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More S3 Drama

Discussion in 'A3/S3 Forum (8L Chassis)' started by Welly, Feb 7, 2010.

  1. Welly
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    Welly VX220 SC Driver :)

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    [Feb 12, 2010]
    Well, if Bill doesn't want it mate, I'll sort something out with you... :)

    Just ordered a few odds and sods from Audi too. They want £5.16 plus VAT EACH for the turbo to manifold WASHERS! The bloody bolts are cheaper than the washers! I nearly fell off my chair!!
  2. jonny87
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    jonny87 Active Member

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    [Feb 12, 2010]
    cool dude!!

    haha weird how some small bits from stealers can cost a fortune and bigger things can be relatively cheap, guess its how they make their money, well extra money on top of the millions they already rake in lol

    remember someone off toyota forum (when i had t sport) wanting a new dipstick, went to stealers, you wouldnt even guess the price £85 + vat so not far off a tun!!
  3. <tuffty/>
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    <tuffty/> Badger 5 Edition Staff Member Moderator

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    [Feb 12, 2010]
    I bought a set of brand new exhaust manifold to head nuts and they cost me nearly £18!!!

    <tuffty/>
  4. A3Tom
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    A3Tom Smell my finger.

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    [Feb 12, 2010]
    Can bolts etc be had from a bolt supplier for loads less or am I missing something?.
  5. Welly
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    Welly VX220 SC Driver :)

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    [Feb 12, 2010]
    I've got a set of those that I didn't use for the K03S conversion.... I see their future.... :)
  6. MIKE GTR
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    MIKE GTR Member

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    [Feb 12, 2010]
  7. Welly
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    Welly VX220 SC Driver :)

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    [Feb 12, 2010]
  8. Welly
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    Welly VX220 SC Driver :)

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    [Feb 14, 2010]
    Happy valentine's day all....

    Work had to stop yesterday on the motor due to having to spend the day with the missus.... However today we cracked on.

    Photos below show progress. Block now now out of the motor awaiting it's replacement. When the new lump arrives tomorrow we will be swapping everything over into the new block.

    Tomorrow will be a big day for this project - head will be back, new shells and con rods arriving (hopefully), new engine arriving.

    And I'm knackered! lol :)

    [​IMG]

    [​IMG]

    [​IMG]

    [​IMG]

    [​IMG]

    Work continues....
  9. jonny87
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    jonny87 Active Member

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    [Feb 14, 2010]
    good stuff dude, keep it up!!

    shame this wasnt planned, with the right amount of cash theres so much that could of been achieved with the engine fully out, such as life though :)

    so if all those bits arrive as planned when you hoping to have her up and running again, the weekend?
  10. Andrew@A.L.D
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    Andrew@A.L.D May add NOS to 600+bhp?

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    [Feb 14, 2010]
    Working fast there mate, i just wish i could have more time working on mine but as every sunday just dosent do it that fast
  11. badger5
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    badger5 www.badger5.co.uk Site Sponsor

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    [Feb 15, 2010]
    Rods look like they should arrive today as promised.. Fedex fast delivery chosen at extra £ to get em here

    as of this morning: Feb 13, 2010 4:59 AMAt local FedEx facilityGLOUCESTER GB
  12. Welly
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    Welly VX220 SC Driver :)

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    [Feb 15, 2010]
    You are a star Bill, appreciated. If they are, let me know and I'll drop in and grab them tonight.

    Hopefully the shells will be here today as well. Picking up the head later. I went to get my £115 piece of metal from Audi this morning and dropped it off.

    The head looks spanking new, so impressed with the work done for the money.... :)

    Jonny, yeah, hoping she'll be ready for her running in at the weekend. I've ordered a sticker for the back window 'Running in - pass while you can'. I got the idea from a Cossie I saw on the motorway once.... :)
  13. jojo
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    jojo S3 Drift King! Staff Member Moderator

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    [Feb 15, 2010]
    Was it a White Sierra Cossie by any chance? Many years back when I was filling up at Shell, there's was a White Sierra with the same sticker on his rear window, and I laughed and asked him why he was running it in? He said he just spent £4k rebuilding the engine after he blew it up.
  14. Welly
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    Welly VX220 SC Driver :)

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    [Feb 15, 2010]
    It was as it happens, I saw him pottering down the M5. How weird, this was many years ago as well. Maybe the same one - seems too close a match to be coincidence.

    Absolutely spanking it was, looked brand new.
  15. Welly
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    Welly VX220 SC Driver :)

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    [Feb 16, 2010]
    More pics from this evening's work...

    New lump totally stripped, everything swapped over. Happy with the clutch, looks really good as does the flywheel.

    New engine has been stood for a while. Oil was NASTY! Taken all parts that I can swap over, but after 1000 miles I thoroughly intend to flush the engine and change the oil to get rid of any lasting 'old oil' nastiness.

    New con rods, and shells arrived (Thanks again Bill - legend :)). Pistons went on the rods fine, and then into the block. Gave one of the oil squirters a nudge, but a gentle push with a flat head screwie put her back where she belonged! What a pain though!

    Head is back also - looking immaculate. SAI blanking plate from Forge fitted as well.

    Ready to refit the block tomorrow...

    Photos:

    [​IMG]

    Engines during the parts swap

    [​IMG]

    AGU head *cough* for sale *cough*

    [​IMG]

    Head back from A&M. Top job they've done for £150, 100% impressed.

    [​IMG]

    New block, water pump fitted, no pistons though....

    [​IMG]

    New IE rods. Out with the old, in with the new.

    [​IMG]

    Ready to go into the block....

    Lost the will to take photos after this.

    Tune in for tomorrow's exciting instalment.... lol.
  16. jonny87
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    jonny87 Active Member

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    [Feb 16, 2010]
    whoa, thos ie rods are proper meaty in comparison to the stock one, no wonder they bend so easy!!

    that head looks sexual i must say, all clean and shiney :)

    what you gonna do with the busted block dude? if you dont make a coffee table out of it il be forced to hurt you ;)

    i thought that cossie may have been my mates, but alas his is green not white, sounds like the kinda thing he would have in his window though lol
  17. Prawn
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    Prawn My other car is a MINI!!!!

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    [Feb 16, 2010]
    are you fitting new rings mate? Surely old rings from one bore into a different used bore is going to cause sealling issues? or are those the AGU pistons going back in?

    Looking great so far though!
  18. Welly
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    Welly VX220 SC Driver :)

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    [Feb 16, 2010]
    Rings looked good mate, so I've re-used them.

    No damage or nicks, so they should be fine as long as the bores are in good condition, even in another bore. A NEW bore would of required new rings. Honing on the current bore will allow the rings to seat properly (hopefully) and it will seal right for power and oil control.

    I would of replaced them if they were worn. They'll soon take to another bore anyway.

    I can't see there being any issues, well, lets hope not! lol.
    Last edited: Feb 16, 2010
  19. Welly
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    Welly VX220 SC Driver :)

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    [Feb 17, 2010]
    Well, the block is in.

    What a NIGHTMARE. Got it up to the right level at about 6 PM ready for it to just 'slot' on.... Then spent 4 hours kicking it and moving it about trying to get it in. Made hell of a mess of the inside of the bell housing of the gearbox (flywheel teeth grinding) so there was filings all over the joint!

    Anyways, after 4 hours of fiddling about trying to rough it in we decided to stop (not having ANY joy) and go back to basics. Pulled block back out, and dropped to the deck. Checked the clutch plate alignment etc etc, all fine. Cleaned the filings out of the bell housing with the Dyson (whoops).

    Block back up, into position - and on first time. I couldn't bloody believe it :mad:

    Bolt the box up. Happy because it's in. Happiness that was short lived.... lol.

    Tried turning engine over. Not a sausage, she wouldn't budge. Check it wasn't in gear, all the obvious things. Nope. Check the metal plate behind the flywheel was visible and hadn't got jammed in the teeth of the flywheel on the way in. Nope. As we were reigning ourselves to taking the block back out I has a brainwave. Got in the car and dumped the clutch. YAY. Engine turns over. :)

    Clutch must of not been located quite correctly, as now the clutch pedal is good, you can hear the thrust bearing pushing on the clutch. And the engine turns over al the time now, nice and smoothly. What a relief!!

    So, all we managed to do last night was get the block in the car and bolted to the box. What a let down! :(

    Only 2 pics from last night as was feeling somewhat lazy after a 10 hour day at work, then another 7 on the car (2.30 AM bedtime :()

    [​IMG]

    Block totally assembled.

    [​IMG]

    Me being a penis. :). Not often you get to take a photo like that though!!

    More tonight....
  20. <tuffty/>
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    <tuffty/> Badger 5 Edition Staff Member Moderator

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    [Feb 17, 2010]
    Good work mate... turning this into an epic LOL

    No point in rushing though...

    <tuffty/>
  21. Matt82
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    Matt82 Active Member

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    [Feb 17, 2010]
    obligatory engine bay shot

    another good pic to take is sat on the down pipe
  22. S3BAM
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    S3BAM Member

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    [Feb 17, 2010]
    Finally getting there then Welly..!!
  23. Welly
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    Welly VX220 SC Driver :)

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    [Feb 17, 2010]
    Totally agree, biggest mistake that can be made I think. Not in any huge rush to get it done, got Friday off so tonight, tomorrow night and all day Friday should see me good. And then have the weekend as overflow anyway.

    Rush = make stupid mistakes.
  24. Welly
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    Welly VX220 SC Driver :)

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    [Feb 17, 2010]
    Oh, and on an unrelated note, I HATE that turbo support bracket. Every single thing I have done, it has been in the bloody way! Grrrrrrrr :mad:
  25. <tuffty/>
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    <tuffty/> Badger 5 Edition Staff Member Moderator

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    [Feb 17, 2010]
    Isn't it!!!! you can't even remove the damn thing without removing the trnasfer box... I ended up cutting it off as close as I could with a disc cutter in the end and sorta cut through the oil level sensor wire :whistle2:

    <tuffty/>
  26. Welly
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    Welly VX220 SC Driver :)

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    [Feb 17, 2010]
    Whoopsie... Meh - oil is overrated..... lol

    No such luck for me mate, I need to use mine again, where as you didn't! I cannot believe it has been designed so badly, the heads of the bolts for it must be 4mm at most from the transfer box. That would actually be impossible to replace if needed. Hex tops at least you could of got a spanner on them!

    Anyway, Jonny discovered whilst we were taking the block out (as the TSB kept fouling on that bit that sticks out on the transfer box), that rather than removing the TSB - we could just unbolt the bit that sticks out from the transfer box - it actually just unbolts and comes off. :rockwoot:

    Was sooooo happy when we found that - block came straight out! It would of been next to impossible otherwise!
    Last edited: Feb 17, 2010
  27. Matt82
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    Matt82 Active Member

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    [Feb 17, 2010]
    that oil level thing is also a temp sensor too for the dashboard
  28. Welly
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    Welly VX220 SC Driver :)

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    [Feb 18, 2010]
    If I know Tuffty dude, I'm sure it was reconnected just fine....
  29. Welly
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    Welly VX220 SC Driver :)

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    [Feb 18, 2010]
    Had a good night last night...

    Started with an engine which wasn't even hanging on it's mounts, and ended up with this:

    [​IMG]

    Needless to say were were pleased! lol.

    Sump is all back on and bolted. All the ancillaries are back on. It's holding water fine which is good. (even though initially I filled the header tank up whilst the pipe to the side of the head was off..... whoops). Loom is all reconnected.

    Left to do is the following:

    Inlet Manifold - fit and connect. Turbo Mani gasket and bolt down turbo. Couple of gearbox-engine bolts at the back. Time up & fit new belt. Refit bottom pulley, aux belt & tensioner. A few other bits and bobs like the MAF and charge pipe assembly.

    Got tomorrow off - so am going to have a break from it tonight. Been at it all night after work for 3 days running until 2 AM every night so I am shafted! (although will probably do a few bits and bobs!) and finish up (hopefully tomorrow during the day. It will be nice to work on it in the daylight!
  30. Matt82
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    Matt82 Active Member

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    [Feb 18, 2010]
    mofo

    that was an effort and a half
  31. Andrew@A.L.D
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    Andrew@A.L.D May add NOS to 600+bhp?

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    [Feb 18, 2010]
    fast working there mate
  32. S3 Nattie
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    S3 Nattie Quattro ist für sissies

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    [Feb 18, 2010]
    Looking good Welly fair play. I done a whole engine rebuild in uni last night in about 3.5 - 4 hours lol, was a pain in the ass at some points but good when its all finshed.
  33. vanilla_ice
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    vanilla_ice Member

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    [Feb 18, 2010]
    Fantastic efforts there Welly. I hope it all ends well for you.

    ICE
  34. A3Tom
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    A3Tom Smell my finger.

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    [Feb 18, 2010]
    Bloody hell you're kicking the arse out of this arent you??!. Glad you're not on my time!!. ;)
  35. Welly
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    Welly VX220 SC Driver :)

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    [Feb 20, 2010]
    Well, we hit it yesterday and got the engine totally back together.

    I was so nervous at first start time..... hands were actually shaking!! lol.

    Anyway, fired up first turn of the key (after a few turns to get some fuel through).

    Anyway, come across another issue now.... oil pump on the AGU block is shot. Keep getting dash oil pressure warnings and there is no oil in the head - it's all static in the sump. In hindsight we should of changed it for the APY's but there we go. What a pain though. Means the sump is going to have to come back off after only just being sealed.

    Arse.

    Hopefully take it out for a test run tomorrow night, once all the rest of the kit has been refitted....

    So happy it works though! :)
  36. Dani_B19
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    Dani_B19 Audi-sports own special child.

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    [Feb 20, 2010]
    Glad to hear it's all but there for you mate.
  37. Matt82
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    Matt82 Active Member

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    [Feb 20, 2010]
    the pump is dry. they need priming. if youre lucky/brave a good rev can do it but you have a turbo so thats risky

    alternative, does your oil cooler have pressure sensors on top like the old golfs?

    if so, pull out a sensor, make up a funnel and pour oil down there. it will fill the pump and youre ready to go again son!!

  38. Broken Byzan
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    Broken Byzan Photographic Moderator Staff Member Moderator VCDS Map User

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    [Feb 20, 2010]
    At least the sump off is quite easy on an S3/ A3 hours work to swap pumps and you good to go. If it didnt prime up almost straight away i wouldnt go running and risk your turbo or cam bearings etc
  39. Welly
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    Welly VX220 SC Driver :)

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    [Feb 21, 2010]
    Evening all.

    Tonight has been both good and bad.

    Good in a sense that the oil pump was swapped out and oil now up to the head and circulating properly! Shibby.

    Then, after letting it idle up to temp, I take it to fast idle to help oil circ (plenty in the head now :)), there is an odd noise and the engine starts missing. Bad.

    Turn off straight away. Checked timing belt. Tight and correct. Try to turn by hand. Engine says no.

    Take spark plug out of cyl 1. Smashed to smithereens. (Will photograph tomorrow). This is a concern..... lol.

    Check all other plugs, all fine.

    Use pen light to check bore. Exhaust valve head visable on the piston face = bad.

    Hard to say whats happened here at this point, but from poking about with a magnet, I suspect that the entire valve and stem has literally fallen out....

    So, as you can imagine, I am less than happy.

    Will take the head off tomorrow night to find cause and extent of damage - hard to say at this point....

    I'm off to have a beer - since I won't be driving tonight....
  40. <tuffty/>
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    <tuffty/> Badger 5 Edition Staff Member Moderator

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    [Feb 21, 2010]
    awww d00de... bad news :(

    Define "...spark plug out of cyl 1. Smashed to smithereens...." please...

    <tuffty/>
    Last edited: Feb 21, 2010

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