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A3 Quattro KO4 upgrade, its started

Discussion in 'A3/S3 Forum (8L Chassis)' started by phil miller, Sep 17, 2012.

  1. Paradox1
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    Paradox1 Active Member

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    I know the feeling. Such a good feeling once you get it back on the road! I may even take a blast down to devon to see ya. my car needs a good blow out
  2. Prawn
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    Prawn My other car is a MINI!!!!

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    The same rings Phil got are available special order through any GSF too dude, £11 per piston, it's what I've used in mine and BeachBuggy uses them in his builds too :)
  3. superkarl
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    superkarl MAN OF STEEL

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    the legend that is phill miller got me some :thumbsup:
  4. phil miller
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    phil miller Member

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    Ideal marty :), once together im gonna drive everywhere so i get the miles on it asap :)
  5. Paradox1
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    Paradox1 Active Member

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    you know your welcome my side aswell, i'll even get you a parley/permit (Think of the film worriors):undwech:
  6. Prawn
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    Prawn My other car is a MINI!!!!

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    Drive it up to Ace Cafe next month :D
  7. phil miller
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    phil miller Member

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    Now that is an Awesome idea and is the best way to get miles under its belt, a fully warm engine being used is better than the warm up cool down run in that it would get using normally round here
  8. phil miller
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    phil miller Member

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    Ideal :) will take you up on that dude
  9. Prawn
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    Prawn My other car is a MINI!!!!

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    you can have Chilli Chips n Cheese with Marty and I!!!
  10. phil miller
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    phil miller Member

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    :) will do that, be a great day out and be good to meet up with everyone
  11. Paradox1
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    Paradox1 Active Member

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    Can you believe I still havent had any Chilli,cheesy chip from there before!!

    Its only like 20mins from me and ive never got around to it.

    shocking
  12. phil miller
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    phil miller Member

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    I know i live in the sticks but ive never been to ACE, a trip would be a very fitting first long run for Ron :)
  13. phil miller
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    phil miller Member

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    Ok so today i painted the bottom arms (no pics tho :( ) and ive decided to fit budget poly bushes in the front lower arms

    Two reasons for this

    first off the engine rebuild has wiped me out, and
    Second i do want to fit S3 hubs and bottom arms at some point, so although the camber bushes are worth it, the cheap ones for £26 for front and rear, front arm bushes will do for the time being.

    Also ive been looking at my old exhaust valves and the seats on the valve are badly pitted, so i think it was a combo of pitted valves and loads of boost and water in my meth that played its part in the shout lived MAN BOOOOOOOOOST, all in all its coming along nicely
  14. phil miller
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    phil miller Member

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    so today i had a plan, when i stripped Ron down i noticed my hot side outlet pipe off the turbo was going black, signs of the hot mani now its running proper boost,

    At Christmas i noticed Prawn had made a shield to protect the hose, my plan was simply, Jardo has about 12 heatshields for the cone filter, i asked if he could spare one and as normal he was only to happy to donate one to the cause, so my plan was to stop this getting worse

    [​IMG]

    so i made this

    [​IMG]

    there is a spare M6 threaded hole on the edge of the rocker cover so this is what it will look like bolted up

    [​IMG]
    [​IMG]
    [​IMG]

    should help keep the heat off the hose now :)
  15. badger5
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    badger5 www.badger5.co.uk Site Sponsor

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    let me know when you want these rods/shells Phil
  16. phil miller
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    phil miller Member

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    Will be on the phone tomorrow at some point (work has been mental) its all coming together well on the Ron front :)
  17. bigal 1
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    bigal 1 Active Member

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    What. Two legends in the south west. Well I never!!!, or maybe I did. Actually I've forgotten. :banghead:
  18. phil miller
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    phil miller Member

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    Im hoping for an easier day tomorrow, where i get chance to call you Bill, my boss has been a nightmare, mainly due to one of the other mechanics snapping his leg in 2 at the weekend, so we are a man down with enough work to have kept us all busy, with him not here its just plain mental :(
  19. badger5
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    badger5 www.badger5.co.uk Site Sponsor

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    owch, snapping a leg in two sounds horrific - ewww
  20. phil miller
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    phil miller Member

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    Yeah i spoke to Ash last night and he snapped his tib and fib, he said his foot was the wrong way round (makes me cringe just thinking about it) from what he said he will prob be off work for around 2 months, boss is not happy and is being a little hard on the rest of us :( thank god for the weekend, although he has been offering OT on friday and monday :(
  21. phil miller
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    phil miller Member

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    Rods and shells ordered from Bill, hopefully start putting Ron back together later this week :)
  22. Paradox1
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    Paradox1 Active Member

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    That what I like to hear! good stuff Phill
  23. phil miller
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    phil miller Member

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    while i took advantage of the longer daylight, Rods and shells should be here any day, so i decided ive block off the block, make it clean so when i hone the bores i wont get dirt down them, that is now done, i wish id bought my honeing bit home from work today as id have honed the bores aswell, the head is ready, the water pump and stat are fitted, cant wait for the fun to begin :)
  24. phil miller
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    phil miller Member

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    Update time :)

    Rods and shells ordered and arrived today Bill you are a total legend :)

    so tomorrow i will be fitting the pistons to the rods and then honing the bores and refitting the pistons, im then planning to lift the head on and torque that down, then saturday evening (after Jake has gone to bed) fitting the cambelt and finishing off, hopefully have it running sunday evening :) i really cant wait

    one question are the bigends 50 ftlbs slacken off 3 times? for some reason i had 55ft lbs slacken off 3 times in my head

    [​IMG]

    They are even more beautiful in the flesh :)

    replacement front dogbone from my very good friend Jardo
    [​IMG]

    Head already
    [​IMG]

    [​IMG]
  25. badger5
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    badger5 www.badger5.co.uk Site Sponsor

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    55lbft is what I use, 3 times yes
  26. Paradox1
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    Paradox1 Active Member

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    And to think you were only just going to fit a k04 standard setup.....

    now you got the engine scattered around in pieces lol

    Loving the progress mate!
  27. A3-Lee
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    A3-Lee Active Member

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    Looking good mate
  28. 16Klappe
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    16Klappe Princess Slayer

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    Beast.

    Can't wait for the beast to be back on the road :)
  29. phil miller
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    phil miller Member

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    pistons fitted to rods and new rings fitted, pistons all cleaned and everything ready to go, this is gonna be a good weekend :)

    [​IMG]

    [​IMG]

    Jardo if you are free i could do with a hand please dude, the head is a fair weight with the mani and turbo on it and my left elbow is still not right :(
  30. phil miller
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    phil miller Member

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    I thought thats what you had said, but wasnt 100%

    They are awesome thank you bill :)
  31. phil miller
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    phil miller Member

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    <br><br>I thought thats what you had said, but wasnt 100%<br><br>They are awesome thank you bill :)
  32. phil miller
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    phil miller Member

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    ok so after playing in the garden for most of the day with the kids i decided it was time to fit the head :)

    [​IMG]

    head on
    [​IMG]

    [​IMG]

    [​IMG]

    and my fav pic
    [​IMG]

    all thats left to do is fit the tip, injectors and cambelt :)

    i think the 2 heat shields will do a good job :)
  33. badger5
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    badger5 www.badger5.co.uk Site Sponsor

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    I would consider extending the heatshielding along by the servo also phil..
  34. 16Klappe
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    16Klappe Princess Slayer

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    Geddon' bey!

    I'll be seeing you tonight reet?
  35. phil miller
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    phil miller Member

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    ok will get a sheet from merlin :) Bill I will be calling in to say hi on our way up for the logging that Niki wants to do, be good to put a face to the voice :)
  36. phil miller
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    phil miller Member

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    :) Ofcourse dude will be over after dropping Jake home :)

    friday when I picked him up he asked what car I had and when I said the black one he didn't look happy and said I want to go in Ron :) bless him even at 4 he knows what's good and what's not lol
  37. phil miller
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    phil miller Member

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    Right not any new pics but tonight ive done a few more bits

    TIP is fitted, plugs and coil packs fitted, filled with Anti Freeze

    so all thats left is Cam belt kit and oil and re fit the injectors

    If all goes to plan i will have Ron running Tuesday evening :)
  38. badger5
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    badger5 www.badger5.co.uk Site Sponsor

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    your Siggys wrong Phil... IE Rifle drilled rods.. not ina...
  39. phil miller
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    phil miller Member

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    sorry :(
    but on a lighter note I've fitted a new belt kit and Ron is running :)

    ive just came in and I can't wait to go for a drive, all I can do is :)

    update later :)
    16Klappe likes this.
  40. phil miller
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    phil miller Member

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    Ok so im BUZZING, ive been out in Ron, only covered 4 miles as im knackered

    Also i havent got any pics because i had dirty hands and i wanted to get it done :)

    Ok so i had it running for about 30 mins all was good, i thought then was the best time to stop, let it cool, check for leaks and eat :)

    anyway after going back to it, it cranked over and back fired :( it then started, so i pulled it out of our garage down the end of our road and drove up to the house, it didnt feel right and the management light came on, my heart sank, i felt that sick feeling again, so i grabbed my laptop and VCDS lead and plugged in, there were loads of codes prob there since i pushed it in the garage 2 months ago with the inlet mani off and everything disconnected, cleared them down and re checked, Cam position sensor :) bloody idiot i am, i connected it and then disconnected it to fit the top cam cover and forgot to reconnect it lol, so i then went out on a little drive to see how he went, i took it steady, changing gear at around 3/3500 rpm everything seems find, i then remembered what id been told about making the engine work, so i changed in to 3rd and gave it a little more throttle to make it boost, and at that moment, i remembered how fantastic Ron was before the valve issue, it boosted to around 20, only for a second as i changed gear again, but all i can say is its GREAT to have it back on the road.

    My Man cave that ive had the head in for the last 2 months is now a dinning room again :)

    i would like to say a massive THANK YOU to Prawn and Jardo (who have put up with me asking silly questions) Bill for sorting me out a with Rods and shell and all the advice over the phone, Dave for being a top bloke, and if it wasnt for the PMs i wouldnt have bothered changing the rods

    Thank you all for your help and advice :)
    JudderMan and Pabl0 like this.

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