My S3 8L Progress Thread

[Adam P]

SHES BACK ON THE ROAD!!!!

All the small issues fixed and the car is running spot on. Just wanted to say a big thanks to Rob as he has been a real help over the last few weeks especially letting me use his garage in the evenings. Thats what i like about this forum, everyone is willing to help and offer advice and point you in the right direction. Anyway here is the final picture of the complete FMIC install sat behind the front bumper.



I wasn't expecting there to be much of a difference, but i was surprised. The car pulls so much better and holds boost stronger for longer. On the way home i couldn't resist a little battle with a ep3 civic type r.............. well lets just say it wasn't really a battle lol!

 

[vrbob]

Yay we win

Looks very neat in that pic and glad we got the LED fogs working too. Our new pipework setup fitted good the way we did it so that the bumper goes back on really well and looks very OEM like mine. S3 twins lol

 

[Adam P]

As some of you will know the s3 is off the road. After considering my options I have decided to rebuild the car. Here is a link to what happened and the route i am going to take from a previous thread.

http://www.audi-sport.net/vb/a3-s3-...ightmare-advise-needed-absolutely-gutted.html

Right last night me and nick started to strip down the front of the car. With only a couple of hours of light after work we managed to remove the FMIC and all pipework, crash bar, headlights and the ecu which i am taking to bills on tuesday when i collect my rods for him to have a look at. I managed to grab a couple of pics and will update this as i go as it is now technically a build thread.

Here is some of the damage to the under bonnet padding from one of the fires on the induction tip side of the engine, on closer inspection there is little damage to the electrical wires and connections with only one visible which is completely melted so i think i have been very lucky!



After stripping that off i located the ecu and removed the wiper blades and scuttle panel and with some jiggery pokery got it out. Whilst i was under the panel i noticed the pollen filter was filthy so ripped that out and have ordered a replacement.





Amazing how many leafs and gunk was under the panel so gave it a good clean out. This is what the front of the car is starting to look like now.



The engine is due to arrive tomorrow so that will be good and I'm also looking forward to going to badger 5 on tuesday.

 

[Adam P]

There has been some progress with the car. The engine finally arrived and we started to strip it down and remove the head. Hopefully this evening I will get the sump off and get everything apart so it can all be cleaned and checked ready for the rods to be installed. Yesterday i was at badger 5 with nick and came away with the b5 80mm tip and billet adapter, time to get rid of the Samco tip currently on the car and do it properly for when bill maps it. Bill also had a look at my ecu which i removed from the car and took up with me. Unfortunately when he took it apart he found a chip soldered into the board which is a pain and another thing to add to the list. Luckily Bill being the helpful chap he is is going to sort me out a ecu with standard software which i can use. Overall yesterday was a good day and it was good to meet Bill and Tufty, watch live mapping and see some awesome project cars. Anyway here are some pictures.




The famous badgerwagon!



And Tuftys stupidly clean and immaculate engine bay!

 

[willh92]

Glad to see things are moving back in the right direction mate! Keep it up and keep us posted!

 

[Adam P]

Glad to see things are moving back in the right direction mate! Keep it up and keep us posted!

Cheers mate, appreciate it :icon_thumright:



Another productive evening working on the engine and its good news. The second hand engine is in good condition with little wear so i am chuffed. Nice clean oil was a bonus and nice to see as well. I broke the block down and removed the DMF and clutch and cover plate which all seem in good condition. The cam belt and runners were also removed. The DMF moves about 1cm when turned and no play when pulled back and fourth, would this need changing? After this out came the rods, pistons and crankshaft. As you can see i made a nice mess which i had to clean up pretty sharpish. Once all dismantled they were cleaned. Have handed it over to the professionals now to do some measuring and testing before the rods will go in but my mind is now at ease as i have a decent block. Always a risk on ebay. Here are some pics of tonights progress.












Few bits piling up ready to go on, badger 5 tip and billet, new pollen filter and a fire extinguisher. Better late than never!

 

[Adam P]

Another little update, the new block is having new bearings, being honed, new rings and new gasket set over the next week. Then I will be building it back up ready to fit the new clutch and cam-belt kit.

I have decided on a clutch which should suit my setup and my rods have arrived from bill @ badger 5 today. Things are moving in the right direction and within budget which is good. The next few evenings are going to consist of stripping down the current engine which is sat in the car on the drive. Here is a picture of the car currently and my new rods.

 

[vrbob]

looking forward to seeing this build progress

rods look great mate pity they will be hidden inside the engine

 

[millsy75]

Thanks for sharing mate. Sorry this happened to you but from reading your posts it has basically made me book my car in at badger5 for rods (sooner rather than later as I wasn't in a huge rush originally) and I have been running my revo stage 2 on the lower boost setting from the SPS switch. My car is very similar in looks and spec to yours.

Glad all work is underway to have the car back on the road and she will be better than before once sorted

 

[Adam P]

Thanks for sharing mate. Sorry this happened to you but from reading your posts it has basically made me book my car in at badger5 for rods (sooner rather than later as I wasn't in a huge rush originally) and I have been running my revo stage 2 on the lower boost setting from the SPS switch. My car is very similar in looks and spec to yours.

Glad all work is underway to have the car back on the road and she will be better than before once sorted

Thanks for the positive comments, its a shame bill is not local to me however its well worth the trip in my opinion. Really missing the car now. Hoping to get my clutch on order this week which will be good.

 

[millsy75]

Thanks for the positive comments, its a shame bill is not local to me however its well worth the trip in my opinion. Really missing the car now. Hoping to get my clutch on order this week which will be good.

Badger5 is a painful 2.5hr journey for me from Manchester and then it will be a 2.5hr train ride home but I don't know of anybody in the Manchester area with his specialist knowledge or that I trust to do the rod job. I have used places local to me over the past 14 month ownership of the car and i've never been overly impressed with the standard of work :-( It's really difficult to find somebody who realises these cars are our hobbies/projects and we want jobs doing spot on!!

 

[Adam P]

Badger5 is a painful 2.5hr journey for me from Manchester and then it will be a 2.5hr train ride home but I don't know of anybody in the Manchester area with his specialist knowledge or that I trust to do the rod job. I have used places local to me over the past 14 month ownership of the car and i've never been overly impressed with the standard of work :-( It's really difficult to find somebody who realises these cars are our hobbies/projects and we want jobs doing spot on!!

I completely agree, I'm very lucky my mates dad owns an engineering company which is at the end of my road where i can work on my block and get help and advise as i rebuild. I get to see everything which is happening and also learn about all the parts as we install them and how the whole build functions and works together as i build it back up.

 

[Adam P]

A little update, the front clip is now off. Thanks to tufty on the pointers it wasn't too bad in the end. Tonight's task after work is to detach the standard down pipe and strip the last few pipes out the way. My new block is now ready for me to reassemble so i will be doing this through the week and taking pictures as i go.

 

[jitvv]

Wow keep up the good work! Wish I was as hands on as you! Your doing a awesome job!

 

[Adam P]

Wow keep up the good work! Wish I was as hands on as you! Your doing a awesome job!

Cheers mate, really appreciate it! At times i feel a little out of my depth but just keep cracking on with it, I am lucky this forum is as good as it is really as a lot of members have helped me with advice which I am very great full for. Researching on this forum has been like a bible to be honest.

 

[superkarl]

Cheers mate, really appreciate it! At times i feel a little out of my depth but just keep cracking on with it, I am lucky this forum is as good as it is really as a lot of members have helped me with advice which I am very great full for. Researching on this forum has been like a bible to be honest.

mate i know exactly how you feel. Without the forums and some great people/mates on here id have gotten nowhere

its a great adventure though and all part of this whirlwind of a hobby.

i admire how you've tackled this and gone for it after **** has hit the fan

 

[Adam P]

mate i know exactly how you feel. Without the forums and some great people/mates on here id have gotten nowhere

its a great adventure though and all part of this whirlwind of a hobby.

i admire how you've tackled this and gone for it after **** has hit the fan

Cheers superkarl, I have always been heavily into my cars and modifying them but have not got too involved with engine internals, all previous cars have had aftermarket, manifolds, exhausts, inductions, suspension, wheels and remaps etc but this really is my most in-depth project to date. Before the 'incident' occurred i contemplated selling the s3 and found myself looking at evo's again which seems to happen every so often as i have driven a few and like them a lot, but i couldn't justify the increase in running cost, tuning and insurance with a bigger outlay on purchasing the car in the first place as i would want a tommy mack edition. There was literally nothing out there i fancied within budget so i knew the s3 was going to stay which was reassuring that i knew i had the right car. I think this has driven me on to do the rebuild and come back stronger to be honest with more tuning potential to be had in the future if i decide to. I literally cannot wait for the day i turn the key and she fires up again

 

[Adam P]

Well last nights task consisted of cleaning, facing and learning how to balance the crank properly. Quite interesting to be honest, and time consuming but there is no point cutting corners. I had to shave a little weight off each end but now it is fully balanced and ready to be seated in the block again. Were just waiting on the last few bits to turn up then the new block can be reassembled with the IE Rods in place. A few bits have arrived in the post, ie: new oil filter, magnetic sump plug and gasket kit for the aftermarket 3" down-pipe which is due to arrive today or tomorrow.

 

[vrbob]

Nice some proper engineering going on there mate I like it

You get any parcels today?

 

[Adam P]

Nice some proper engineering going on there mate I like it

You get any parcels today?

Cheers mate, nope was waiting eagerly at work and it hast shown there is still ten minutes left but i don't have great faith in couriers!

 

[Adam P]

So today was a good day purely down to this arriving, the standard down pipe and cats on the car have seen better days and this will be easy to install once the engine is out. Great product and really well manufactured if anyone else is after one let me know and i will pass you some contact details. Only two more items to buy then I have everything I need. Anyway here is a shiny picture

 

[Adam P]

Right we are getting there, the current engine is ready for removal when the crane gets dropped off next week, so have a couple of mates coming round and were going to attempt to hook the engine out followed by dominos pizza if we are successful! On the engine building front I'm getting there. We noticed that the current sump had a weld repair so i have ordered a replacement for piece of mind which should turn up tomorrow from gsf. Last night me and my mate cracked on with cleaning the pistons and replacing the rings. New bearings were oiled up and we seated the new IE rods on the crank. All my other engine parts have been cleaned and the rocker cover is in the acid bath as we speak. Estimated another 4 hours work until she is rebuilt and i can pallet it up and take it back to mine to swap the ancillaries across from the old engine. Grabbed a few pics throughout the evening, enjoy.

 

[<tuffty/>]

Nice progress mate.. building engines is one of my favourite jobs

<tuffty/>

 

[Adam P]

Nice progress mate.. building engines is one of my favourite jobs

<tuffty/>

Cheers mate, I am enjoying it too. Much more than i thought i would to be honest. I think my main issue is going to be with pipework and wiring connections once its fitted in the car. I cannot wait to get it down to bills when its ready for mapping!

 

[Adam P]

The new sump turned up today so i took that down to the garage and we finished rebuilding the bottom end, just got the head to fit on monday, pop the new sump and timing belt etc back on then she's done. Before i got there one of the guys from regal autosport was in the workshop discussing his 800bhp vxr build when he noticed my block and complimented how clean the engine was and approved of my rods which was good to hear :icon_thumright: Here is a picture of the bottom end complete mid torque.



Just bit the bullet and ordered my clutch, hopefully it will arrive Monday. Will post when it arrives. Having a weekend chilling out away from the car so will be ready to tackle it all on Monday.

 

[vrbob]

Nice

 

[Adam P]

The new engine is nearly there now. Just waiting for the head to be re-timed then its good to go. Re-torqued the bolts and double checked everything before fitting the oil pick up pipe and fitting the new sump complete with all the new gaskets as you can see in the picture. Tonight and tomorrow evening are going to consist of removing the old engine currently sat in the car on the drive. Everything has been stripped out of the way so in theory a few bolts to undo and it should swing out but knowing my luck it wont be a simple as that. Anyway here is a couple of pictures of the block taking its shape.




One of the final pieces of the jigsaw arrived today, my stage 2 clutch kit from CG motorsport. Well packaged and arrived quickly. Great website and customer service so would recommend them.




To be continued......................................

 

[millsy75]

Hi mate, can you give me some more info on the clutch please? I'm going hybrid this year and don't know what to do for a clutch. Do some people modify/do something with the standard item???

Thanks.

 

[Adam P]

Hi mate, can you give me some more info on the clutch please? I'm going hybrid this year and don't know what to do for a clutch. Do some people modify/do something with the standard item???

Thanks.

Hi mate, yeah lots of people seem to be using the standard dual mass flywheel and standard cover plate but using a paddle clutch inbetween on high performance builds. This is what tufty is running in his beast. I have the standard dmf and just opted for a stage 2 clutch kit which should meet my requirements and have a long life. The company i purchased my kit from also do higher stages and race clutches here's a link to there website, you will be able to see my clutch and others available. Mine is the stage 2 kit. Hope that helps.

Clutch Specialists Manufacturer and Supplier of Handmade Clutch Kits

 

[vrbob]

Engine is looking good mate will have to pop over at some point after I have been to Bills 2moro

 

[millsy75]

Great info. Thanks mate

 

[Adam P]

Well the last two evenings have consisted of swearing, power tools, blood, pizza and a lot of persistence. But the old engine is finally out!
Me and two of my mates got started on wednesday evening and finished it this evening. Everything came out fairly simply then i went to town on the down pipe with the angle grinder as it really really frustrated me :bang head: Anyway heres some pics.

Final bits being removed before moving crane in place



Up she goes





Couldn't get the lambda near the cats out, can i run without this one and just use the one situated in the down pipe?



And the picture of the hole in the block for anyone who is interested

 

[Adam P]

More parts have landed, i am only waiting on the final piece of the puzzle now which is the ECU. I know Bill is a busy man so i will give him a call later in the week for that. As far as i could see there was one melted sensor which is located on the back of the gearbox which will need to be replaced, hoping to get a picture of it this evening so someone on here may be able to help identify where i can source a replacement. Tonight's task is fitting the replacement gear knob and the down-pipe and de-cat.

Forge uprated actuator from g60leigh


8P Gearknob from jezzy

 

[Adam P]

Steady progress made last night. Manged to strip most of the old engine down ready to transfer the bits onto the new block. Got everything done apart from splitting the gearbox, might have to research this a little as we removed quite a few bolts and it wouldn't budge so I must be doing something wrong or missed something. Let the research begin on that one! After removing the turbo i am pleased to say it is in good condition. Managed to replace the old tired gear knob with the new 8p one which updates the interior nicely, the downpipe and decat are now lined up provisionally on the car, have left a bit of movement for when the new engine goes in, have got to replace an outer CV boot at some point this weekend, that's if the weather stays dry.







This is not a for sale plug. I will have a lot of engine parts kicking about over the next few weeks, DMF, clutch, cover plate, AMK head, standard rods, rocker cover etc i am happy to let these go for beer money to fellow asn members only. I get a lot out of this forum so thought i would try to give a little bit back. PM me if interested.

 

[Adam P]

We have finally made it! The engine is now complete and timed up Here is a picture of the new cam belt after install.



I have recently purchased the forge uprated actuator and been warned that it is not the best item on the market, i have tried to get in touch with beach buggy but no reply so went for this, if it doesn't hold up well when mapping and there are issues it will be removed and replaced simple as that really. Anyway here it is fitted to the ko4.



For those that are interested i hooked out my old piston and rod which caused the damage...........



So all that was left to do was split the gearbox off the old engine and install the dfm and stage 2 clutch. We got the box off and discovered this!





YES! thats a hole in my transfer box, currently sourcing a 2nd hand replacement now online and I have posted in the wanted section.
But all in all I'm pleased the engine is finished now. More updates to come shortly. Time to enjoy a drink in my s3 mug!

 

[superkarl]

can we be piston buddies??


yours earns more man points as it was power related. Mine was just an epic fail

 

[millsy75]

Wow! Really interesting thread mate! Thanks for posting! You're nearly there

 

[Adam P]

We should make a club Superkarl! I have spoken to a few people who have seen the piston and rod and they have mentioned i should check my injectors so they are being cleaned this weekend as i have a ultrasonic cleaner I can put them in. Im picking up the last few bits over the next few days so we should be 100% complete by next week then iv just got to put the dam thing back into the car and plumb it all back in.

 

[Adam P]

UPDATE TIME

I managed to get a replacement transfer box from fellow forum user vrbob :thumbsup:so i went over to his and picked it up and bought it home. I bolted this to my old gearbox and moved across the shielding from my old transfer box aswell.



On went the CG motor sport stage 2 clutch and cover plate with the standard luk DMF, also changed the slave cylinder.









Finished bolting on all the ancillaries and checked all the turbo lines and pipes were plumed in correctly. Added my nice shiny badger 5 billet adaptor and transported the engine and gearbox back home.



During the week my replacement ecu had arrived from Bill.



Today has been wet however this didn't stop me and my mate. Up went the parents BBQ gazebo!









The engine is now back in! the ecu is mounted back in its bracket and plugged in. Just have the task of building everything else back up. Time for a beer in front of the tv whilst my injectors are cleaning in the ultrasonic bath.

 

[limbo118118]

Looking good matey... ino how you feel with the gazebo iv got a massive umbrella over mine atm with this dam weather! !