Car ran for few secs with DSG and horrible grinding noise. I think its the middle metal sheet between gearbox and engine and I really really hope it is not hard to fix and I have a clue where it came from, possibly the rear small cover is bend inwards and makes contact to flywheel.
Positive was that at least now it didnt leak so far, I hope it wont start when I get more pressure to it.
BTW the CR is 9.8:1 I had wrong figures on one spot whe I calculated it, so no wonder it started to knock with 98 fuel on 1.2bar boost, now its E85 and car worked really well with it.
Then I noticed the ECU wont talk to DSG and of course it wont if you forget to connect +12v acc wire D'oh!
I have run into problem after problem after problem and making things worse, my hands are overworked, they hurt day and night so I have had to push this project forward and forward.
New parts or changed:
1300cc EV14 matched set
https://finjector.com/eng/ev14_1300_cc_12_ohm_c_jetronic_liitin_keskipitka_o_o_49_mm-p-486741-0 I really suggest this place, they ship worldwide too. Fast&Great customer service, fast shipping and delivery in total, make account if you order(the more you buy, they give you personal discount that applies to prices when you login) These have very great spray!
Turbosmart - GenV HyperGate 45 14psi External Wastegate
Now I am missing downpipe+wastegate pipe+some breather lines. So close but so far away still...
Not much I know but I am not good with making downpipes or the pipe for wastegate. Now the downpipe has to be put in below with twisting it many times to it goes to place. I have to weld 2"v-band close to the pipe for connection to wastegate and then I hope it still will fit.
All this on ground too witch is pain in *** to do.
List what you need
at least on my build)
- DSG, I have MTX Gearbox from Golf R 2011 (its been said it can handle 650Nm on stock clutch pack so I kept it, I will limit torque)
- ECU what can control it, I prefer and suggest Ignitron, it is the best there is
- Electrical connector round for DSG box 1J0927320
- Electrical connector for DSG shifter 1k0972776, doesnt come with connectors so get them elsewhere, on VW they cost 15€/pcs and that price is a gunless robbery! Dont waste money on the VW fix wires which are 15€/pc here at least! You can use the small amp square connectors that cost less than euro, sorry I forgot the number for them. Get 5 of them but I usually buy more cus i **** them up regulary. I suggest buying good crimping pliers example aliexpress.
- Right side driveshaft flange from 02M gearbox, the one with MTX and seems with others too, dont fit
- Driveshafts: Left fits just like that, right you have to cut 40mm. I cut mine with lathe and TIG welded. I could not find ones that would fit without modding and I tested 9 different driveshafts. TT 3.2 ones dont fit with this one
- Flywheel 06F105266L or Sachs 2295 000 541
- Bigot bearing middle of flywheel Sachs 1863 869 047 <-DO NOT forget to put this in
- Starter motor 02E911023L
- 2 coolant hoses 8N0121096H coolant hose from DSG cooler to waterpump. 8N0121073A, coolant hose from interior heat exchanger to DSG cooler.
OR DIY hoses, i used 16mm 90degree ones 2 of them, warmed the hose so I could push it to one way valve
-One-way valve
1J0122351
- Engine mounts 1J0199117AT/ 8N0199555G or use OEM S3 mounts, the fit except on transmission site you are missing one bolt and there is chance two wont hold it in place BUT 1J0199555BB seems to have right bolt pattern and looks like it fits, I have not tested it.
- DSG shifter from Passat B6, touran dont fit to 4wd, see pic
Optional:
- better clutch pack 02E398029C, I am going with OEM cus I dont plan pushing over 600Nm nonstop and ppl say that this OEM pack should hold 650Nm without slipping if you program it to clamp harder
- Oil filter housing made from aluminium with fins for better cooling. I bought mine from china and it was ******, idk did i get unlucky since others bought same and they got great item.
- CAN support cluster to see what gear is engaged, I skip this for now or make external that shows me it but I dont really need it for now.
- Paddle shift, basically on/off switch for Ignitron and digital inputs
My list for parts from where I got them from:
- Sachs flywheel 2295 000 541 (Autodoc)
- Sach bigot bearing 1863 869 047
-
CASCO starter motor: CST10444AS (Autodoc)
- Elring DSG cooler O-rings 886.810 (Autodoc)
- Vaico repair kit with DSG oil pan, oil filter, O-rings for electrical round connector, 6litres of DSG oil V10-5138(Autodoc)
- Elring park gear axle gasket(renew if leaks) 886.780 (Autodoc)
- Elring metallic gasket for oil pump DSG 149.060(Autodoc)
- Shifter from Passat B6 junkyard
- Driveshafts left fits, right one you need to cut 40mm DIY
- One way water valve
1J0122351
- Cover for clutch pack and hydraulic block gasket maktrans poland, almost all gaskets are one time use on DSG as listed below
- 16mm and 19mm ID diameter water hoses with 90 degree corners on them, they are cheap and must. Even better to get few of the ones that have several curves, makes things easy.
Repair parts for DSG, these are bare minimum you need to open box and assemble:
- 02E321385A Gasket for oil pump, needs to be renewed (
- 02E301580C gasket for hydraulic block, needs to be renewed(cant get from VAG they don make it but eg. maktrans poland makes it)
- 02E301205C cover for clutchpack, has to be renewed -everytime
- 02E301859A Lock ring for clutchpack cover, has to be renewed
- the round electrical connector needs new o-rings everytime too.
- DSG cooler needs new 2x O-rings
For sealant to use, when mating casings back together, Elring AFD2018 was the one I went for. Anaerobic, I could not find anywhere what they use when they make DSG so I saw one elring video they used this.
So what else?
G25-660 is now in
Wastegate is turbosmart hypergate 45 instead of Tial
Battery is in trunk now, 50mm2 welding cables full copper, small strains version(better conductivity)
Start and stop battery 75Ah
300A automatic fuse
Also amps are in spare wheel cowl, pics are from not ready state
Wiring DSG connector
DSG pinout, these are from my car but this is the pinout on 20pin ones almost all same, to my knowledge. Please check your gearbox one before doing this. I am not resposible for errors.
DSG shifter pinout
New subframe because old ones dogbone nuts got loose inside of the frame and I could not get them to stick or weld.
Had to cut triangle out of body so the DSG would fit, the OEM intercoolers hook into that. I dont know why but gearbox would not fit without removing that. There seems to be different version of S3 where that thing dont exist (?) since few ppl said they dnt have it. I know A3 might not have that but they said they have S3. and no, I did not cut the frame, only the triangle what is made of thin metal. So frame integrity is still same
Passat shifter in, I broke the button from this when I tried to remove it. It had crack and got loose. I have been trying to find new button but not luck yet.
Lathe cut the right driveshaft
Tig welted shaft ready for paint
Making new engine mounts, Shore65 rubber. Cheapest mount and 1litre kit approx 60pounds and they do not move
Getting there but still to do and tidy stuff up. I put vacuum block top of intake. I know my engine room is nothing beautiful like others but I make it so it works. The line to air filter too is going to be different, that was just a test
Final waterlines for DSG . I put extra bolt on that tranmission mount, made threads to the one connected to transmission but I have the right mount too. I was thinking of testing this and to see is that 1 extra bolt enough, so you could use S3 oem mounts. If it moves I replace it.
From picture you can figure out how the water lines for DSG go too or at least I think you can make it out
thats it so far. I cant list all the trouble I have had with this project and I think its last time I touch the car. No more changes