My engine rebuild

[lucifer666]

Was speaking to them earlyer and they said pretty much the same. They think my turbo has a crack in it since my symptoms are the same as yours after your car after your rebuild. Was the smoke down to oil or coolant coming through the crack. I know coolant burns white but so does oil if it gets burnt in the exhaust side of the turbo

 

[lucifer666]

The car is booked in to TSR on 25th, deposit made

1. Complete engine rebuild, new gaskets, seals, bolts, etc

2. 2mm overbore, and larger capacity pistons designed to absorb heat from the combustion, decided to go standard compression for use with standard map. Increasing capacity has this effect anyway.

3. Forged rods

4. Port and polish depending on gains which we wont know until we look at them

5. Aftermarket valve springs which should help higher rpm function(even eliminate high rpm misfiring under higher boost)


Car was producing 235bhp about a year ago. After speaking to various people, they expect an instant 5-10 bhp increase once hybrid turbo is fitted and the larger capacity pistons should give another instant 9bhp without changing the map giving me around 244bhp to 249bhp.
Plus the turbo spool up time will be much better so the most impressive thing will be midrange bhp.

It should allow the headroom to run the 100ron setting on the revo sps. Alhough it is recommended that before I get a tune more specific to my setup to maximize gains, I should get water/meth installed to keep everything silky smooth and cool.

Will keep this thread up to date with any new developments

 

[Deleted member 49882]

Sounds good. Expensive ... But good. Will certainly be unique. Hope its worth it in the end.

 

[lucifer666]

thank you. Me too.

Yes it is expensive, but I thought at some point in the near future I will need new pistons, and so will many other people after their warrenty has expired. My car is at 50k now and has been well seviced and warmed up and loved and my rings are deteriorating, I expect most cars past 50k to end up having to have this done.

And seat charge something silly like 900 for their pistons and then theres fitting which is another 1000 at least I would say, then 60k down the line your in the same place or your engine is so old, other parts have broken.

Or you could go down a used engine route and drop another complete unit in which your looking at 1000 for but then it may have dodgy pistons too and labour would be at least 1000 ish

So in my mind for an extra 1000 on top of the above, you can

1. eliminate the problems with the pistons by getting bullet proof pistons and bullet proof rods while your at it
2. Replace all parts, gaskets with new ones so you essensially have a complete new engine
3. Improve performance while your at it

Obviously the loba was just cuz I wanted it

 

[Ben-ibizaFR]

Out of intrest why have you changed turbo and gone for a logs hybrid ?

Great project though ! Looking forward to see how it goes !

 

[Damoegan]

I thought that VAG had a new set of pistons & rings that would stop this hapening again?

 

[lawrieIbizaMk4]

I thought that VAG had a new set of pistons & rings that would stop this hapening again?

They brought out all sorts of "fixes" but it looks like they only slow the problems long enough to take the cars out of warranty. I'm waiting until the new engines are rolling out from the facelift before taking mine in

 

[old 'uns]

thank you. Me too.

Yes it is expensive, but I thought at some point in the near future I will need new pistons, and so will many other people after their warrenty has expired. My car is at 50k now and has been well seviced and warmed up and loved and my rings are deteriorating, I expect most cars past 50k to end up having to have this done.

I'll applaud you for what you're doing and passing over 2k for what potentially should be what you should still have at 100k let alone 50k, failing at 50k is a joke especially when yours is not the only one.
For the life of me i can't see why people still consider this engine?
i think if i had one i'd be jumping ship asap

 

[Beazy]

For the life of me i can't see why people still consider this engine?
i think if i had one i'd be jumping ship asap

For all its faults it's still a good engine when it does work, touch wood I've had no issues with mines.

When remapped it drives like a diesel around town, put the foot down and it just goes. Mines returns 45mpg on the trip to work, that's all mixed driving with no motorway/dualcarrage way.

When it does see the motorway it gets 48ish at 70mph and 53 - 55mpg at 60.



Amazingly good engine, but that said I'll be getting rid of mines at before the warranty expires. I'm not made of money

 

[lucifer666]

My problem is I never give up. Thing is like everyone has said, when it works its such a great little, giant killing eco car. Build quality is not best but then you could just get the a1 or polo

 

[Ghunter]

For all its faults it's still a good engine when it does work, touch wood I've had no issues with mines.

When remapped it drives like a diesel around town, put the foot down and it just goes. Mines returns 45mpg on the trip to work, that's all mixed driving with no motorway/dualcarrage way.

When it does see the motorway it gets 48ish at 70mph and 53 - 55mpg at 60.



Amazingly good engine, but that said I'll be getting rid of mines at before the warranty expires. I'm not made of money

Your get 45mpg !! Ther must be something wrong with my cupra since i only get 30mpg :0

 

[Beazy]

Your get 45mpg !! Ther must be something wrong with my cupra since i only get 30mpg :0

Nah I just drive like a granny 90% of the time. The other 10% more than makes up for it though

 

[Jay1990]

Its easy to get good mpg. I get about 30-35 but I'm usually in town for 10-15min trips.

This engine is brilliant, when they work and/or looked after.

 

[Ghunter]

I may jus drive like a granny then lol

 

[lucifer666]

Out of intrest why have you changed turbo and gone for a logs hybrid ?

Great project though ! Looking forward to see how it goes !

The stock turbo I dont trust at all. Im almost certain its whats causing alot of my oil consumption and the exhaust has been smoking white for a while now and its getting worse.
After every trip I get oil droplets on the back of my car and/or black little dots. Shouldnt look like that after 200miles.
I believe the seals on the exhaust side to be allowing oil through, the fact I have a decat so no back preassure at all will be making things worse,
Some might say that its down to the decat but I disaagree, the day I had the decat fitted I remember the smell of smokey bacon, ie oil in the exhaust burning and only a few months ago I had to have a new catalytic converter since it was shot, so I think the burning oil was causing that then too.

There have been quite a few horror stories with this turbo breaking. Most early on when the car first came out so I dont know if it was to do with the mapping of the engine, the misfiring or what.

I plan on using the same setup with the new turbo so I want it to be bulletproof. Thus the loba which is plug and play, no mapping needed but can be done to optimize performance. It will allow up to around 300bhp too which is the ABSOLUTE max I would ever want to run this car at because the extra power is pointless over that.
The loba has uprated internals so should be nice and strong

 

[lawrieIbizaMk4]

The stock turbo I dont trust at all. Im almost certain its whats causing alot of my oil consumption and the exhaust has been smoking white for a while now and its getting worse.
After every trip I get oil droplets on the back of my car and/or black little dots. Shouldnt look like that after 200miles.
I believe the seals on the exhaust side to be allowing oil through, the fact I have a decat so no back preassure at all will be making things worse,
Some might say that its down to the decat but I disaagree, the day I had the decat fitted I remember the smell of smokey bacon, ie oil in the exhaust burning and only a few months ago I had to have a new catalytic converter since it was shot, so I think the burning oil was causing that then too.

There have been quite a few horror stories with this turbo breaking. Most early on when the car first came out so I dont know if it was to do with the mapping of the engine, the misfiring or what.

I plan on using the same setup with the new turbo so I want it to be bulletproof. Thus the loba which is plug and play, no mapping needed but can be done to optimize performance. It will allow up to around 300bhp too which is the ABSOLUTE max I would ever want to run this car at because the extra power is pointless over that.
The loba has uprated internals so should be nice and strong

So the loba could be a direct replacement for a completely standard car? I'm intrigued!

 

[lucifer666]

Yes. Estimated to add 5to10bhp to stage 2 map. Obviously a custom map could give 30to40bhp

 

[lucifer666]

Right, Im 3 days out from my build starting.

Everything has been ordered, i have my shiny new pistons sat on my back seats right now with the loba hybrid turbo, tsr have the rods and the pace products radiator will be with them by next week.

Was torn at one point between re bore'ing the cylinders with full rebuild and just dropping in some standard size pistons and rods, using the extra cash for full stainless steel turbo/supercharger pipes, manifolds and intake, and fitting a larger turbo capable of over 300bhp at a mildish boost.

But then i realized I had lost sight of the point of this car. Its not about brute power, its about being tractable and quick off the line, light, with no lag and fast gear changes making up for its lack of power.

Stage 1 cars keep up with 300-350 bhp cars on a drag strip, even show some up.

I want the engine to be rock solid, and as efficient as possible, as reacive and free revving as possible without having to run too much boost.

So by the end of this build, the spec should be a:

1.5tsi, uprated valve springs, gas flowed head, loba270 hybrid, 3"decat, itg, forge twintercooler, oil catch can, pace radiator
......running revo stage 2 to begin with and a dsg limit delete from shark performance until i get it dyno'd (looking for estimated 254bhp) and get a conservative map made running a constant 20-21psi for as long as it will hold(without misfiring; which should be helped by the gas flowed head and larger capacity pistons)

This better be worh it..............TO BE CONTINUED

Oil catch can, race battery, high flow grille mod, heat wrapping/insulating work which i carried out myself over the last few weeks will be posted up on this thread when i go home fri/sat.

 

[Big-Pete]

Right, Im 3 days out from my build starting.

Everything has been ordered, i have my shiny new pistons sat on my back seats right now with the loba hybrid turbo, tsr have the rods and the pace products radiator will be with them by next week.

Was torn at one point between re bore'ing the cylinders with full rebuild and just dropping in some standard size pistons and rods, using the extra cash for full stainless steel turbo/supercharger pipes, manifolds and intake, and fitting a larger turbo capable of over 300bhp at a mildish boost.

But then i realized I had lost sight of the point of this car. Its not about brute power, its about being tractable and quick off the line, light, with no lag and fast gear changes making up for its lack of power.

Stage 1 cars keep up with 300-350 bhp cars on a drag strip, even show some up.

I want the engine to be rock solid, and as efficient as possible, as reacive and free revving as possible without having to run too much boost.

So by the end of this build, the spec should be a:

1.5tsi, uprated valve springs, gas flowed head, loba270 hybrid, 3"decat, itg, forge twintercooler, oil catch can, pace radiator
......running revo stage 2 to begin with and a dsg limit delete from shark performance until i get it dyno'd (looking for estimated 254bhp) and get a conservative map made running a constant 20-21psi for as long as it will hold(without misfiring; which should be helped by the gas flowed head and larger capacity pistons)

This better be worh it..............TO BE CONTINUED

Oil catch can, race battery, high flow grille mod, heat wrapping/insulating work which i carried out myself over the last few weeks will be posted up on this thread when i go home fri/sat.

on the serious note, will the gearbox stand up to the 260ish bhp/tourqe ???

 

[Jay1990]

Should do if done properly. Nice plans, glad you've not lost sight of what you set out for. 240-260bhp if its consistent and tractable will be immense,never mind on just a 1/4mile run.
You should be fine running 20-21psi without misfire issues.

Looking forward to seeing this little animal at some point!