was leaking like a b**ch.

Head inside still looks good, nice and gold from the full synthetic oil used its whole life.

Old tensioner

New Tensioner fitted

So after being all positive and starting her up, the noise was still there, so very ****** off Gizmo and I run Vag-Com to check for codes, and found that a code that pointed to the CPS (Cam position sensor), so went and purchased a new one, but to no luck, still makes the noise.

So the chain rattle/head noise directs to a few things:


Chain tensioner failed
Cam chain slack
Oil pressure channel to tensioner blocked/sludge
Oil pickup blocked
Low oil pressure


So tensioner has been replaced and noise is still there, so next on the list was to flush the motor and do a sump service.


New oil was purchased (Indy oil 5W40 Full synt) and two filters and new pickup with pan sealant.
Motor was flushed and oil pan dropped, was expecting to find a sludge filled oil pan with blocked pickup, but to my surprise its actually damn clean.

Oil pan inside

oil pickup

So I will clean the pan out, fit new pickup and then run the new oil for 500km, then drain it again and fill with new oil and filter, and see if this clears up the problem.


So after having chain rattle/tensioner problems for the past 2 months I have done the following to try and cure it.


New tensioner
New cam position sensor
Engine flush
New oil
Sump service
New oil pickup
Oil pressure test


So one thing that was left to do was change the chain itself.


Gizmo and Daniel popped past saturday morning to lend a hand with changing the chain.
What we found was the timing was out 2 teeth, so the previous owner who changed the cambelt fcuked it up.


Well we changed the chain, set the timing and the car is running like a dream, no more chain rattle, power is back (Better than before, never wanted to boost past 0.8 bar, now boosting 1 bar).


Some random pics that gizmo snapped.

 

[Gizmo20VT]

thanks bud!

 

[Sam_]

Guess you didn't re-use that old cam belt?

I'm fitting a new VVT tensioner plus chain on the new engine. Pretty glad after reading this!

 

[Sidey]

Guess you didn't re-use that old cam belt?

That belt has actually only done 5000km. They previous owner did not install the plastic cover right and it rubbed a little bit, but inspected the belt and it is still 100%.

 

[Sidey]

At last I have got a rear hatch emblem, thanks to gizmo.

Fitted my badge last night, its the one thing that was missing from the start.

 

[*P3nfold*]

That looks fresh

 

[Sidey]

De-wipered the rear yesterday, might not be everyone's taste, the rubber grommet is just for temporary, getting a glass plug cut shortly.


Before

After