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Limbo's S3.... Never Ending BT Build Thread :)

Discussion in 'A3/S3 Forum (8L Chassis)' started by limbo118118, May 1, 2013.

  1. <tuffty/>
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    <tuffty/> Badger 5 Edition Staff Member Moderator

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    Ahhhhh!... thats who that was for LOL... I did wonder... looks familiar :)

    <tuffty/>
    #81
  2. limbo118118
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    limbo118118 LORD

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    hah yess tis me! was like christmas day opening the box of goodies today lol!
    #82
  3. limbo118118
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    limbo118118 LORD

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    carried on with the build this weekend after booking the friday and monday off from work.

    managed to get alot done, heres my progress so far.

    only problems iv got now is that the waste gate is in the way of the gear cables so going to have to think of sumit to do with that!
    :/

    next jobs are too -

    1. fit the new fuel filter in the engine bay where i removed the carbon canister from.
    2. fit DA-31 inline fuel pump
    3. heat wrap downpipe
    4. fit engine back in and plumb in ready for first start!
    5. get exhaust made up!
    6. send parts for powedercoating

    hopefully should be first start up in the next 2-3 weeks im hoping..

    heres some pictures from the weekend anyways...

    [​IMG]

    [​IMG]

    [​IMG]

    [​IMG]
    #83
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  4. Sam_
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    Sam_ Down under

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    Not good news. Hope you can sort the shift cables issue. I can't work out if they have tweaked the angle of the wastegate on the later manifolds or not? I hope so:

    [​IMG]
    #84
  5. StaceyS3
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    StaceyS3 Well-Known Member

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    Afaik the wastegate position was moved on later models as well as the turbo sitting higher up which is the reason I had to wait for mine at the time as waited for the next revised batch :(

    Here's a few pics managed to dig out of mine (missing loads as the 6-8 months when all the car action was happening the phone I used got broken loosing most pics)

    [​IMG]

    [​IMG]

    [​IMG]

    [​IMG]
    #85
  6. limbo118118
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    limbo118118 LORD

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    Cheers for the photos. Yeh mine is one of the original manifolds believe it has a smaller size port for the wastegate too as this one suffers boost creep aparantly :/ will look on the weekend what my options are maybe run one cable either side of the waste gate with a home made heat shield... will have to see anyways!
    #86
  7. limbo118118
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    limbo118118 LORD

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    well its payday today!! so just ordered my new catch can got this one off ebay...

    Saikou Michi Oil Catch Can For VW Skoda Seat Audi. With 19mm Inlet/Outlet! | eBay

    hopefully get the exhuast finished this weekend if weather is nice! i got 2 more metres of 3'' stainless and also 2 new v bands.

    iv decided to place a bit more pipe in by the waste gate to move it over abit to clear the gear cables abit like tufftys and staceys above...

    new spark plugs arrived today also, went with these in the end off ebay! seem cheap! :p just need to gap them correectly think its around 8?

    4x NGK Copper Core Spark Plug BKR7E (6097) | eBay


    also got a right bargin last week, got 4 standard s3 wheels (all curbed) but with 4 good tyres all over 6mm tread! for £100!!

    im going to powdercoat them silver and hopefully they are going to be my track wheels :) for show wheels im going with XXR 527 in flat bronze :)

    hopefully all should go well this following week and i should be turning the key very soon!!

    just need to get my head around fitting this DA-31 inline pump! :/
    #87
  8. limbo118118
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    limbo118118 LORD

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    finally got the manifold modified. wastgate sits perfect now for screamer pipe to point to floor :)

    full system is made up all v banded! nice and flowing!

    majority of the engine is plumbed in and wired up.... luckily 2 of my friends have s3's so i could figure everythin out!

    just waiting on getting my intercooler brackets made and parts back from powedercoaters :)

    also need to fit inline pump this week just hoping for good weather!!

    20140413_124253.jpg

    20140421_190237.jpg
    #88
  9. Sam_
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    Sam_ Down under

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    Seriously, a screamer? :)
    #89
  10. limbo118118
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    limbo118118 LORD

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    Hell yeh screamer :p going to make a pipe so I can re route it back into the system if its too loud.
    #90
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  11. badger5
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    badger5 RIP S3dave Site Sponsor

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    you extended the wastegate pipe, but did you use the same size pipe as it had or larger?
    remembering it had creep on james's lcr
    #91
  12. limbo118118
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    limbo118118 LORD

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    used the same diameter pipe bill. didnt need extenting too much. yeh still gunna have that issue :/
    #92
  13. limbo118118
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    limbo118118 LORD

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    Luckily had o-k weather this weekend so got the fuel pump fitted and wired up. Thanks to tuffty and prawn for there help and advice!

    Geting very close to turning the key now. Picking up parts from powdercoaters tomorrow. Majority of fmic is fitted. Exhaust is all made up just needs fitting and hangers going on.

    Pictures to follow probably tomorrow. ..
    #93
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  14. limbo118118
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    limbo118118 LORD

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    some pictures from my weekend....

    got majority of engine plumbed in and wired up... had engine cranking over. but randomly stopped. trying to suss it out tommorow.. wasnt firing either so need to find that out aswel...

    anyways pictures!!....

    20140424_173223.jpg
    20140424_153119.jpg
    20140428_155117.jpg
    20140502_152440.jpg
    20140504_173416.jpg
    #94
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  15. Sam_
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    Sam_ Down under

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    Looking good in the last pic.
    #95
  16. limbo118118
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    limbo118118 LORD

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    cheers sam. powdercoating came out a great.

    other news....... IT LIVES!!!!!!!

    sourced the problem down to inline pump wiring.. something not right there. but bypassed it and standard pump primed up and boom it started up :)

    soo happy! gotta finish off plumbing some things in and few adjustments then will take make sure no leaks etc etc.

    take around the block bring back make sure no leaks again, then will tow her to a friends mot station get new mot / tax / insurance and hopefully get some miles on her! also temporary penciled in for dropping car of with bill on 7th june so best get cracking!

    just ordered my WMI kit too so need to fit that!
    #96
  17. superkarl
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    superkarl MAN OF STEEL

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    How did you install the fuel pump?
    #97
  18. limbo118118
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    limbo118118 LORD

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    Fitted it using prawns guide on his thread. Using bills direct fittings.


    Another update.
    Have a small oil leak by gearbox/sump area. So had sump off to locate the leak an seems to be the rear main seal :( so basicaly mad rush and gunna take engine out tomorrow to fit new rear main seal.

    Other things I needed to finsih off was catch can and connections for WMi but apart from that its looking ok. Just gunna be a mad rush of running her in when I finsih work when im back on days in work!.

    God I hate cars sometimes! !!
    #98
  19. limbo118118
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    limbo118118 LORD

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    well had a chaos week... luckily i have been on nights in work so was a matter of geting into bed at 8am then up before 1pm to get cracking on with the car! :s safe to say i was quite stressed and tired!.

    long story short... took engine out as found it quicker than working on my friends ramp.. iv never worked on one before and didnt like taking the gearbox off up there! :-0


    sooo everything off.... rear main seal looked fine no leaks.... hmmm..... i had fitted a new forge baffled sump and guess what one of the penetrating welds had a small crack and was leaking!!! soo glad its sorted now quite happy didnt have to tackle the rear main too!

    engine back in today, so my jobs stand at....

    1. fit oil catch can
    2. plumb in vac hoses for n75 etc
    3. fix small leak on inline pump
    4. fit bumper / headlights
    5. fit exhaust downpipe bracket
    6. figure out why fuel pump doesnt always kick in :s


    also fitted my EGT gauge which i love currently at my firends getting the cover plasti dipped! :)

    wmi is installed but just need to fit into an intercooler pipe. also got new discs on the front for mot

    all going well mot wednesday....

    run in over next week....

    mapping on the 7th :p

    picturesss.....

    20140517_134055.jpg
    20140518_122033.jpg
    20140519_134254.jpg
    20140518_150951.jpg
    20140522_134502.jpg
    #99
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  20. <tuffty/>
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    <tuffty/> Badger 5 Edition Staff Member Moderator

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    I have a crick in my neck looking at those pictures lol

    Glad you sorted it mate..

    <tuffty/>
  21. limbo118118
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    limbo118118 LORD

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    Hah least of my worries ;)

    Yehh its finally getting there. Hopefully thats the end of the problems! But they are expected when doing this for the first time! Just glad iv got this forum and a good set of mates who help out :)
  22. 00monkeyboy00
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    00monkeyboy00 New Member

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    Just read the thread from start to finish, love the effort spent and the fact it's your first attempt, fair play to you fella!! Looking forward to seeing the end result! :salute:
  23. limbo118118
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    limbo118118 LORD

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    been busy all week once again! car is now all mot'd and taxed and on the road! currently done 230miles :)

    i was abit concerned that my turbo setup was going to be laggy. but that doesnt seem to be a problem! :)

    all going well. fixed the fuel pump issue...fixed the wmi issue....just my traction light comes on after about 1 mile :s going to book it in to get the brakes better and thinking to get the haldex serviced and new earth strap... but its just been scanned and nothing came up on vagcom and also went into the haldex bit and checked the clutch and pump and they were fine :s

    also other thing is... dam exhuast is insanely loud!!! :(

    going to get a high flowing but resonated backbox made up in the next 2 week hopefully. havnt even noticed the screamer pipe yet because not boosting... but just the standard system is loudddd!!! only thing i could compare it too is a focus RS with straight pipes lol!

    it pops and bangs and flames have been seen :s

    also need to move DP a little bit as its vibrating the inside a bit but thats not a biggy currently..

    running in procedure iv used is... standard MAF and standard injectors...

    running in oil....10 mile using 4k as limit...
    next 10 mile using 6k as limit....

    oil change. +filter
    still running in oil
    used for 100 mile...6k as limit... only 5psi boost but hard up an down gears loads of overun..

    going to oil change at 350mile mark to fully synth from tps... plug n75 back in and off i go :p

    only thing is theres always been something dodgey with my n75.. disconnected it will still boost over 5psi area (limp mode) previously would boost up to 30psi!! clearly something weird there!!

    i personally think the guy i got the car off has had a poor remap on it and some how that it affecting the n75 or the boost i dont know much about this sort of stuff :s

    all i know is iv replaced the n75 with other ones and a brand new one and its always had that issue. but n75 connected it would just boost to around 16psi and not rise.. im sure its nothing that carnt be fixed with the remapping process..

    only other thing is the car is going to bill mid july now as it wouldnt of been ready for the 7th!
  24. badger5
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    badger5 RIP S3dave Site Sponsor

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    what is the boost on acuator only?
  25. limbo118118
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    limbo118118 LORD

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    With n75 plumbed in just electrical disconnected it will go over 10psi just I havnt been letting it go over 5psi during the running in process. With it connected if I remember correctly it used to be around 16psi
  26. limbo118118
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    limbo118118 LORD

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    Well heres some good news..... NOT! Was going to get some more miles on here last night so started engine. Lettting warm up... seemed to idle an sound abit rough :/ hmmm... gave a little rev.. white smoke out exhaust! .... checked oil... strange whitey looking in the oil.. misfiring its back off!! Read up last night.... looks like headgasket!!! F##k!!!borrowing a tester and compression tester tomorrow but im 90% its headgasket.. so iv ordered new bolts and gasket but can anyone help. ... why would it of gone on my engine only 230miles in? Had head skimmed etc for the build!? Will it need skimming again? Any advisee!! Its not bothered me in the way it can be fixed this week and for not alot of coin... but its the fact ots happend!!! Dont understand why! Had no leaks no watwr loss last weekend and car felt 100%!!!! Ggrrrrrr!!!!
  27. badger5
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    badger5 RIP S3dave Site Sponsor

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    what colour plugs? one or more of them clean as a whistle?

    other place oil and water can mix is oil cooler above oil filter

    misfire sounds combustion/head related tho..

    kinda weird tho, as head gaskets are very sturdy

    std bolts?
    fitted how?
  28. limbo118118
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    limbo118118 LORD

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    thanks for your input bill,

    i compression tested the head today, all plugs look fine! .... all cylinders are giving great compression averaging 220 across them :)

    checked oil an had no white marks etc like it did the other day, car hadnt been ran today tho.

    oil smells fuely!

    full vagcom scanned and showing 0 faults!

    next step is change oil and filter tomorrow, only things that have changed are i have put standard injectors in rather than the 750cc's... i turned on my wmi just to see if it was running for the last 50 mile other day... and inline pump was on too on the last drive.

    so not sure if any other them could of made it have this weird problem? spoke to a couple friends and they recon head gasket is fine, thinking old bigger injectors could of been putting too much fuel in flooded bores abit? so thats why oil smells fuely?

    so oil change and see what happens? this is were my lack of inexperience is a problem! :(
  29. limbo118118
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    limbo118118 LORD

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    so changed oil today, oil came out smelly very fuely, looks in my eyes a bit grey? seems to have streeks of white in too :s

    started up seemed fine, drove around the block, no white smoke, but still mis firing!

    checked oil did have little bit of white in, and top of oil cap abit white...

    will scan again later... this is with wmi off, inline pump off. and just standard injectors and standard maf.... should i try with my rs4 maf and bosch ev14 750cc injectors which did work fine previously?

    maybe dodgey standard maf or injectors are the problem? but didnt show on vagcom last night? or could headgasket be f##ked and still show good compression??
  30. badger5
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    badger5 RIP S3dave Site Sponsor

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    you stuck in the larger injectors not what its currently mapped for???
  31. limbo118118
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    limbo118118 LORD

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    No has standard s3 injectors in and standard maf currently did have them in for a little bit ran fine on them but put standards in for running in. I spoke to you on FB about it week or two ago
  32. badger5
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    badger5 RIP S3dave Site Sponsor

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    so maf and injectors match its existing map now yea?

    (remember I receive 100's of messages online from folks dude, and combined with my "memory of a goldfish" I just dont remember conversations - its me age - lol)
  33. limbo118118
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    limbo118118 LORD

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    Fairenuf lol. Yes standard injectors and maf currently. Just wondering incase maybe one of them is dodgey an didnt show on vagcom last night? Coulf stick others in drive around the block see if misfire is still there then it would show its them? Any ideas?
  34. badger5
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    badger5 RIP S3dave Site Sponsor

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    i dont know dude
  35. limbo118118
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    limbo118118 LORD

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    Tryed again with vagcom before still showing no faults.

    So I unpluged the standard maf and car ran ok.
    Was lumpy once over 2.5krpm but I would of thought thats alright with it being unpluged as its having to guess the air flow or whatever!?
    So I thought dodgey maf was the problem... so I plugged my rs4 maf in and... did exactly the same... misfiring straight away with it pluged in... unpluged ok.

    So my idea is now that I have a maf wiring issue? Sure this is a common thing on these cars too?

    Dont know if I can buy maf wiring separately or anything?
  36. badger5
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    badger5 RIP S3dave Site Sponsor

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    is your DV vent outlet close to your MAF?
  37. limbo118118
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    limbo118118 LORD

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  38. <tuffty/>
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    <tuffty/> Badger 5 Edition Staff Member Moderator

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    Pics?

    <tuffty/>
  39. <tuffty/>
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    <tuffty/> Badger 5 Edition Staff Member Moderator

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    Actually... found one...
    [​IMG]

    Did you buy the TIP from James as well? the way the DV is firing into the TIP is fine... where Bill was coming from is that the discharge from the DV too close to the MAF will cause it to read erratically... on yours the blast fires away from the MAF so this won't be causing the issue

    <tuftfy/>
  40. badger5
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    badger5 RIP S3dave Site Sponsor

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    quick test is unplug & temp block off the dv vac pipe and see if it settles down.

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