Audi S3 - Stroker Big Turbo build.

The head has some indent on it like a some foreign piece of metal entered the cylinder but didn't find anything when I stripped it down, if might have been pushed out through the valve but didn't notice any damage on the turbine blade. So not sure if that caused the damaged or if the cylinder temp was too much. Spark plug was still in one piece.
Anyways, I was due to strip down the engine as the cold start misfire from day one has been very annoying.Would of been nice if I did it before the piston died.
But building engines is fun :)
 
The head has some indent on it like a some foreign piece of metal entered the cylinder but didn't find anything when I stripped it down, if might have been pushed out through the valve but didn't notice any damage on the turbine blade. So not sure if that caused the damaged or if the cylinder temp was too much. Spark plug was still in one piece.
Anyways, I was due to strip down the engine as the cold start misfire from day one has been very annoying.Would of been nice if I did it before the piston died.
But building engines is fun :)
I feel your pain. I'd go with expensive over fun. Lol
 
Just read this thread, got to this page and thought not again! And expected to keep reading on about her being fixed, didn't reslise these posts where this recent.

Brilliant work mate, all the best ;)
 
****** hell mate, one thing after another! Shame to see another BT S3 in bits but as always I'm sure it'll be back faster and stronger :)
 
I feel your pain. I'd go with expensive over fun. Lol

ok ok, expensive fun.

Just read this thread, got to this page and thought not again! And expected to keep reading on about her being fixed, didn't reslise these posts where this recent.

Brilliant work mate, all the best ;)

its not really a thread, its more like a "how to" break things, one thing at a time o_O

It is, but you're nuts

How so ?

****** hell mate, one thing after another! Shame to see another BT S3 in bits but as always I'm sure it'll be back faster and stronger :)

I need to be as faster than the F430 and keep up with the 458 :lmfao:

it upsets me so much that you keep destroying my motor

I'm still in the testing phase, I don't want to hand it over to you until all parts have been thoroughly tested.


The crank thats in the car is ok but I am too lazy to take the block out the car and strip it down. I managed to get another block and cast 2.0 crank for about £75, so its just easier to get the block machined for the new pistons, assemble the new engine, then pull the block and box out the car, swop the box and clutch over to the new engine and pop it back into the car.
Piston have just arrived in the country, so hoping to get the block machined over the weekend and start assembly early next week.
 
Round 3 ..... ding ding!!!

Since I don't have access to a workshop anymore, I had to do the next best thing to creating a clean environment as its always blowing sand outside in this country.













 
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LOL... nice one mate... nice choice of safety footware too I see ;)

<tuffty/>
 
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LOL... nice one mate... nice choice of safety footware too I see ;)

<tuffty/>

What ever do you mean, cant you see the bubble wrap everywhere. I feel its a very safe working environment :lmfao:
 
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All the plastic everywhere it looks like your going to kill someone with engine block, wrap them up and dig a shallow drave in the desert.

The plastic is dual function,
1 - save my life ( oil/grease spills on the furniture = wife will kill me )
2 - a preset crime scene ( oil/grease spills on the furniture = wife will kill me )
 
I'm surprised she let you in the first place!!!...

"Just doing some decorating luv... need to put plastic down in the living room... nah... its fine... you go away for the weekend, I'll be done by the time you get back!!..."

;)

<tuffty/>
 
funny thing is, she was meant to go away for a week and I had it all planned out. Then her tripped got cancelled and I was like, so ummm.... you know the area we sit down.......I'm just going to wrap that in bubble wrap
AND
 
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and since the engine and box is coming out, I thought it was rude not to get these and pop them in, especially since I got them for €346 shipped to my door - gotta love the Germans
 
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So the ARB's arent going to be here anytime soon as they been sent via the postal system :(

So tomorrow I plan to get the new block fitted to the gearbox and fit it into the car.



I also have a new gearbox mount :)




On my way back to the office today, I saw 2 of these puppies being transported. They said to cost $3.4 million dollars :think:
http://www.wmotors.ae/
 
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Thank feck for that. Those are sold as already done... pah are they hell as like.

Yeah, I know all about that issue. First set of pistons cleared the oil squirters on assembly, but then the pistons smashed up the oil squirters after breaking the engine in. I can only assume the extra heat and force from high boost caused the pistons to expand just enough to cause damage.
These pistons definitely hit the squirters on assembly as the crank locked up on rotation.
 
How do you clearance them? Surely they should be done already!! has anyone informed the manufacturer?
 
I spaced out the whole oil squirter with a copper washer. You need to file/cut/grind the washer to suit, so that the piston doesn't hit the washer instead.
You could also cut a notch in the piston skirt so the squirter misses the piston but that would be a ball ache :)
 
Manufacturers know but do nothing. I prefer the notch job as it can be useful as a place to remove material to balance the pistons too
 
Whoopsy... dude... you built this off the car!!!.... ;)

did you fit the head with the block in the car?? good job you have a manual tensioner huh... lol

<tuffty/>
 
Yeah, head went on in the car as I couldn't carry the complete engine from the crime scene to the car.
I did the cat cam timing correctly but the vernier pulley doesn't have a TDC mark, guess I need to make a TDC mark on the pulley for future.
It has the most epic big cam idle at the moment ;)

Hopefully I can sort this out this evening, then its Merry Christmas to me
 
Turned out the camshaft timing gears were the issue for the code error. Had to redo the gear timing on the exhaust cam.

No code error now, but this engine is misfiring at cold start just like the previous engine did. So now I'm convinced there is something wrong with the valvetrain as its the same head that was on the previous block.

What happens is the following.
Cold engine, the car starts and runs in "warm up mode" at 1300rpm then it starts to misfire after a few seconds and stalls.

Then won't start.
So I did a compression test.

Before starting a cold engine all cylinders have compression. Approx 180psi across all 4 cylinders. After starting and misfire drama, there is no compression in usually 2 cylinders.
This means valves are stuck open for some reason. After about 20min the valves close and I can start the car again but it just starts to misfire after a few seconds of running as its still cold and runs at 1300rpm.

Going to try drop the idle rpm with unisettings, to attempt to get the car to run longer than 10 seconds and warm up so I can drive it.

SO BLEEEEEEEK !!!!
 
Oil pressure is at 70psi on cold start, pressure relief valve was all clean and moving freely when the engine was assembled.
It definitely feels like hydros are popping open. The thought of get solid lifters has crossed my mind A LOT :) but maybe I should try use another oil filter housing assembly before removing the head and valve train.
 
Don't understand why its runs fine when warm tho.
Well I haven't got this engine warm yet but previous engine ran fine when warm/hot.
Going to try lower the idle rpm in unisettings tonight and get it to run and warm up.
 
hydro either pressure or physically sticking.. warmer is clearance and/or oil pressure/viscosity related

could be initial priming is being a pia, so if you can keep it running it may well settle down once cycled a few times.
 
I manged to get the engine running by lowering the idle to 400rpm, so cold start was around 900rpm. Still misfires but doesnt stall, warmed up the engine and she purrs. But this is not the solution as the car wont idle at 400rpm, so I have to change the idle back to 800 once its warm. PITA, but it works for now, so I can do some logging/testing.

But I found this link on audizine, so thinking about getting a new oil filter housing as this is the same one that I used on the previous engine.

http://www.audizine.com/forum/showt...essure-Survival-Guide-and-troubleshooting-DIY
 
I am currently using an oil filter housing that came of a 2.0 n/a 06A block. Now I cant remember if I used the same housing on the 1st engine but I have definitely used the same housing on the 2nd engine and this engine. The 1st engine ran as normal, 2nd and 3rd have this damn misfire issue. So I'm going to change the housing as it might be the culprit, but I wont be holding my breathe.

So I did some comparisons between some oil filter housings. I have one from an AGU motor, one from my original AMK motor and another one from a mk4 2.0 8v motor.
All 3 housings have the same part number - 06a 115 417
AGU & AMK have the additional turbo oil supply feed.
2.0 8v doesnt have the turbo oil supply feed.
AMK and 2.0 8v have the same type of drop in one way valve, while the AGU has a screw it type.

Now the pressure relief valve springs are different. AMK and 2.0 8v have the same length of spring while the AGU has a short spring. This might be related to the one way valve being different.

AGU, AMK, 2.0 8v


AGU vs AMK


AGU vs AMK


AMK vs 2.0 8v


AMK vs 2.0 8v