My engine rebuild

[lucifer666]

Might have spoken too soon Pistons may need to be taken out again.

Spoke to tsr today and they said that the engine is rattling. I said, thats to be expected until the pistons expand, its part of their design. The rattle will subside as it warms up. Small price to pay for some beasts.

They said after a 5mile drive, the engine was still rattling. They then said about the rod to piston clearance.

Basicly where the rod connects to the piston via a wrist pin, there is sideways play between the piston and rod. This is because arias have removed some material from this area under the piston to make them less heavy and to accomodate different rod designs. What is done usually is shims are to be added over the wristpin in order to make sure the piston cant move from side to side along the pin. This is what the other blokes engine shop did to remove excess play(who also runs arias). I didnt know about this problem until today though so i couldnt do any research into it. The play should be exactly the same as the play on the other side of the rod.

Just need to confirm that has been done, or driving it will cause problems. By the conversation I had earlyer though i think it may not have been done. Hopfully tsr will be as good as they have been throughout the build and will address it. Cant see why they wouldnt as they have been decent and helpful and informative from the start.

Finger crossed it dosent need stripping down again or I will have to wait another 2 weeks since Im away with work.

 

[lucifer666]

Right, its all done. Ready to be picked up next week. Valve springs were upgraded in the end. They also recoded the dsg so now its ok, just needs to re-learn.

Slight issue, they said they would turn the revo settings down since it was pulling timing. Dont know why this would happen. Its not down to heat as it also has the pace products radiator fitted. Maybe its the capacity of the pistons? Im going to ask them about the knock sensors, as i know ibizaracebrake had his turned down.

 

[ibizaracebrake]

You know more about my engine than I do! Done 17,000 miles on rebuilt block so far.

 

[lucifer666]

Pick her up Thursday. Everything is good. According to a tuner I have been speaking to, I will be looking at around mid 4s 0-60 with the dsg map booked, customized ecu file running 270(100%possible) or even 280(temps,misfiring dependant) Im looking at breaking the into the 12s 1/4mile times and low 4s 0-60.

WATCH THIS SPACE

 

[ibizaracebrake]

About time someone beat my 0 to 60 time!

 

[ayacoub92]

sounds impressive. space=watched.

 

[lucifer666]

I think that that's the absolute max you'll be able to get from this car unless you bolt on a larger turbo, custom piping, your then looking at over 300bhp but the dsg WILL NOT substain the resultant torque, especially with shift timings reduced after dsg mapping.

Would be VERY surprised if someone can beat my 1/4mile time after this is all done. Hardcore stripapge would be required with same mods as my car isn't like ibizaracebrake in terms of weight. Leather standard interior and sprayed panels, bodykit etc.

 

[Rezelion]

looking forward to this creation sounds very promising!

 

[LJA]

i hope this is as good as it sounds

 

[lucifer666]

Just confirmed by TSR that they replaced the plugs as the ones taken out were completely shot. They were covered in oil. Sign of engine, pre build burning oil. I knew crank preassures were high and oil was being consumed, but thought it was the exhaust side of the turbo.

May be the turbo too, just masking what was happening in engine.

 

[ibizaracebrake]

If you weighed those leather seats you would never be happy bolting them back in. Huge amount of dead weight.

 

[lucifer666]

Picked her up. Small piston slap at start, goes away after 5min as expected. Little smoke from oil filler when engine on but I think it should go after rings are fully sealed after run in. 100miles done 900 to go then the fun starts

 

[Jay1990]

Does the new engine look any different?

Cant wait to see this thing in action mate Looking forward to it. I'll take it around Cadwell for you if you want

 

[rae1001]

Thats some amount of work dude, cant wait to hear the results on this!!

 

[lucifer666]

Engine looks exactly the same......horrendous, such an ugly looking bay. Anyway, I have found an oil leak underneath, by what I described to TSR its a gasket between the crank housing. Its very very minimal at the moment, just dripping, 150ml of oil in 800miles which is less than a standard TSI LOL. When TSR get a courtesy car in, i'll take it back down. Not too worried about this.

LOBA is going on this week too.


Still having issues with the dsg unit after amd tried to read it. It got re-coded to a value that I had been told was wrong. Was fine for 500miles but now I have the dsg gear indicator flashing and have only 1st, 3rd, 5th and 7th gears, all others including reverse are not working, been doing a lot of pushing over the weekend!

Comes up with clutch position incorrect. Could be down to a number of things, lets hope its software related and not because the dsg kicked down to 1st at 80mph all those weeks ago. Pretty pissed off at the moment.

 

[duzza90]

Hi mate, have you had the loba fitted yet?
Hows it going in general now since the rebuild bud?

 

[lucifer666]

Build went well, run-in finished etc. Loba went on but still smoking, its back at tsr now getting the loba replaced since my exhaust and boost pipes are full of oil. Hopfully they will do a one for one swap. Also have an oil leak from the crank seal so they are replacing that once more and looking into why id didn't seal properly

Was able to test the setup as it only smoked under idle. Rapid in gear but during changes there is a problem with the ecu short shifting the dsg, and feathered power delivery. So once its working properly, ill get it dynode and then its off for a dsg/ecu map. Looking at around 300bhp

 

[ALEXZ360]

Anymore news on this mate? Been watching this for a while now

 

[Nath.]

Just thought I would post a vid of what to look for when your turbo is burning oil. This was take a couple of weeks ago

http://s760.photobucket.com/user/lucifer__666/media/VIDEO0001_zps62f2b375.mp4.html

That isn't smoke.

It looks perfectly normal to me. Looks like a cold damp day so the hot exhaust gasses show as steam. Same as your breath would have done whilst you were recording that.

 

[lucifer666]

All complete just needs mapping now for Ecu. Has dag remap and launch control and am running okada coil packs too which stop the higher capacity pistols increasing misfiring potential.as we now know the misfiring on these engines is down to small exhaust ports.
Going down to Santa pod Sunday for a test run. Then back to get Ecu map done which is what's limiting performance at the moment