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ShaunS3 - S3 8L Major Service/Mechanical Overhaul **LOADS OF PICS**

Discussion in 'A3/S3 Forum (8L Chassis)' started by ShaunS3, Apr 28, 2013.

  1. ShaunS3
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    ShaunS3 Yorkshire & Humber Rep. Regional Rep

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    So this is kinda the sole reason I have been absent from the forum for some time...

    I was quite fortunate when buying my S3 as it came with stacks of receipts and service history. I was also pleasantly surprised to hear that my car had previously been a member of an owners forum of which I then later stumbled across when i signed up to ASN.

    So of course I then contacted the previous forum owner (1animal1 aka Tim) and obtained more info on it's history and got an idea on how it had been looked after previously, although this doesn't cover the more previous owners.

    I made a decision that although the paperwork was stacked to the roof, i would carry out a major service. This was purely based on the cars age and mileage now hitting over 120k. In addition to this, the car had suffered the infamous PCV system failure and was causing major power loss. It was playing in the back of my mind for some time and I'd rather do it all whilst in my possession for peace of mind more than anything. However, as most of you will know, whenever working on a car (especially an S3), it never really stays at service only stuff.....pics will reveal all :)

    The aim of my thread is to show the less mechanically minded people how a car like the S3 8L ages over 11 years as I can only make an educated guess that the car will have seen some hard usage in it's life. I have tried to take before and after shots where possible (If i remembered to do so).

    For informational purposes, my car is a 2001/51 S3 8L (BAM 225) + Stage 1 CustomCode. The majority of service parts are all genuine Audi parts, sourced from my local TPS franchise.

    So, without further ado.....here's the pics:

    Dyno printout before works (Supposed to be around 260bhp - Stage 1)....
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    Saikou Michi S3 OCC + Flourosilicone hoses from Roose Motorsport
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    S3dave Tie Bars & OCC inserts
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    AH Fabs V2 FMIC
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    Sachs/Black Diamond Stage 1 Clutch Kit (Carbon/Kevlar)
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    Black Diamond Performance Brakes
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    I forgot to take pics of all the parts/mods, so here they are waiting to go on:
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    First up then was the brakes....
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    Last edited: Apr 28, 2013
    #1
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  2. ShaunS3
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    Front end strip/FMIC test fit
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    Engine out:
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    Gearbox/Exhaust manifold off:
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    #2
  3. ShaunS3
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    ShaunS3 Yorkshire & Humber Rep. Regional Rep

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    The infamous PCV system:
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    #3
  4. ShaunS3
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    ShaunS3 Yorkshire & Humber Rep. Regional Rep

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    Oil Sump/Pick-Up/Oil Pump
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    #4
  5. ShaunS3
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    ShaunS3 Yorkshire & Humber Rep. Regional Rep

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    Rocker Cover
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    #5
  6. ShaunS3
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    ShaunS3 Yorkshire & Humber Rep. Regional Rep

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    Ball Joints/Track Rods:
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    Ball joints/track rods/drop links fitted:
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    #6
  7. ShaunS3
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    ShaunS3 Yorkshire & Humber Rep. Regional Rep

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    Timing belt/tensioners/dampers fitted:

    [​IMG]
    #7
  8. ShaunS3
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    SuperPro Polybushing:

    Front Wishbones
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    Steering Rack Mount
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    Front ARB's
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    Rear Lateral Arms/S3dave Tie bars/Rear ARB's
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    #8
  9. voorhees
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    voorhees Moderator Staff Member Moderator

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    Looking good,Tims old car before his 8P and Beemer.
    #9
  10. ShaunS3
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    ShaunS3 Yorkshire & Humber Rep. Regional Rep

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    Why is a wheel alignment required after SuperPro/S3dave Tie bars?

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    #10
  11. ShaunS3
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    ShaunS3 Yorkshire & Humber Rep. Regional Rep

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    Something I really didn't want to find....

    Cracked Turbo
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    #11
  12. ShaunS3
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    ShaunS3 Yorkshire & Humber Rep. Regional Rep

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    New Turbo (courtesy of AET Turbo's)/Relentless V3 Manifold/Relentless DP

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    #12
  13. ShaunS3
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    ShaunS3 Yorkshire & Humber Rep. Regional Rep

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    Pollen Filter:

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  14. ShaunS3
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    ShaunS3 Yorkshire & Humber Rep. Regional Rep

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    Engine back in:

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    #14
  15. ShaunS3
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    FMIC fitting (not for the faint hearted lol) - Bumper cutting required :)

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    #15
  16. ShaunS3
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    The finished article:

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    Last edited: Apr 28, 2013
    #16
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  17. ShaunS3
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    There were some other parts that I forgot to take pics of but the majority of work done is shown in the pics. For anyone unsure what the pictures show, here's a list of things fitted/replaced:

    Oil filter
    Oil Pump
    Oil pick-up pipe
    Water pump
    Thermostat
    Fuel Filter
    Haldex Oil & Filter
    Shell Helix 5w 40
    NGK BK7RE x4
    Black Diamond '6 groove' front & rear discs
    Black Diamond Predator Pads
    Ball Joints
    Track Rods
    Front Drop Links
    s3dave Tie Bars
    Saikou Michi S3 Oil Catch Can
    Roose Motorsport Flourosilicone hoses
    SFS Silicone Hoses (Coolant and turbo)
    AH Fabs V2 FMIC
    Complete SuperPro Front & Rear 'Alignment correction' Polybush kit
    SuperPro Dogbone bush kit front & rear
    Relentless V3 Manifold
    AET K04 hybrid turbo
    Relentless DP
    Modified straight through exhaust (resonator & bends delete)
    Golf MK4 Aero wiper arms & blades (Front)
    Sachs/Black Diamond Stage 1 clutch kit
    New PAS pipes due to corrosion

    I also completely drained all diffs, gearbox etc and re-filled with brand new genuine Audi oils.

    As it stands, the car certainly feels alot faster than before but has currently developed another boost leak somewhere, thought to be the re-circ valve as all boost hoses appear to still be on tight. In order to get it running to it's full potential, the car will need to go back in for re-mapping as all the airflows etc will have changed massively with the PCV bypass and FMIC.

    Anything else i can think of later on, i will edit and add accordingly. My brain is currently fried after uploading in excess of 200 photo's and doing this thread all in one shot haha

    Thanks for looking. All feedback welcome (within reason).

    Shaun.
    Last edited: Apr 28, 2013
    #17
  18. Jason.s
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    How's the clutch? Since it was mentioned a while back I've been interested in the black diamond kit as its a good price considering its got Sachs parts in it.
    #18
  19. Sandra
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    Sandra MODERATOR Staff Member Moderator

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    ​Car is looking fantastic Shaun. A lot of hard work and a lot of time has went into this project. Its good to see all the pics as you have done the work, and the finished car looks ace. :) x
    #19
  20. ShaunS3
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    I will be honest as say that the original clutch that I removed still had plenty of life left in it, however it was the DMF that has seen better days and certainly needed replacing.

    The kit I bought is actually a genuine Sachs complete kit. The friction plate is then re-surfaced with carbon/kevlar material at Black Diamond. Again, i will be honest and say that the feel of the clutch is no heavier/lighter than the OEM Audi/LUK and seems to hold well with the increased power/torque from my mods but I won't really know 100% until the car has been re-mapped to stage 2 :)

    What I will say is that the Sachs kit uses smaller pressure plate bolts (M7) as aposed to the LUK that uses M8. I had to source these from TPS using a MK4 Golf GT TDI as the car to order them as the M7 bolts are used in the diesel 02M boxes.

    I managed to get this kit for £400 posted which was only a £50 more than a standard LUK kit from ECP. Would be silly not to upgrade now and wait for the standard kit to go bang.....

    Hope this helps?
    #20
  21. ShaunS3
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    ShaunS3 Yorkshire & Humber Rep. Regional Rep

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    Thanks Sandra.

    Are you going to AITP?
    #21
  22. ShaunS3
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    ShaunS3 Yorkshire & Humber Rep. Regional Rep

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    Cheers dude.
    #22
  23. AVLO
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    good itemized thread shaun, nice to see all the time and effort you have put into it! i will have a good look round at the next meet and you will have to take me for a blast in it! ;)
    #23
  24. ShaunS3
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    I'm certain there is stuff that I have missed off the list, more will be added as and when I remember what they are haha. There is still a few little bits to tweak here and there but the main work has been done now and the car certainly feels alot better.

    I will be going back to GR Performance for a dyno before i get it re-mapped and then after aswell so i can get readings from the same dyno before/mid/after which will hopefully show good gains throughout. Will let you know when i'm going back down there for the next run....

    Shaun.
    #24
  25. Dani_B19
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    Dani_B19 Audi-sports own special child.

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    Very impressed with what youve done matey, really brought the old dog upto standards.

    Did you buy a full oil pump kit? If so wheres it from?
    #25
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  26. Dani_B19
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    Dani_B19 Audi-sports own special child.

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    Let me know when you going to the dyno mate as i want to see mines putting out and i missed the last one, ive also raised the car up so should be able to get on haha.
    #26
  27. ShaunS3
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    ShaunS3 Yorkshire & Humber Rep. Regional Rep

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    Thanks mate.

    Oil Pump and Pick-up pipe were both genuine Audi and sourced from my local TPS dealer.

    I will be going again once i've found the mysterious boost leak, will drop you a line. Unsure if i will open it up to the forum meets again at this time but we will see...
    #27
  28. Squirrelofdoom
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    Squirrelofdoom Member

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    that looked pricey.... :) Can only imagine how much better the car feels now though
    #28
  29. s33nyboy12
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    s33nyboy12 Active Member

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    Masterpiece
    #29
  30. Tim_Attard
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    Beautiful
    #30
  31. ShaunS3
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    ShaunS3 Yorkshire & Humber Rep. Regional Rep

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    I daren't even look at all my invoices :/

    tbf, i actually managed to negotiate some substantial discounts on most stuff, so even though it was pricey....it worked out less than half of what i should have paid for parts alone.

    Yeah, she feels like a totally different car now :)
    #31
  32. ShaunS3
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    ShaunS3 Yorkshire & Humber Rep. Regional Rep

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    Thank you :)
    #32
  33. ShaunS3
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    Thank you :)
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  34. wheatobear
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    looks **** lol....nah alot of work gone into this shaun like it mate...
    #34
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  35. ShaunS3
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    ShaunS3 Yorkshire & Humber Rep. Regional Rep

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    Cheers Wheato.

    You can attend some of my meets now your back to being a VAG FAG :)
    #35
  36. REDNERRAW72
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    REDNERRAW72 New Member

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    Looking good Shaun nice to see her back on the road!
    #36
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  37. ShaunS3
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    Thanks dude.
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