Normal service is being slowly restored, so I thought I'd add an update on what has been done some far. Drove my baby home yesterday, so here is a summary of a day's worth of emotions and impressions...
I left her in the hands of Alex and Andy at Storm Developments just before leaving on holiday a couple of weeks ago and asked that we do a few extra bits while the engine is out, so here is a list of what has been done:
- Strip the old engine and install new unit as supplied by @mjr901
- Replace every gasket, seal, stretch bolt and belt that needs to be replaced while the engine is out, includingnew crankshaft pilot bearing
- Installed a full set of blue Forge silicone pipes using forge clip kit: DV to Intake Return hose, lower coolant hoses, silicone coolant hoses
- AirTec Stage 2 intercooler, including hoses
- Renew S-Tronic, Haldex, rear diff and front transfer oil and filters
- Fit an uprated dogbone insert
- Fit OEM R8 spark plugs
- RS3 intank fuel pump
- New TTE420 turbo unit
While the car was in bits, I also asked the guys to adjust the H&R ARBs to have them on soft front and hard rear in order to further reduce under-steer too. Big improvement and I think it's the only settings anyone should use with these ARBs.
As you can see, the amount of work was huge (the bill was eye-watering too), but the guys at Storm were brilliant throughout. Andy helped to put together a list of work that needed doing and offered solid advice, kept me away from getting overambitious with my modding and provided updates when I called in to checkup on how things were progressing, even while being mega busy with all the other work that was going-on. They fitted my job around a few other big pieces of work they had on and I just can't thank the team enough for pulling this off with minimal fuss and interruption to my schedule. Top guys who I will aim to use for all of my tuning work in the future.
As mentioned above, I was looking at all the work that was going to happen with the new engine and decided to go down a brand new TTE420 turbo unit (Andy helped me to get a good deal on it too, which was awesome!) My logic here was that the original turbo had already done 66k and if I was to keep the car for a few more years, then it made sense to replace it together with the engine. Given the price difference between a new OEM turbo and a TTE420 unit, minus the money I'd get by selling the old turbo, it made some sort of man-maths sense to upgrade now, even if it meant that the final bill would be bigger. While at it, the RS3 LPFP was also upgraded at the same time to support the new fueling needs.
So, what's it like now, I hear you ask
Well, the new engine is gleaming and runs much nicer that the old unit. Gone are the funky mechanical noises, replaced by a very crisp clicking sound of the injectors. The engine is in it's running-in phase for the next 1k miles, so I can't take it above 4k rpm for now.
The current Stg2+ map is still on, but once I get the engine run-in, I'll make a trip down to Storm to get new engine oil and filter followed by a custom engine map and a DSG map to make proper use of the new hybrid kit. We'll see if the RS3 LPFP controller is required at that time and fit that on the day.
The exhaust note seems to have changed a little, and sounds a bit more raspy - I suspect this is down to the new turbo, but may also have something to do with the new AirTec FMIC too - I really like it! The induction noise has changed too - it's now less pronounced inside the car with windows up, but outside the intake is sounding more aggressive. I suspect that the new turbo is not being taxed in the same way that the OEM unit was and runs much quieter, hence the lower induction noise inside the car, plus the TTE came with the charge pipe baffles removed, so that must make a bit of a difference too.
I must admit, the new engine bay is looking more colorful and much cleaner
I very much like this! I'm tempted to paint the TTS engine cover, but haven't decided on the color - I think blue will be overkill at this point
Any ideas?
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To my surprise, the biggest impact to normal driving so far has been the uprated dogmount insert! While there is quite a bit more vibration with the DSG is in D while stationary, or slowly pulling off (forward or reverse) the way the engine feels connected to the rest of the car makes for a more engaging driving experience. I didn't realize how positively it would impact the throttle response - there is now no hesitation between you pressing the throttle and car reacting to your input. Feels much more engaging now, but I suspect that the added vibration in the cabin may not be for everyone. Andy explained that with the stock/worn dogmount, engine will twist more on its mounts, which adds a bit of lag between you mashing the loud pedal and car reacting - it's milliseconds, but you do feel this. The harder dogmount insert stiffens this motion and reduces the amount of travel involved, so you get the drive from the engine a fraction of a second sooner, resulting in a better feel. Seeing as my car has turned more into a weekend toy/family trip mobile after I started a new job working from home, I do not expect this to bother me (in-fact, I kinda like it - #racecar
). Obviously, renewed oil in every orifice of the running gear may have also contributed to the improvements.
When I got her home, the first things was to give her a wash:
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While all of this work was going on, I've been spending some time in the garage, clearing it out and optimising how I'm using the space, to make the S3 fit in there. Since we moved into this house two years ago the garage was a dumping ground for all sorts of rubbish and made it unusable for storing a car. I'm 99% there and did a trial fit to see what needs moving around to make it easier to use - it fits!
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Once I got that out of the way, a friend of mine popped over and we went out for a chilled night drive to start getting some miles on her
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I'll get the Team Dynamics wheels cleaned up today and fit them ahead of the trip up to AITP on Sunday. I wasn't sure if I was going to make it, so didn't bother asking for any club passes, so the car is not on any club stands unfortunately - maybe next year
In summary, it really feels like a new car now and every time I've driven it so far, I get that tingling sensation of how it feels now as well as in anticipation of how it will feel when full potential of the upgrades is realised in the next month or so... I can't wait!
Focus will now shift towards sorting out a few small bodywork blemishes and interior... watch this space
