A3 1.8 - 8L To Track or Scrap?!? - Slow Project

[CabbageGT]

Ok, here goes..

Going back 6month, my Boss gets a phone call regarding an Audi A3 (p.reg) being sold for a small sum, and that the Plate was Porsche 911 related... Needless to say he ripped the owners arm off and pinched the plate for his pride and joy.
Having had no luck discarding of the A3, It has since been sat at the back of the factory/workshop.

Following recent months of hard work and increased efforts at the office, I have been rewarded for my dedication... Any guesses as to what my reward was....

As the title suggests, I have mixed feelings about this A3. With a limited history of "doing up cars" and my constant ranting about engineering and mechanics, mixed with cravings for the track... I think I really need this project.

Financially, I'm stuck between a rock and a hard place. I live in an Apartment while my tools are held up at the Missus's parents, and we have one parking space.. on the plus side, Work includes Fabrication workshop, some Tools, and tonnes of space to work on a car.


So far I've had two Hours to suss out the A3. This is what I know so far, and what I'm here for!

• It runs on 3, Lucky I went in early and could see the sparks jumping about.. so I need a fresh set of HT's.

As it heats up, the 4th cylinder joins the party... but it still runs like a bag of bolts

• when you press on the throttle, the revs drop... Even with my thumb covering the vacuum leaks.
• The Instrument Cluster is dead to the world... apparently it works when it wants to?! sounds familiar! I suspect bad earth, but I'm fearing the whole Motorola chip issue? NEED HELP WITH THIS ONE! PLEASE
• OIL... EVERYWHERE!!! :/
• Wipers don't work... I can hear the Motor, and the grinding, but I don't know what the real fault is yet.

So as you can tell, I'm still on the fence with this... Ill post a picture tomorrow for you all to Laugh at... but in all seriousness, I wouldn't mind the project providing I can Iron out a couple of things.... Main worry being the Speedo. If its going to cost me an arm and a leg before I can even get Her on the road, then Its just not feasible.

As for the A3.. I can feel the bond already, and as much as I want to, I'm refraining from writing out my list of things I want to do..
Plus It would be nice to meet a few fellow petrol heads in the process

Cheers........... ........... Joe

 

[jojo]

If it's a 1.8 20v, then scrap it mate, if it's a 1.8T 20v, then there's a project to be had! You need to have a look at 'Prawn's' track A3 to see what's possible, but it has taken him a long time and money to get it to what it is today. Really depends on what your budget is.

 

[jcs356]

As Joe says, if it is 1.8T do it. I've had tremendous fun firstly in my Ibiza and latterly in the Cordoba. It's also improved my driving no end.

 

[CabbageGT]

Yeah and id agree, but somehow I've found myself in a very awkward situation where Scrapping this banger isn't a valid option.. not yet anyway.

Spending too many hours pondering over what to do, when secretly all I want to do is murder it on the track.
Budget depends on where this is heading.
First thing is to get this running right. Exhaust will be coming off for welding when I get 5 min. Ill get some HT leads and vacuum hose, then I really need to tackle this Dash problem..
And in the meantime Ill be scouring eBay for anything I can make use of.

It may only have a 1.8 normally aspirated lump in there now. but who knows, maybe one day if the chassis is still up for it, ill treat myself to a few more bhps and swap it out for a BAM. I understand the work required to a degree, and its the hours spent tinkering that will make this worthwhile to me, that and the Track.... I will get this to the Track... (with dignity attached)

 

[jojo]

Great colour! Make it into a track slag!

 

[CabbageGT]

Oh thanks... Not sure if your being sarcastic haha, you'd be having second thoughts if you saw it in the flesh. Any idea on what colour it is? And don't say blue!! Colour code?

Getting my tools together tomorrow, then off to a scrappy to scavenge a few bits, could do with a few bumpers to play with... But I'd best stick to getting the engine running smooth for now...
Work on the exhaust starts soon.

 

[Tim_Attard]

imo mate if your 100% going down the track route i would sort out the non engine problems and then swap out the engine first asap and not to worry about fixing the NA 1.8.

 

[jojo]

Oh thanks... Not sure if your being sarcastic haha, you'd be having second thoughts if you saw it in the flesh. Any idea on what colour it is? And don't say blue!! Colour code?

Getting my tools together tomorrow, then off to a scrappy to scavenge a few bits, could do with a few bumpers to play with... But I'd best stick to getting the engine running smooth for now...
Work on the exhaust starts soon.

Cornflower Blue I think it's called, I was being serious, sharpe colours make great track cars! I'd like an orange or green S3 track car!

 

[jcs356]

Yep, Cornflower Blue.

 

[CabbageGT]

What s***e weather we had today, I got my tools stored nicely ready for some action, but nothing else happened today. Missed out on some vinyl wrap at an insanely low price, and I've got my eye on plenty of parts. May start looking for a 1.8t lump or donor, so much to think about.

Does anyone have any ideas about the instrument cluster? I've spent a lot of time reading deadend threads and my eyes are now in pain. Will my 96 dash have integrated Imobilizer? And if I did a straight swap do I need a specialist to reprogram it?

 

[phil miller]

yes it will, speak to scottB5 he can help with the cluster

 

[CabbageGT]

ScottB5, Cheers for your help dude, I've not fixed it like, but at least I have a better understanding of the issue. Will let you all know what the outcome is when I get to it.

As for Progress.. Well the HT leads got very wet today, and I got a jolt from the B**tards.. The 2 tonne jack was too small, didn't give me enough height, so I made a ramp.. but the car decided to Only idle on 2cylinders... So I got the BIG Jack out.. Rated 25 Tonnes!! Now I can access the Exhaust and remove it tomorrow

Anyone have any advise on making 8mm HT Leads?

 

[CabbageGT]

Since last post:-

pondered over 1.8 overhaul or 1.8t lump.. currently don't have the coins for either :/

started taking things apart.. broke many brittle plastic components :/
all wiring put to one side.
the past owner has glued the indicator to the wing.. need a new indicator unit :/
radiator and water hoses are all out, the steel water pipe is heavily corroded.
removed the front bumper, crash-bar and frame.
pas pump and badly corroder cooler removed.
cam belt is off
took the head off.
removed the block from the gearbox. lesson learnt - use a hoist next time, that lump must weigh about 90kgs
sandblasted a tonne of parts while my back recovers. (manifolds, rocker cover, steel water pipe, brackets etc)

changed springs, wishbones, trackrod ends and droplinks on a Peugeot 206.. what a waste of f***ing time!!

driveshafts need replacing, or perhaps I'll actually bother changing the boots and servicing them.
the whole car needs degreasing.. its a friggin mess

exhaust valves are out, Needed to make a tool to fit the inlet valve caps.. need a thinner magnetic rod to retrieve the collets.

so with that said, I have a few small questions for anyone willing to give my 1.8 project (if you can call it that) the time of day. I understand that by not having a turbo I am completely out of place here as the forum title suggests "Audi-Sport" haha.

My questions are.

Valve guide play. how much is acceptable-ish?

the steel gaskets from Chain tensioner, oil cooler to block, and sump. can I reuse with Loctite 515?

is the front end compatible with A4 components? I.e. facelift lights and bumpers and such?

the car is currently sitting on the original pepper pots... which I actually quite like.. would coilovers make contact with 15" rims? and roughly how much spacing would be required?

the current tyres are 195 65 15. can I fir 195 50 15 Yokohama prada 2's?? or will this make it less likely to be successfully lowered on coilovers?

anyone here done much vinyl wrapping?

Welcoming criticism... I know my car's a bag of ****e

 

[RGL]

Wow what a thread! As a fellow free breather who has been buggering these turbo fanatics here at audi-sport for a while now I applaud you sir. I aswell have a 1.8 N/A, even might have the exact same engine since mine is from '97. The itch for a 1.8T will be haunting you forever, that's all I can say (it has haunted me for about 1,5 years, even though 1.8 N/A isn't actually the worst choice possible IMO). Unfortunately I have no answers to your questions, but I will be following your progress with popcorn at hand, since your car is almost identical to mine. This is going to be interesting.

 

[jay651]

as of next week with have the complete engine and gear box out of my old a3 that I would do a deal on shes a health running 1.8 agu only sell due putting the car on its roof

 

[Squirt]

I also have a complete AUQ 180bhp engine, wiring loom, turbo, 6 Sp gearbox, driveshafts and hubs out of car and ready to fit! Let me know if interested.

 

[s3mad_dude]

Err.....well I don't have anything to offer you except for one of those metal clips to hold the rear tailgate trim on! Aside from that, loving the thread and car looks great too! Good luck getting it back on the road!

 

[CabbageGT]

Cheers, Thank you all for your support. Nice to see some enthusiasm for the 1.8 N/A's. I'll see how it goes with the current lump before I swap it out.. It'll give me more time to bond with the car before I'm tasked with wiring and tuning a 1.8t. or V6

Anyway.. pictures so far








and some sandblasting.... Id like to try vapour blasting on this.




The seats have kinda gone mouldy, not to worry though, the whole interior needs a refresh and bucket seats. proper ones.. maybe.

planning to spend an actual day on it this weekend... haven't really had more than 15 consecutive minutes with it yet. Would be nice if it was dry too.

 

[CabbageGT]

Haven't had much time to play this past few weeks. Sun was out today.. I was in work :/ . Still, I got 15min to whip the valves out of the head.
Epic cleaning time commence!!


Did this.. The parts list is growing

cleaned 1 alloy.. needs finishing with some cutting compound and polish

I've actually done abit more than this but I always forget to take pics

Brake Lines are off, ABS is off, Master Cylinder is off, ECU is out and most of the loom.. Almost ready for a de-rust and paint. The plan is to Wrap the car, So all the detailed areas like under the bonnet will be sprayed white. because I'm stupid and want to highlight all my oil leaks.

 

[superkarl]

I tell you what, I admire your dedication with this!
Its not going to be a performance or track beast, but how about making it a show queen, put some money into making it look sweet.

 

[CabbageGT]

I've been thinking about which direction to take to be honest, I'd be quite happy gutting it, cleaning it, getting it running, and then while its functional and I've learned the in's and out's of the car, I could then look at getting a fresh lump on a stand and starting down the performance route. One things for sure though, It cant stay looking like it does.

 

[CabbageGT]

Ok, So I've not been keeping my thread up-to-date Like I said I would, bottom line is that I've just been way to busy to even upload photos. the current state of my project is ... fairly good... and I'm about done getting it running. remember this isn't Turbo'd.....Yet.

The strip-down was quite long winded as the state of all components required me to clean and assess Everything. Parts where ordered and more parts ordered after that. by which point there's no turning back, its full commitment now.

Re-build was more straight forwards, and re-fitment to the car was a piece of cake, even though I did it all alone, it couldn't have gone smoother.

So I hope it doesn't look too tacky, and as always I expect to be slated for wasting time and money on a N/A lump like this.

















So that cuts a long story short. Now for the fun part.. Bleeding, electrical faults, exhaust, body work and interior.

The Dash is still Dead. and I have no temp Gauge to go by when running the engine in.
the exhaust is a bit naff.
bumpers and lights are crappy, not a major issue, just crappy.
Alternator has been back-feeding, its been diagnosed today as faulty. will be repaired by Thursday. then I can tackle the dash and instrument cluster..... Advise on the instrument cluster is always welcome.
I should now have some extra time to be able to post and keep my thread alive, Starting to get exciting now

 

[CabbageGT]

Slight progress on the rear.

everything removed from the rear. Hopefully the exhaust parts will arrive in time for the weekend, nothing fancy, I just don't want to put the original exhaust back on as its horrid

Before and after. Both have been blasted now ready for paint this weekend.

I got the alternator back today, but it didn't solve my electrical issues, I've already put together a separate topic about this issue today, if anyone has any clues I'm all ears.

still none the wiser on the instrument cluster, Ive ordered a Vagcom lead, and downloaded lite. will register on the works laptop and investigate #17 - instrument cluster and post back with results if any :/

 

[CabbageGT]

Well, Its been a Long time since I've visited the site properly and Its looking awesome on here now, So much has changed to the layout and functionality, I'm impressed

Firstly, Happy 2015! to everyone on here. I received great support with my project last year which has enabled me to continue playing.

The second half of 2014 set me back a bit and the Car hasn't really seen much action. I've Changed Wheels and sorted a few minor issues out and I've also learned of some additional problems which are coming my way if I don't act soon...

Looking back, I never even mentioned that the car passed its first MOT with me as its owner with 0 issues 0 advisories, Or that I even got the car running :/

I fixed the Dash problem by replacing the entire unit and reprograming Keys to suit

I initially had a hard knocking under the car, which later turned out to be a stripped Sub-frame mounting bolt. the short of it is that I had to remove it all and weld in an insert.
The OEM Droplinks lasted 1 month before exploding, I've now bought Metal ones.

The Alloys are Inovite Rays (I think), I found them at a powder coating firm. They where recoated free of charge, or as part of the deal with part worn tyres and a balance.

I attempted window tinting with a £5 roll. put it this way, I'd rather try and fail than pay £125 for a window tint that I don't even know I'll enjoy. as it turns out 5% is just too dark. when the time is right I will fork out on a professional job at 25% light.

I found that my spare wheel well was holding 4L of water, but I don't know why. I thought the sloshing noise was the Antifreeze mix I carry around, I only went looking because my Windows have been condensate'd every morning over winter. its getting better now but I anticipate a return.

Changed my rear lights as the old where split.

And my gear linkage failed while I was parking in a Morrisons carpark... Though ive now replaced the damaged components, the setup is in need of .. well, Setting up properly.

My brakes are utter Sh*te since I got the car on the road. This will be my next target area... However as I'm playing on a budget, the first step is to find some donor S3 Hub assemblies, Callipers and possibly Discs. Time to start querying.

My Engine Stand Is currently holding the Block of a Toyota MR2 MK3, the engine build is nearing completion and soon I will be looking for the next power-plant for the A3. There's no TrackDay on the Horizon yet, but This year should be fun.

 

[Erikn89nl]

Glad to see you are back to give this car some TLC must say your dedication so far is most impressive!

With regards to the water in the spare wheel well, I have heard that the aerial base can get leaky sometime, might be worth checking out.
Also, behind the stock sub in the left compartment in the boot is a join for the rear window washer, which can come loose.

Good luck with your project, and keep us updated! I know how hard it gets when noone seems to be reading what you write, but consider me interested

 

[Nathan Barnes]

Can I ask what colour code paint you used on your block and where you sourced it? I like!

 

[CabbageGT]

Sweet, thanks for the positive feedback, it's something I love to do, it's crap when your doing it all alone. There a lot of inspiration across this forum, it's great to see other people putting so much time and effort into what we love to do.

Can I ask what colour code paint you used on your block and where you sourced it? I like!

Um, I'll be honest, the paint I used on the block can be found on eBay for £8.95, I managed the block and gearbox with just 250ml
Engine lacquer by carplan ELP003 Blue
I found it was easy to use as a brush on paint, I've has some disasters using brush on. Prepare the block first, I didn't bother masking, the paint dries like a hard coat and is easy to scrape off with a Stanley blade.
I'd recommend painting it flat and putting a good coat on as it levels out very well.
I was quite impressed with the coat, if I'd bought 2 tins id have given it another coat, and perhaps cleaned the block more. Any oil left on mixes with the blue and darkens the colour. Its also easy to clean as the coat is quite glossy, oil runs right off.
http://www.ebay.co.uk/itm/4-x-Carpl...636?pt=LH_DefaultDomain_3&hash=item1c38fc990c


After posting last night for the first time in quite a while, It got me all fired up and wanting more.. so today I bought 2 second hand Front Brake setups from the turbo series of cars. as my car is on FSIII's

There's Discs, Callipers and pads in one set, and Callipers and hubs in another. The plan is to refurbish the lot, fit the hubs and 1 pair of 288mm callipers to the car and flog the rest. I may even brake even... Jesus did that just come from me?!!

Question.. master cylinders.. is there a difference or a need for me to change, as I understand it, both the FSIII's and 288mm's have 54mm pots. so is a bigger MS really necessary?

 

[RGL]

It's been cool to see you deal with your car, since you have the exact same engine as mine. I'll be sad to see you switch the AGN.

However I really do understand the need for something more powerful. I still regret not buying atleast a 1.8T myself.

Will still be following your thread. Keep it up!

 

[CabbageGT]

It hasn't happened yet.. it'll always be an AGN at heart... unless I tell the DVLA otherwise

sometimes I do forget just how much work has gone into just getting it on the road. If the car was a good runner to begin with I would have still taken it all apart, I think that was the whole idea was to begin wit. Its miles from being a decent car yet, but every little adventure brings new life back into it.

I think what I need to keep reminding myself of at this stage is that the moment I stop tinkering and begin admiring this little gem for what it is, it becomes completely redundant. If I've not got my work cut out, I've kinda got nothing... to not go there for fear of ruining what I've worked hard to achieve so far, Its moments like these where I want to just rip the interior out and start seam welding like a mad man. Why not just get on with it

I'm actually glad that its not a 1.8T, one day the car and myself will be ready for the transition, but that day is not here yet


Question for you Sir,
When you rev the engine, does it take its sweet a*se time coming back down to earth? I'm wondering if I have programming/mapping issues. I had an E36 1.6 which had a similar rev feel to it. just wondering if Audi made the 1.8n/a's perform a little calmer. Its quite a sluggish response. just wondering if theres anything I can do to the N/A to liven it up.

 

[RGL]

Hmm I guess it depends on one's experience, but I haven't really noticed that the revs take much longer than on other cars to come down. However haven't paid that much attention to it tbh also. I know it takes sweet *** time to get the revs up though, and the car moves like crap unless you're atleast at 3000-3500 rpm range or upwards. I've always regarded my A3 as being rpm hungry, meaning you have to get the rpm's high in order for it to liven up a bit. Shifting down is a usual must-do for me. However I guess the E36 1.6 engine should be even worse.

 

[CabbageGT]

Hmm I guess it depends on one's experience, but I haven't really noticed that the revs take much longer than on other cars to come down. However haven't paid that much attention to it tbh also. I know it takes sweet *** time to get the revs up though, and the car moves like **** unless you're atleast at 3000-3500 rpm range or upwards. I've always regarded my A3 as being rpm hungry, meaning you have to get the rpm's high in order for it to liven up a bit. Shifting down is a usual must-do for me. However I guess the E36 1.6 engine should be even worse.

Ha actually the E36 was a beast.. I had 99 problems with that car but power wasn't one of them, I was very impressed with the performance, shame it was a compact, Drifting is a life saving skill when you own a compact. Don't get me wrong it wasn't fast as in "fast", it was alright though

Yeah that what you get with a 1996 5 speed. 4500rpm gets you 75mph or something like that. when I put the engine back in the car, being mindful of the new bearing and all that I promised myself a clean 1000miles to run her in, get used to the drive. not to expect to much in return... but there's this one road....
she screams in 2nd, that's when you hear her drawing in the oxygen through the induction filter, especially on a cold morning

 

[RGL]

...when I put the engine back in the car, being mindful of the new bearing and all that I promised myself a clean 1000miles to run her in, get used to the drive. not to expect to much in return... but there's this one road....
she screams in 2nd, that's when you hear her drawing in the oxygen through the induction filter, especially on a cold morning

Haha the ending sounded almost poetic...beautiful.

 

[CabbageGT]

A step in the right direction today, this lot arrived.

So I guess I'll be cleaning and painting this month.. so far I've done 1 carrier

Blue is my choice colour for the callipers as I'm trying for a Blue & White theme overall.

 

[CabbageGT]

Took the car into work today for a wash, but instead I ended up taking the Gear Linkage apart.

Having already started a thread asking questions about the Linkage and what can be done to improve, I'll just go ahead an put up a picky of what I've done today.

Work in progress. realistically about half an hours work so far, But it took a lot longer to figure out what I was going to do and what materials to pick. I think it will do the job well.

First off, measuring and scribing.

A bit of drilling and taping

Drilling a Hole through 15mm Dowel. Surprised myself how I got it straight

The Dowel was drilled 50% at 6.8mm and 50% 5mm. So One side is tapped M8 and one side is Tapped M6

Tack the Dowel to the Plate, you can see where this is going now.

Test fitment, Theres much fettling to do yet. but I think this is gonna work a treat... not to mention shorten the throw Left & Right.

Still looking for Short Shift Levers to alter the front to back movement.

After putting the car back together as I was running out of daylight, I altered the position of the original plastic linkage, so far Its an improvement and 1st & 2nd are going in easier for now.

Callipers are coming on too, I have no pictures though. Maybe tomorrow When I clean the Car..