Sky InsuranceMonster Motorsport
Page 4 of 7 FirstFirst 1234567 LastLast
Results 121 to 160 of 264
Like Tree63Likes

Thread: BAM S3 full rebuild for Hybrid or BT

  1. #121
    Westy's Avatar
    Double Dark Side! Diesel & 8P

    Status
    Online
    Join Date
    Dec 2008
    Location
    Cambridgeshire sometimes Hertfordshire
    Posts
    17,160
    Quote Originally Posted by hoffmanvp3 View Post
    AEB head for £90. Worth a punt for the big port head?
    I've got an AEB head. Was about £120 and needed a further £300 worth of work on it. As long as the head doesn't have any cracks in it you should be fine.
    8P A3 TDI - 220bhp - 335lbft
    A3 Maintenance Thread
    Bye bye S3 you will be missed.
    S3 Build Thread







  2. # ADS
    ADS
    Join Date
    Always
    Location
    Global
    Posts
    Many
     
  3. #122
    hoffmanvp3's Avatar
    1st Gear

    Status
    Online
    Join Date
    Sep 2013
    Location
    Oldmeldrum
    Posts
    276
    Are they prone to cracking? Any where in particular?

  4. #123
    superkarl's Avatar
    MAN OF STEEL

    Status
    Offline
    Join Date
    Mar 2010
    Location
    Liverpool/Southport. N west
    Posts
    7,455
    Across the exhaust valves.

    Just make sure you check the guides for wear, esp exhaust side and replace, also stem seals.

  5. #124
    hoffmanvp3's Avatar
    1st Gear

    Status
    Online
    Join Date
    Sep 2013
    Location
    Oldmeldrum
    Posts
    276
    well as expected my bores are oval`d
    so that means re bore and some shinny new pistons are needed
    whats people recommendations on new pistons and new bore sizes?
    I know that 82.5mm is the max safe limit for a road car





    Cylinder one average: 81.111mm with ovality of 0.127mm
    Cylinder two average: 81.274mm with ovality of 0.224mm
    Cylinder three average: 81.308mm with ovality of 0.246mm
    Cylinder four average: 81.260mm with ovality of 0.233mm

    Cylinder three looked like it was running hotter than every one else as thats the worst one

    But this is with a very good factory cross hatch still shown but its done 115K so some things gotta ware.

  6. #125
    s3dave's Avatar
    TFSI Hybrid

    Status
    Offline
    Join Date
    Nov 2009
    Location
    west yorks
    Posts
    10,061
    Not many people check for ovalness say good shout, 83mm pistons all the way...!!

  7. #126
    hoffmanvp3's Avatar
    1st Gear

    Status
    Online
    Join Date
    Sep 2013
    Location
    Oldmeldrum
    Posts
    276
    isn't that too much for a road engine?

  8. #127
    hoffmanvp3's Avatar
    1st Gear

    Status
    Online
    Join Date
    Sep 2013
    Location
    Oldmeldrum
    Posts
    276
    Cylinder 1

    Cylinder 2

    Cylinder 3

    Cylinder 4


    the Oil pump chain tensioner didn't look too bad either, but will be replacing it any way


    Shame i gotta replace the pistons as theres not a mark on them


  9. #128
    superkarl's Avatar
    MAN OF STEEL

    Status
    Offline
    Join Date
    Mar 2010
    Location
    Liverpool/Southport. N west
    Posts
    7,455
    83mm is the biggest most people take them as its safe. 83.5mm is the limit, but some people do it.
    If youre going to rebore may aswell go for the biggest displacement you can, 83mm.

  10. #129
    hoffmanvp3's Avatar
    1st Gear

    Status
    Online
    Join Date
    Sep 2013
    Location
    Oldmeldrum
    Posts
    276
    well i`d like to air the side of caution plus 82.5mm i can still use the oem head gasket.
    If i go to 83mm then the block is scrap if any thing goes wrong, where as with 82.5mm ive still got a bit of meat left just in case

  11. #130
    1st Gear

    Status
    Offline
    Join Date
    Nov 2011
    Location
    Finland
    Posts
    131
    Did You measured the ovalness with bare block? As the measuring should be done with the head on and torqued.

  12. #131
    hoffmanvp3's Avatar
    1st Gear

    Status
    Online
    Join Date
    Sep 2013
    Location
    Oldmeldrum
    Posts
    276
    Was measured by bare block. Didn't know about the head being torqued on.
    Didn't think it would make any difference.
    Not like they machine the bores in the factory with the head torqued on

  13. #132
    Westy's Avatar
    Double Dark Side! Diesel & 8P

    Status
    Online
    Join Date
    Dec 2008
    Location
    Cambridgeshire sometimes Hertfordshire
    Posts
    17,160
    Quote Originally Posted by hoffmanvp3 View Post
    Was measured by bare block. Didn't know about the head being torqued on.
    Didn't think it would make any difference.
    Not like they machine the bores in the factory with the head torqued on
    I'm assuming there might be a very minimum change in ovality with the head on and torqued up, but very minimum.
    8P A3 TDI - 220bhp - 335lbft
    A3 Maintenance Thread
    Bye bye S3 you will be missed.
    S3 Build Thread







  14. #133
    superkarl's Avatar
    MAN OF STEEL

    Status
    Offline
    Join Date
    Mar 2010
    Location
    Liverpool/Southport. N west
    Posts
    7,455
    There will always be a degree of ovality with any used engine due to the way the piston pivots on the rod. Pretty pointless measuring if you ask me. Piston to wall clearences is what you need to be concerned about and if they are within spec all the way round.
    Which is something your machine shop will need to know when boring for the larger pistons.

  15. #134
    <tuffty/>'s Avatar
    Badger 5 Edition

    Status
    Offline
    Join Date
    Sep 2008
    Location
    Gloucestershire
    Posts
    15,025
    Quote Originally Posted by hoffmanvp3 View Post
    Was measured by bare block. Didn't know about the head being torqued on.
    Didn't think it would make any difference.
    Not like they machine the bores in the factory with the head torqued on
    I would imagine they use a torque plate though

    Integrated Engineering 1.8T 20V Torque Plate

    My block was bored with one bolted on...

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

  16. #135
    s3dave's Avatar
    TFSI Hybrid

    Status
    Offline
    Join Date
    Nov 2009
    Location
    west yorks
    Posts
    10,061
    I dont think an ali head is going to alter the shape of a steel block torqued or not, it just wouldnt happen....

    Karl, Ive just examined my old block, and still scratching my head in why it failed (#2 piston well down on comp....)
    no visable signs of damage, i thought a ring had snapped, but all is fine, i have noticed play front to back in the bore so im guessing it has gone oval, i will measure when i get time, maybe bore wash ??

  17. #136
    superkarl's Avatar
    MAN OF STEEL

    Status
    Offline
    Join Date
    Mar 2010
    Location
    Liverpool/Southport. N west
    Posts
    7,455
    dave there is always the tiniest bit of front to back movement, but yeh if its excessive then bore wash could account for that. I think tuffty had worn rings due to bore wash at one point.
    But havent you always been running tuned and afrs ok etc.

    Check the head, and the valves/seats.

  18. #137
    s3dave's Avatar
    TFSI Hybrid

    Status
    Offline
    Join Date
    Nov 2009
    Location
    west yorks
    Posts
    10,061
    I put oil down the bore when it was still altogether and the comp came straight back up,,,
    Andrew As got my head so im sure if anything is a miss he will spot it, the head as only done 5k since rebuilt by Drakes

  19. #138
    Andrew@A.L.D's Avatar
    Cylinder Head Master

    Status
    Online
    Join Date
    Jun 2009
    Location
    Leeds
    Posts
    3,352
    It was me that damaged rings due to bore wash

    Dave. Picked up your head today and port three is oily, I'm sure your right about your bore or it could be a bad set of rings or they didn't bed in that well?
    Was 531bhp 8L S3 thats going to break the 600+ bhp Club then break something else. Lets see what this OD HTAGT3582r can do
    My S3 Twists Drive shafts for fun.

    FOR SALE
    Sparco Torino 2 sport seats
    Adjustable FPR from 1-5 bar, 2 sets of Unused ARP 3/8 2000 rod bolts
    , relentless 200 cell cat pipe, Std AGU Crankshaft. Ported & Reconditioned Cylinder head service.

  20. #139
    s3dave's Avatar
    TFSI Hybrid

    Status
    Offline
    Join Date
    Nov 2009
    Location
    west yorks
    Posts
    10,061
    RS tuning built it last time, and it never made good power on hybrids, so maybe the problem was there all along?

    Anyway sorry for the slight derail....carry on
    badger5 likes this.

  21. #140
    <tuffty/>'s Avatar
    Badger 5 Edition

    Status
    Offline
    Join Date
    Sep 2008
    Location
    Gloucestershire
    Posts
    15,025
    Quote Originally Posted by s3dave View Post
    I dont think an ali head is going to alter the shape of a steel block torqued or not, it just wouldnt happen....

    Karl, Ive just examined my old block, and still scratching my head in why it failed (#2 piston well down on comp....)
    no visable signs of damage, i thought a ring had snapped, but all is fine, i have noticed play front to back in the bore so im guessing it has gone oval, i will measure when i get time, maybe bore wash ??
    Its not just the ali plate/head that does it... its the force induced from the bolts that can pull the block out of square...

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

  22. #141
    hoffmanvp3's Avatar
    1st Gear

    Status
    Online
    Join Date
    Sep 2013
    Location
    Oldmeldrum
    Posts
    276
    Well today i got my brother who`s a machinist and got him to measure the block, crank, pistons, piston ring grooves and gudgen pins the old fashion way with mic`s and was very happy with the results
    He didn't believe that on of the cylinders was coming back at 81.308mm which should of been slapping like a ******* and smoking oil.
    He also doesn`t like the Faro arms as his work just got rid of theirs as it kept giving false readings.
    Here`s what we found





    Last edited by hoffmanvp3; 19th October 2013 at 18:56.

  23. #142
    hoffmanvp3's Avatar
    1st Gear

    Status
    Online
    Join Date
    Sep 2013
    Location
    Oldmeldrum
    Posts
    276
    Took ages converting back to Metric as the Mic`s were imperial.
    But very impressed with the results after the engines done 115K but had FASH and was completely standard when i got my hands on it

  24. #143
    hoffmanvp3's Avatar
    1st Gear

    Status
    Online
    Join Date
    Sep 2013
    Location
    Oldmeldrum
    Posts
    276
    What's every ones perspective on balancing an engine when you've just replaced the rods?
    id agree and do it if I'd re bored the block with new pistons but don't see the point if the new rods are gram for gram?
    cheers guys

  25. #144
    s3dave's Avatar
    TFSI Hybrid

    Status
    Offline
    Join Date
    Nov 2009
    Location
    west yorks
    Posts
    10,061
    If you are planning a higher revving engine than stock i would do the crank, while its all out

  26. #145
    superkarl's Avatar
    MAN OF STEEL

    Status
    Offline
    Join Date
    Mar 2010
    Location
    Liverpool/Southport. N west
    Posts
    7,455
    Get the oem pistons checked and balanced. Mine werent within a gram like the rods were.
    Also get the crank done, and if going single mass, get that done with it too.
    s3dave likes this.

  27. #146
    hoffmanvp3's Avatar
    1st Gear

    Status
    Online
    Join Date
    Sep 2013
    Location
    Oldmeldrum
    Posts
    276
    Well not much of an update but parts are starting to roll in.
    Shells for the main and big end
    Forge coolant hose kit
    Will be seeing my Rods and stud kit tomorrow



    Now i know its not every ones brand of vodka but couldn't just leave the block all rusty and scabby after all the hard work of re building her so painted that and its needing a few more coats but liking what im seeing
    s3dave and Brazuko like this.

  28. #147
    hoffmanvp3's Avatar
    1st Gear

    Status
    Online
    Join Date
    Sep 2013
    Location
    Oldmeldrum
    Posts
    276
    Well the blocks finally cured after 3 coats


    A gathering of parts have now turned up so starts the assembly process.




    Weighted the new rods and was amazed how they all weighted the same.

    The heads off to a specialist i know up here so i`ll have that back in a week, providing its not needing too much.
    Some odds n ends blasted and then heat painted

    Thinking of making a old crank from the scrapyards and make a pretty cool lamp lol


    Crank lower main shells in and lubed up with assembly lube

    ARP main stud kit in place

    Sump needs a little tickle with a file for the stud clearance on the clutch side
    Plastigauge in place for reading the oil clearances


    And all within spec
    Freshly de glazed bores


    And slowly starting to look like a engine again

    Sumps only there to catch assembly lube drips in case any one says i forgot to fit the crank oil seal flange lol
    Westy and Brazuko like this.

  29. #148
    hoffmanvp3's Avatar
    1st Gear

    Status
    Online
    Join Date
    Sep 2013
    Location
    Oldmeldrum
    Posts
    276
    Forgot to ask but there no mention on the IE Tuscan rods which direction their to be fitted?
    Thought there was a arrow which has to be pointed towards the timing belt?
    Cheers

  30. #149
    <tuffty/>'s Avatar
    Badger 5 Edition

    Status
    Offline
    Join Date
    Sep 2008
    Location
    Gloucestershire
    Posts
    15,025
    Tang faces towards inlet side of the engine

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

  31. #150
    hoffmanvp3's Avatar
    1st Gear

    Status
    Online
    Join Date
    Sep 2013
    Location
    Oldmeldrum
    Posts
    276
    That`ll do for me, Cheers tuffty
    Would of thought IE would of said lol

  32. #151
    www.badger5.co.uk

    Status
    Offline
    Join Date
    May 2004
    Location
    nr Glos
    Posts
    6,943
    Quote Originally Posted by hoffmanvp3 View Post
    That`ll do for me, Cheers tuffty
    Would of thought IE would of said lol
    IE will assume the engine builder knows this fella

    same as oe ones which were removed
    **http://www.facebook.com/Badger5Ltd**

    Check out the ever Growing eBay Shop>
    http://stores.ebay.co.uk/Badger-5-LTD?_trksid=p4340.l2563

    Badger 5 Ltd, Queen Annes Gate, Oldends Lane, Stonehouse, Glos, GL10 2DG


    http://www.badger5.co.uk, Tel:01453822880
    bill@badger5.co.uk
    **NEW** Badger5 Section CLICK here>> http://www.audi-sport.net/vb/213-badger-5/

  33. #152
    hoffmanvp3's Avatar
    1st Gear

    Status
    Online
    Join Date
    Sep 2013
    Location
    Oldmeldrum
    Posts
    276
    Yea that's true. I miss driving the S3 and the smell of the leather seats. Might just sit in her tomorrow and have a nice big sniff lol
    Been driving the octy4x4 that has a stage 1 map for the winter car and miss the tight handling of the S3. The octy's like a boat in the corners and shouldn't be running 200 brake with the standard shocks lol
    Westy likes this.

  34. #153
    www.badger5.co.uk

    Status
    Offline
    Join Date
    May 2004
    Location
    nr Glos
    Posts
    6,943
    Quote Originally Posted by hoffmanvp3 View Post
    Yea that's true. I miss driving the S3 and the smell of the leather seats. Might just sit in her tomorrow and have a nice big sniff lol
    that sounds all kinda of wrong - lol
    **http://www.facebook.com/Badger5Ltd**

    Check out the ever Growing eBay Shop>
    http://stores.ebay.co.uk/Badger-5-LTD?_trksid=p4340.l2563

    Badger 5 Ltd, Queen Annes Gate, Oldends Lane, Stonehouse, Glos, GL10 2DG


    http://www.badger5.co.uk, Tel:01453822880
    bill@badger5.co.uk
    **NEW** Badger5 Section CLICK here>> http://www.audi-sport.net/vb/213-badger-5/

  35. #154
    hoffmanvp3's Avatar
    1st Gear

    Status
    Online
    Join Date
    Sep 2013
    Location
    Oldmeldrum
    Posts
    276
    Lol
    well that's the engine booked in for balancing. £120+vat. Think that's a bit steep but their the only place up here so gonna have to bite the bullet

  36. #155
    hoffmanvp3's Avatar
    1st Gear

    Status
    Online
    Join Date
    Sep 2013
    Location
    Oldmeldrum
    Posts
    276
    More bits from TPS



    timing belt kit, aux belt, vag sealant, after run pump, thermostat, slave cylinder, crank case breather housing gasket, complete piston ring set and crank cam belt pulley bolt. Just waiting on new crank thrush washers
    Brazuko likes this.

  37. #156
    Westy's Avatar
    Double Dark Side! Diesel & 8P

    Status
    Online
    Join Date
    Dec 2008
    Location
    Cambridgeshire sometimes Hertfordshire
    Posts
    17,160
    Quote Originally Posted by hoffmanvp3 View Post
    More bits from TPS



    vag sealant
    Dani_B19, Gops and superkarl like this.
    8P A3 TDI - 220bhp - 335lbft
    A3 Maintenance Thread
    Bye bye S3 you will be missed.
    S3 Build Thread







  38. #157
    hoffmanvp3's Avatar
    1st Gear

    Status
    Online
    Join Date
    Sep 2013
    Location
    Oldmeldrum
    Posts
    276
    A ********...that's prob cheaper lol
    always amusing when u wonder in and ask for vag specific sealant
    Westy likes this.

  39. #158
    hoffmanvp3's Avatar
    1st Gear

    Status
    Online
    Join Date
    Sep 2013
    Location
    Oldmeldrum
    Posts
    276
    Well thats the crank and rod/piston assy balanced now, picking them up today
    cos i was only getting the crank done got it for £90 all in, normally more if flywheel was geting the same treatment.
    They did ask for it but i argued that when its clutch changing time then the balance will pointless.
    Plus im getting the LOBA stage 2 SMF kit which is lightened and balanced so happy days then.

    Well some intresting parts came through, the Thrust washers for the crank which looked no where near like the old ones and tps were saying these are the part numbers for my BAM, which clearly isnt right
    top ones are the originals and the bottoms are what tps gave me

    so the correct ones are coming today 026 105 635 A
    the wrong ones were 06A105637A which look like its for the older 1.8t blocks which have 4 thrust washers where as the BAM only has 2.

    New clutch bleeder which is metal instead of the plastic oem so wont flex so im hoping this will make my LOBA clutch on/off feel more precious
    s3dave likes this.

  40. #159
    hoffmanvp3's Avatar
    1st Gear

    Status
    Online
    Join Date
    Sep 2013
    Location
    Oldmeldrum
    Posts
    276
    Well this morning I've removed and fitted the new clutch slave cylinder and checked the gearbox input shaft oil seal and its not leaking
    fitted the new clutch bleeder




    also picked up the newly balanced crankshaft and con rod assy from Agra machine shop, just a baw hair out they said lol




    Brazuko likes this.

  41. #160
    CMcKenzie's Avatar
    It's supposed to do that..

    Status
    Offline
    Join Date
    Apr 2012
    Location
    East Yorkshire
    Posts
    259

    My Social Networking

    Add CMcKenzie on Facebook Visit CMcKenzie's Youtube Channel Visit CMcKenzie's Instagram Channel
    How have I been watching this on Facebook but not noticed it on here. Keep up the good work and all the best fella.
    Callum.
    hoffmanvp3 likes this.
    2000 APY S3

 

 
Page 4 of 7 FirstFirst 1234567 LastLast

Similar Threads

  1. Milltek Full System for the Sportback 2.0 TDI
    By b19ctr in forum A3/S3/Sportback (8P Chassis)
    Replies: 10
    Last Post: 16th July 2010, 07:33
  2. full service for s3
    By crackers187 in forum A3/S3 Forum (8L Chassis)
    Replies: 2
    Last Post: 1st April 2010, 09:41
  3. 2002 A3 1.8T Full Leather. For Sale.
    By bennojones2003 in forum A3/S3 Forum (8L Chassis)
    Replies: 5
    Last Post: 2nd March 2010, 15:38
  4. full service for 150
    By zeeeebo in forum A3/S3 Forum (8L Chassis)
    Replies: 5
    Last Post: 14th August 2009, 03:05
  5. Full leather for my B5 Avant
    By albgut1 in forum A4/S4 forum(B5 Chassis)
    Replies: 7
    Last Post: 20th October 2005, 11:05

Posting Permissions

  • You may not post new threads
  • You may not post replies
  • You may not post attachments
  • You may not edit your posts
  •  
Single Sign On provided by vBSSO

Garage Plus, Vendor Tools vBulletin Plugins by Drive Thru Online, Inc.

Content Relevant URLs by vBSEO