A3 Quattro KO4 upgrade, its started

[badger5]

Ok sa few questions for Prawn, Bill and Paul, hope you can help

Ok so once Ron is rebuilt Niki wants it back for logging, his words to me on thursday were, once its together and running call Ben and bring the car up for a day so we can log and health check it and tweak the mapping anyway you want to make use of the rods, if you wanna add any hardware we can sort that aswell

so first off im really pleased with Nikis customer service, he messaged me at gone half 9 in the evening

Right first question, having seen the VVT on Facebook and bearing in mind Ron was a VVT car, and his head is in bits would it pay to fit a VVT unit so once logging has been done the VVT can be tweaked?

Also thoughts on the AGN NA cams, is this worthwhile to do, if it is then i could change the cams once logging has been done as lets face it, changing the cams isnt hard

last one, Ron is gonna cost a bucket load more than i first thought so a miltek is even futher away than it was (ie prob never now lol) i saw Prawns comment about removing the centre box, would this gain anything on my standard S3 cat back?

hope someone will be able to help

to me it seems worthwhile as im making the engine stronger so lets make the most with more power

yes fit agn cams and yes use vvt, gains over non vvt can be had
our lupo aum has run it for years... Active vvt like k04 cars already have... its only k03 vvt cars which dont use it once warmed up.

 

[phil miller]

If you've got or can get a VVT unit Phil, then get it fitted mate, it can't hurt, and looking at the gains realised on Toms AUM yesterday it could be well worth while.

As for cams, Nick C at AMD saw his Ibiza of a VERY similar spec to yours (ko4, wmi, relentless) gain 18bhp and 32lbft as a direct bolt on gain with no map changes at all, so for the sake of £50, as it's being rebuilt, I'd get searching. I picked up some ADR cams for mine yesterday I reckon ADR are more common than AGN, as there are loads of 1.8 passats and A4's around.

Get your rings from GSF, they're £11 per piston. Beachbuggy and I use these and my engine is great.

Centre section isn't going to add any power, just make it a bit louder, if that's what you want.

Thank you mate, that was what i was looking for, ok rings from GSF at £11. really? do you have a part number? my boss fell out with GSF years ago over something very petty, silly thing is we use to spend 6/7 k a month with them, so over a £100 ac pump was it worth it?
anyway back on track, if you have a Part number i will get some ordered asap, im starting to gather the parts, head will be ready Friday, will be on the Phone to Mr badger at some point thro the week to order Rods and bigends, then its rebuild time

 

[phil miller]

yes fit agn cams and yes use vvt, gains over non vvt can be had
our lupo aum has run it for years... Active vvt like k04 cars already have... its only k03 vvt cars which dont use it once warmed up.

Thank you Bill, i still dont fully understand how or what the VVT does on the Ko4 and what benefits it will aid on Ron, one thing is for sure i see it will help ron so its worth doing

Bill will be calling later in the week to order Rods and bigends

cant wait to get Ron sorted, miss driving it, even tho i only drove a few miles before it went pear shaped

 

[phil miller]

Today i started on the bottom end strip down, ive decided to do away with the AC (because i put a saw thro the rad last year ) so i took the AC pump off, the AC rad and as much pipework as poss will be removed and a non AC belt will be fitted, after Tea im gonna get the sump off and get the pistons out, then tomorrow after fitting Jardos new bottom arms im gonna hone the bores ready for the rebuild

here are the bits ive gotta get
OE rocker cover gasket, VVT gasket and half moon
Head gasket and bolts
OE valve stem oil seals
Cambelt kit and water pump
non AC aux belt
oil filter and oil
NGK plugs
coolant
turbo oil return gasket and 6 crush washers
order Rods and bigends from Bill
piston rings
have the injectors tested

im sure there is stuff ive missed please feel free to add it

 

[beachbuggy]

I've got a couple of bags of valve stem seals, send me your address and I'll stick a set in the post.

 

[beachbuggy]

GSF piston rings


GSF no. Sc501


Part no. 08-502900-00

goetz .....

 

[slowcoach3]

Mate at this rate your going to beat me to rods, already beaten me to r-tech and i've had my car 18 months lol I'll have you on the rollers when i'm finished though....

 

[phil miller]

I've got a couple of bags of valve stem seals, send me your address and I'll stick a set in the post.

Dan you are a star, will PM you now dude

thank you for the GSF part number, that saves hassle when i call them

 

[phil miller]

Mate at this rate your going to beat me to rods, already beaten me to r-tech and i've had my car 18 months lol I'll have you on the rollers when i'm finished though....

LOL you know me Russ, when i get an idea in my head i have to do it before i change my mind

 

[slowcoach3]

Same here, gets me into loads of trouble! Luckily my wife is supportive/forgiving lol Brst hope Rach stays that way after you get that ring on your finger!

 

[phil miller]

Same here, gets me into loads of trouble! Luckily my wife is supportive/forgiving lol Brst hope Rach stays that way after you get that ring on your finger!

although Rachel is very supportive she has told me if ron goes bang again then thats it

 

[slowcoach3]

Do it right do it once, regardless of cost and bomb proof it lol In all fairness it has been 'suggested' to me i sell my ibiza. What she doesn't know is that that may go towards spraying mine white

 

[phil miller]

I like your thinking Russ

well I went down to Ron and took the sump off then took the pistons out, all looks good apart from the bigends on cyl 1 has a mark on them, the crank looks fine tho, which is great news, will post up pics when I'm on my laptop

 

[phil miller]

Well had a strange day yesterday, and needed stuff to do, so i decided to do some on Ron, so here are the pics i mentioned above

no AC

there is some marking on no1 bigend but the crank looks fine

all ready to be cleaned, have new rods fitted and new rings

 

[Broken Byzan]

nicework Phil

 

[phil miller]

Ok so today i got the call from willis to tell me the......

guides are fitted

Valve seats cut

Valves cut

so i collected it after work and im gonna give the valves a light lap in just to seat them, then on monday willis is having the head back to hot wash again, fit Valve stem seals and refit the valves, he has been great, he was just gonna cut the seats to start with and fit guides, but has said he will fit the seals and valves as he knows there a pita, he also said i can drop my pistons and sump into him and he will clean them aswell for me, even tho he makes out to hate road going petrol low BHP cars (lol) i think deep down he likes helping me out

so on the dinning room (what am i on about its been a workshop bench for the last 4 weeks) table i have it all laid out ready for some lapping later tonight/tomorrow night

shiny new guides and the seat that the satan valve was in, Willis has assured me the seat is fine (and lets face it, if he had said it was ****** then i would be paying him to replace it, so as he said its fine thats good with me )

so Kid in sweet shop explains how im feeling now , plan is get the head back say wednesday (im in no rush so Willis can fit it in around his other work)

So once i have the head back and refit some NA cams its then the bottom end, which thro this week i will be ordering all the parts i need (Dave star) and all being well the rebuild will start saturday (and end with Ron running saturday) i really really cant wait, more so now than when it was at Rtech being mapped

 

[phil miller]

ok a little update

All 20 valves are lapped in, so the head is going back tomorrow to have all the valves fitted, then i can build it again

Ive started ordering in the bits i need, today ive bought NGK plugs, water pump, thermostat and the vvt gasket and half moon gasket

 

[phil miller]

I've got a couple of bags of valve stem seals, send me your address and I'll stick a set in the post.

Arrived today

thank you Dan your a star


NGK plugs, vvt gasket and half moon arrived, i had the red slip thro the door which means my water pump and thermostat is at the sorting office

gonna get the head gasket, head bolts and rocker cover gasket tomorrow

Im looking forward to getting all the parts so i can start the rebuild

 

[badger5]

rods, shells 1 x set left in stock currently

 

[phil miller]

ok so i collected the head today

and then set about fitting the relentless mani back on to it

now at this point i decided im gonna left the head on with the turbo bolted to the mani as it will save the hassle of the mani to turbo bolts

Now please for the love of god dont burn out again

all clean

 

[phil miller]

I ordered up a new set of rings today, they are Goetze and have cost a massive £11.38 inc vat per piston

Had a good chat with Bill yesterday, and everything is in the pipeline, the rebuild has started

 

[Prawn]

Awesome news Phil

glad its coming together!

 

[16Klappe]

Wooooooooooh Ron!

 

[slowcoach3]

Good work mate, quick as ever!

 

[s3dave]

Snap...

 

[phil miller]

Snap...

your manifold looks alot shinyer than mine great minds think alike on fitting the turbo to mani off the car

Great stuff dude, when are you fitting yours?

 

[phil miller]

Ive been waiting for my water pump to arrive all week, so friday evening i emailed GSF to find out (i bought online due to GSF not delievering to us at work) and i was emailed back a tracking number and it was at the post office, which was strange as i hadnt seen a slip thro the door, anyway was upstairs just now, and one of our dogs has a habit of making a den in the corner of our bedroom, i thought id be nice and wash her blanket and as i lifted the blanket i found a few chewed letters and then a silver parcel force slip, so looks like my water pump has been waiting just down the road for the last 5 days, BLOODLY DOG lol

 

[s3dave]

Next Saturday Phil, too busy all week... are you putting the oil/water lines on the turbo before refitting?

 

[phil miller]

Next Saturday Phil, too busy all week... are you putting the oil/water lines on the turbo before refitting?

Good stuff, my plan is to leave the oil feed and the coolant on the block, the short coolant pipe with the banjo bolt that faces the back of the block and the oil return pipe i plan to bolt to the turbo first, ok it will make it a little harder to fit and will prob take 2 people to lift the head on but it will save a lot of hassle, then if there is any problem getting the oil feed pipe on the turbo its easy to undo it from the oil filter housing and fit it that way

well thats my plan, as the mani to turbo nuts are a pain to get at when the head is on, im hoping this way will make it easier

Hope it goes well Dave, let me know, i think this weekend i will be honing my bores and fitting my Pistons and rods in the bottom end, i really cant wait

 

[phil miller]

so with Ron moving forward i got a little bored and remembered when Niki mapped it he said it had boost weeps around the 75, DV and MAP points, now i made a pikey Map housing so that will be replaced with a forge one, so i decided to chem metal the other 2, thats what ive been doing

before

After

I must add i hate doing things like that, i hate working with stuff that goes tacky, i also tend to play with it fair to much when i should just put it on and leave it, im thinking of painting the pipe to help make it look a bit better

Also ive been thinking of building my own 3in cat back, i can get 3in T304 easy and for cheap, so it would just be time, i was also thinking of using the S3 back box but cutting it open and removing some of the baffle fluffy stuff to help flow, any thoughts on this?

 

[Broken Byzan]

You rodded him? That sound a bit wrong....

 

[phil miller]

You rodded him? That sound a bit wrong....

Lol, and it was a good rodding to

 

[Lewis583]

Do it Phil, you know you want to. I'm building the entire system on my project and while it's taking forever it will be so rewarding when finished. Plus I've learned how to TIG weld in the process, when I say I can TIG weld what I really mean is faff about with a new toy haha

 

[phil miller]

well ive been talking to a friend who works in a factory, he does the tool making side of things, what im getting at is 2.5 metres of T304 3in stainless is easy for him to get for me as they throw loads out when they refit, so apart from a bit of time and giving my mate a large drink the exhaust will be done on a budget of next to nothing

 

[phil miller]

well a little closer today, was flat out and didnt get a chance to breath today

anyway today my rings and water pump arrived also a lovely customer with a mk3 golf gave me £5 tip after i fixed her golf so i want and picked up a non AC aux belt

Rods
B ends
Head gasket and bolts
Belt kit
thats what left to order, waiting on funds to clear in the bank then the next round of ordering starts

i really cant wait now

 

[superkarl]

Where did you get the rings so cheap dude?

 

[phil miller]

Where did you get the rings so cheap dude?

kevin coopers motor factors in tavistock dude, if you want a set I can get them and send them up mate

 

[phil miller]

Ok so im rough as **** today, sent home from work, crashed on the sofa and thought, ****** i need to do something, so after much thought, coffee and pills (the headache type ) i took myself, blanket and coffee into the dinning room, sat at the table and decided to refit my cams

I thought even if it takes me all day i will have got something done, so i got it all laid out, and made a start

and all finished

Id got a new VVT gasket and half moon aswell, to be on the safe side

Ive also fitted a VVT unit (thank you J-rod) as the VVT can be used to aid timing, as it was in bits i thought it best to fit one as Ron is wired up for it but Niki mapped it out last time, so when i go back once Ron is running i will ask him to tweak the map alittle

Chain is all set up although counting to 16 has always been an issue even worse when im not well (im joking ofcourse i can count to 16 )

so its going ok, not long now

 

[Paradox1]

Good work Phil.

we can all tell your determind, Not even the deadly manflu can hold you down!

 

[phil miller]

Good work Phil.

we can all tell your determind, Not even the deadly manflu can hold you down!

Lol, i just wanna drive it again ive done about 900 miles in it since August last year and all bar 4 weeks of use its been in bits but i feel im almost there