Rothers S3 Build Tread.

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rothers

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Right, I'm new to the Audi scene and circumstances have dictated I get a more usable second car as a daily driver that the better half can use as well. I currently have a 350z which is my pride and joy but not really practical as a daily user for the wife. So went out and found me a nice little S3 now it's a nice little car for it's age but comes with a few issues that the seller omitted to disclose when selling it. Don't get me wrong it's 12 years old and i don't expect perfection but don't leave things out when selling.
The S3.
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Looks nice, what are theses issues the seller left out?
 
First job at hand to fix the faulty temperature gauge. Replaced the temperature sensor still no difference still not reading above 60 so in with a new thermostat. I read a few threads which said remove this, that and all under the sun. Managed to do this without removing anything other than a few wires and the water pipe connected to the thermostat housing. Job done, now sits at 90 no issues. The second thing on my list was to refurbish the head lights as they had lost all of their clear shine. The results are not bad for 30 mins work, need to have a second application. The next think is to combat the brakes they are very soft and spongy I'm sure the fluids haven't been changed for ever and the oil is disgustingly black, so much for full service history an update to follow.
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It's had a bit of a knock at some time on the drivers rear quarter panel which has been very poorly fixed, school boy error on my part bought the car after a rain shower. I'm now believing that it may use a little more oil than they said as well. but will need to wait and see. doing all the fluids this weekend plus a complete service. i am a little anal when it comes to my cars and will not settle for anything than the best it can possibly be.
 
you seem pretty handy, the thermostat is quite a fiddly job. With the headlights did you sand them at all or just machine polish?
 
Jenno007 said:
you seem pretty handy, the thermostat is quite a fiddly job. With the headlights did you sand them at all or just machine polish?
Click to expand...
Both, started with 800 wet and dry then 1200 then machine polish with Meguiars G220, yellow pad and 105 Ultra Cut Compound.
 
audi upgrades
Thanks mate I'm due to do mine. Surprised the 105 removed 1200 grit marks!
 
Off to do a full oil change tomorrow, Brakes, engine 4x4 system etc. But I have a few questions for the people in the know. Firstly the car has a k04 Hybrid turbo, panel filter and i believe the uprated coil packs fitted. would the car need a remap to run the new turbo and other minor mods? Not withstanding all the minor mods it seems a little odd that the previous owner would do all this without a remap anyway. Would it be a simple visit to a tuner to confirm yes or no for the remap?
Thanks Rothers.
 
You sure its got a hybrid turbo on it? Just judging upon everything else you've said.
 
audi upgrades
It's the only piece of documentation other than the service book that came with the car. But it wouldn't surprise me if that was untrue as well. I'll be in a better position to comment later this week when i do the oils.
 
A quick update. As predicted Full service history my Bxxxxxx firstly coil spring broken now i know these can go at any time but having just had an alleged service you would have thought they would have pick up on this. Haldex oil change this looks as if its been there since day one. I thought i'd hit crude oil when i saw it. Now of the piece de la resistance brake fluid. Now i'm no expert but if this had been changed even 2 years ago it wouldnt be like this.

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Is there not some complex way of bleeding the brakes that requires the use of vcds, otherwise you risk damaging a seal, or did i dream that?

Car looks good. Got one just about the same :)

Dunno if you still have the OE turbo intake pipe, but the Badger 5 ones fit easily and free up a bit of power.

I had a spring break too, so fitted an eibach prokit and new oe bilstein dampers.
 
You only need to use VCDS to bleed the ABS unit if you replace it or suspect you haev got air in it

Use a pressure bleeder like Gunsons Eezibleed... use no more than 15psi and bleed OSR, NSR, OSF, NSF then the master cylinder... worth doing the clutch too if you are doing a full fluid replacement

<tuffty/>
 
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Rear spring changed, whilst doing the fluids last week notice the N/S rear spring broken. Upon taking it off the evidence was clear, spring broken not once but twice. How do you not know your spring is broken? Had it about a 2 weeks now and the general maintenance of the car needs a lot to be desired. The seller has just lied his *** off. So far since having it, New thermostat, temp sensor, set off Platinum plugs,camshaft kit and water pump (although there is a stamp in the book 3k ago saying changed) visual check the other day says otherwise. its going to need valve stem seals replacing as well (tell tale sign a bit of blue smoke upon start up). All this on top of the Forge inter cooler and Pipeworx down pipe and de-cat. For heavens sake hope the better half doesn't find out.
 
I hope you are going to put a bead of some description on the end of those alloy pipes

<tuffty/>
 
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Up early this morning to install the Forge FMI.






 
see ya later foglights! looking good tho

so installing FMIC = DIY just as long as you have the right tools? (scale of 1-10 for difficulty?)
 
IanPG said:
see ya later foglights! looking good tho

so installing FMIC = DIY just as long as you have the right tools? (scale of 1-10 for difficulty?)
Click to expand...

Yep by-by fog lights. DIY ok, if you have a little mechanical know how it not too difficult probably 7 out of 10 for difficulty. Modified horn carrier, and a little fettling of the bumper (Good old Dremil). Just ordered 2 x 40 degree silicone pipes to mount strait off the inter cooler which will enable to set the pipes further inside the bumper. Now for the exhaust.
 
Bead rolled ends stop the hoses from coming off under boost... if you have plain ends and you will pop a hose

<tuffty/>
 
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What did that Forge intercooler come off originally? looks a bit like a modified TT cooler as the Forge one for the S3 is smaller, retains the fogs and has 51mm outlets...

Looks a decent size core though

<tuffty/>
 
<tuffty/> said:
What did that Forge intercooler come off originally? looks a bit like a modified TT cooler as the Forge one for the S3 is smaller, retains the fogs and has 51mm outlets...

Looks a decent size core though

<tuffty/>
Click to expand...
Not sure what it originally came off maybe a TT who knows. The outlets are 63mm diameter. ordered some 45 degree silicon bends to mount directly off the inter cooler which will direct the initial pipework inwards allowing less protrusion.
 
hose blow off tastic without beaded ends...
and decent clamps not ebay band clamps hoepfully too..

take some tools on your first test drive too.... just in case :p
 
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Can confirm, been in too many cars on the first spin with a new FMIC, POP!! Always happens. You will NEED a bead on the end of every pipe AND good clamps. I think sfs/ramair or something like that on ebay do 3 in a packet and had a decent offer on 3 for £15, 9 good clamps for £15 is very good.
 
JCS Hi-Grip stainless clamps is what you want... not t-bolts or generic jubilee clips... bead rolled ends and JCS clips easily keeps 600hp of airflow where its supposed to be :)

<tuffty/>
 
Off with the head. The little issue of a small puff of blue smoke upon start up would seem to be from the valve stem seals. Cylinders 1 & 4 seem to be the culprits.







 
A little re-routing of the inter cooler pipework and the fitting of the Badger 5 TIP to the OEM air box. The air box needed a little modifying by cutting off the locating lug to allow for a steeper angle for the air box to marry up to the inlet pipe.









 
A brief update, The S3 is now booked into R-tech for it's remap and waiting for a set of DBA brake discs and Yellow stuff pads from Clarke motorsport. Pictures to follow.
 
So today fitted new discs and pads.



























 
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A Trip to R-Tech yesterday. Now Running a healthy 276 bhp.



 
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rothers said:
A Trip to R-Tech yesterday. Now Running a healthy 276 bhp.



Click to expand...
booking mine in with them when I finally get her back. What mods do you have to achieve that figure?
 
Forge, FMI, Forge DV, Badger TIP, K&N Air filter, 2.0lt coil packs, full service etc. Mapped at Sage 2 and would have easily reached 300 if i had put a cone filter on and it wasn't being restricted a by a old collapse breather pipe. All in all happy with the results.
 
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