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superkarls overhaul

Discussion in 'A3/S3 Forum (8L Chassis)' started by superkarl, Feb 18, 2011.

  1. Dani_B19
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    Dani_B19 Audi-sports own special child.

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    [Dec 21, 2012]
    Yu getting puffs of blue spoke mate? Mines being doing this since start of the summer and its not got any worse, my mechanic thinks its the piston rings too as the turbo seems healthy.
  2. Alex C
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    Alex C Well-Known Member

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    [Dec 21, 2012]
    valve stem seals maybe?
  3. s3dave
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    s3dave TFSI Hybrid

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    [Dec 21, 2012]
    That will kick your ass in getting things moving Karlos...:happy:
  4. superkarl
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    superkarl MAN OF STEEL

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    [Dec 21, 2012]
    Heres what happened.
    Well i dont use the car since moving to the city, so when i went back to see rents i naturally wanted to take the s3 out for a hooning. It flew, great fun, until it got to about 110mph where it seemingly hit a limiter and engine light persisted to flash. Well i havnt had vcds available as my mate has the laptop and he is in oz, so after talking with some lads off here westy suggests unplugging maf and trying again, which was last night, maf unplugged it did the same but at 80mph in 3rd, bit strange i thought, but didnt really matter to me as the car wont get used. Then as im heading down the dual carriageway it goes to 3 cylinders, 'ahhhh' i thought 'bloody coilpack', so i limp it half a mile to the nearest stopping place to find the dead coil and unplug the injector for that cylinder to prevent bore wash.
    I pull over and the smoke of oil and smell of it is unreal, hmmmm. Pop the hood and theres oil splattered everywhere. So i found the coil, cylinder 4, and unplugged the injector for it, as you should. Oil continues to smoke from somewhere.
    So, no fire on No4, clearly oil burning, then i pull the dipstick, compression chugging out of it.
    those 3 things tell my inexperienced brain piston rings are shot. They clearly arent sealing, and 3 isnt firing properly.
    I limped it home as slow as poss with a cloud of smoke and its left on the drive.
    My dad will have a look eventually and remove spark plug to see how it looks.
    im not overly bothered by all this, i arrived home after calling my dad and net him outside followed by a cheer and 'its dead'.

    But nOw my thoughts turn to the block, how bad are the rings? Is my bore now ****ed? Meaning either A. New block. Or B. Overbore and expensive pistons.
    Time will tEll, it'l be taken apart in the new year, which was the plan anyway.

    Please let me know your thoughts on my diagnosis.
  5. Dani_B19
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    Dani_B19 Audi-sports own special child.

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    [Dec 21, 2012]
    Excuse to stroker it me thinks mate :).
  6. Dan-Jnr
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    Dan-Jnr Active Member

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    [Dec 21, 2012]
    Not what you want to be sorting out over Xmas.
  7. superkarl
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    superkarl MAN OF STEEL

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    [Dec 21, 2012]
    I have an aeb head, agu pistons and various other things to be fitted anyway. So its cool
  8. Westy
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    Westy Double Dark Side! Diesel & 8P

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    [Dec 21, 2012]
    I think it'll be fine mate. Nothing a honing and some new rings won't fix. I can't wait for you build.
  9. StaceyS3
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    StaceyS3 Well-Known Member

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    [Dec 21, 2012]
    O dear that isn't good mate, think your thoughts are probably right :(
  10. s3dave
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    s3dave TFSI Hybrid

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    [Dec 21, 2012]
    At least you got its last breath before the rebuild...:arco:
  11. dre_S3
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    dre_S3 Member

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    [Dec 21, 2012]
    **** news mate :( what are your main plans for the car then and what kind of power you going for ?
  12. crazy88
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    crazy88 Loving the anonymity

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    [Dec 21, 2012]
    But were you still able to beat a fiesta when firing on 3 cylinders?
    Westy likes this.
  13. superkarl
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    superkarl MAN OF STEEL

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    [Dec 22, 2012]
    ferrari f430, did you not hear?
  14. 05ayersa
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    05ayersa New Member

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    [Dec 23, 2012]
    great build thread! just read from front to back!
  15. Gops
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    Gops 6th gear @7000rpm

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    [Dec 24, 2012]
    Ouch not what you need near Xmas, it always happens near Xmas aswel! But probably best to inspect the block and go big turbo ;) or tfsi :p
  16. superkarl
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    superkarl MAN OF STEEL

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    [Feb 4, 2013]
    just to let everyone know, i do still own an S3, its just not very good at the moment

    [​IMG]

    but hopefully it will be awesome again in the near future.
  17. superkarl
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    superkarl MAN OF STEEL

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    [Feb 27, 2013]
    opened my engine to find this:
    [​IMG]
    [​IMG]

    detonation at its finest.
    the white looking material in picture 2 is melted piston lining the bore. This will be cleaned off lightly with wet and dry, il hone it, then see what the damage is and whether its useable. I will most definately NOT use this block if there is any scoring to the bore at all. its not worth it.

    i didnt expect this at all. as mentioned previously we thought it would be blown rings, blown piston just seemed too extreme for my spec.
    As for the cause, il prob never find out what it was. Il scan the car see whats on there, prob just misfire codes. but i doubt itl lead me to a conclusion.

    if anyone more experienced (bill, ben, tuffty etc) have any professional opinions of the cause, please tell me your thoughts.

    If indeed this block is fubard, il either A. need a new block to work with. or B. bore this to 83mm and get 83mm pistons.
    the latter i would love to do, but simply cannot afford.
    If anyone knows of any bare blocks lying around, please :( please help me
  18. BENJAMIN
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    BENJAMIN Active Member

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    [Feb 27, 2013]
    Lean! Melty melty. Get the injectors tested, possible fuel pump.

    Bore it to 83mm.....
  19. superkarl
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    superkarl MAN OF STEEL

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    [Feb 27, 2013]
    how can i test the injectors dude?

    dont forget its never been mapped. any fueling logs have always shown standard lambda and A.ok
  20. Reesy
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    Reesy Well-Known Member VCDS Map User

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    [Feb 27, 2013]
    This is your problem. Your car got fed up and decided to attempt suicide as a cry for attention.
    StaceyS3 likes this.
  21. [Dave B]
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    [Dave B] Rrrrrrrr-tech

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    [Feb 27, 2013]
    **** dude, unlucky! It'd be interesting to hear the cause if you do find out. What mileage has the lump done?
  22. superkarl
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    superkarl MAN OF STEEL

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    [Feb 27, 2013]
    153203 Miles. seen alot, but i thought being standard map its whole life, had an easy life. obv not.

    im not really arsed the car shat itself, i hardly use it and wanted to rebuild it anyway, which i have all parts for.

    I just never anticipated this, and the block being possibly ****ed. Im doing this with the block in the bay yiu see, up a drive, on axle stands. If block is shagged its more of an inconvenience than the extra cost that bothers me.
    I do really wish i could afford to go 83mm tho. Ahhh well.

    Il update this when rods and pistons have been dropped and the bores thoroughly checked.
    Il moVe the car to my mates garage aswell, plenty of room and nice and sheltered.
  23. Westy
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    Westy Double Dark Side! Diesel & 8P

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    [Feb 27, 2013]
    Well as you're rebuilding it at least the injectors will be getting changed but maybe you should also order up a new in tank pump!
  24. superkarl
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    superkarl MAN OF STEEL

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    [Feb 27, 2013]
    Id rather check it somehow. An inline pump was on the cards anyway
  25. Westy
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    Westy Double Dark Side! Diesel & 8P

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    [Feb 27, 2013]
    No point in an inline if the one in the tank is screwed. Get that sorted first mate.
  26. superkarl
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    superkarl MAN OF STEEL

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    [Feb 27, 2013]
    im not going to replace an intank based on a hunch. id rather there was a way to test it first.
    i suppose when its back up and running i can assess whether its up to the job then, and sort fueling from there
  27. Dani_B19
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    Dani_B19 Audi-sports own special child.

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    [Feb 27, 2013]
    This thread is really worrying me, i think i need to do some logs and get my car in for a health check.
  28. Westy
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    Westy Double Dark Side! Diesel & 8P

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    [Feb 27, 2013]
    Well of course get it check first, I didn't say just go out and buy one!
  29. StaceyS3
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    StaceyS3 Well-Known Member

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    [Feb 27, 2013]
    Bit of bad luck mate :(

    Possibly an injector failed? Was there any evidence of det in the other pots?
  30. Andrew@A.L.D
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    Andrew@A.L.D Cylinder Head Master

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    [Feb 27, 2013]
    I'll have some agu pistons for sale soon so if you can find a cheap block you'll be sorted
  31. superkarl
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    superkarl MAN OF STEEL

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    [Feb 27, 2013]
    no evidence of det in the others no.
    although evidence of a snapped belt in its lifetime. valve marks on the top of pistons, very slight. maybe caused the hot spot?

    i've got a set of AGU pistons that i was putting in anyway mate but thanks.
  32. Jason.s
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    Jason.s Active Member

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    [Feb 27, 2013]
    If its still on its original i`d replace it anyway regardless of it being ok or not. Seeing sooo many things popping on facebook recently from Bill and Niki when mapping about old tired fuel pumps causing top end to run lean and limiting what they can achieve. Hence why i changed mine 2 weeks ago with 124k on it.
    Westy likes this.
  33. superkarl
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    superkarl MAN OF STEEL

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    [Feb 27, 2013]
    how much it set you back?
  34. Jason.s
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    Jason.s Active Member

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    [Feb 27, 2013]
    I can do you one for £208.46 inc vat and obviously some extra ontop for postage. Retails at £289.46 inc vat
  35. superkarl
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    superkarl MAN OF STEEL

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    [Feb 27, 2013]
    :ohmy:

    p.s. cheers jason.
  36. Prawn
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    Prawn My other car is a MINI!!!!

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    [Feb 27, 2013]
    jesus they're not cheap are they!

    For that money you could get a decent used S3 pump, and a DA31 mounted inline.
  37. <tuffty/>
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    <tuffty/> Badger 5 Edition Staff Member Moderator

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    [Feb 27, 2013]
    Wow... sh*te luck dude..... some kind of lean event happened there fo sho... det tastic... injectors don't go 'wrong' often but you could get them professionally cleaned and this would 'test' them too as the rigs used cycle the injectors to get the cleaning fluid through...

    I would also check the state of the fuel filter and fuel rail... filter could be blocked and would drop fuel pressure, check the state of the vacuum line to the FPR as an air leak here would be fatal to the engine, remove the FPR and see if there are any rubber deposits in there.. the rubber hoses to the rail corrode internally due to the ethanol in modern fuels... this could lead to the injectors getting clogged and subsequently a lean situation...

    Where there any fault codes present? this could give a clue as to why this happened...

    I may be able to sort you some S3 pistons if you are stuck...

    Pump can be tested using a fuel pressure tester... connects inline with the feed to the fuel rail (no the return) and should be just under 3bar on idle and 3bar + boost under load... tbh its best to test on the dyno... (we do this quite often)...

    You could also test (although not as accurate especially as you are not mapped) using VCDS logs but its safest on a dyno with the pressure tester as a non mapped car is lambda 1 pretty much all the time (0.95 under load) so when it goes lean you have no margin of error

    Dani... you are narrow band and therefore screwed... you will need to get a wideband AFR gauge or get yer arse to Bills (other dynos are available)...

    <tuffty/>
  38. AVLO
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    AVLO Active Member

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    [Feb 27, 2013]
    well karl, after spending a couple of hours to read your thread from the start im sorry to see this has happened. Its been a well documented thread buddy, just a pity you've had this happen. :banghead:

    hope all gets sorted soon
  39. Welly
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    Welly VX220 SC Driver :)

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    [Feb 28, 2013]
    Deffo some form of lean event there to cause it, no doubt.

    Weird however that it's only the one cylinder. It's got to be a faulty injector really... At least that's what I would have thought due to no evidence on any other cylinder.

    Blocks can be picked up cheap and to be honest, after that I would just be replacing it. My advice? Buy a cheap AGU, (something like this: VW GOLF MK4 AGU 1.8T ENGINE 86K MILES | eBay) strip it, hone bores, new rings, new shells and whap it in.

    It'll be like a new engine for lets be fair, for £600 - £650.
  40. S3Zek
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    S3Zek Member

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    [Feb 28, 2013]
    I have a good bam lump to go if that will help, pm me if ur interested mate,

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