My engine rebuild

[lucifer666]

As many of you know, I have a late 2009 1.4tsi ibiza fr. I was one of the first to experince the misfiring which was at 10k miles less than 6 months after buying it.

I had the early problem with injectors and poor software.
Then the uprated fuel pump, coil packs. + cat(damaged through misfiring)
Finally it was solved mid 2011 with different spark plugs and software

Since the major mifiring stopped, although the car has worked and performed well with stage 2 software for the last year and a half, but I have still suffered misfiring when humid and wet and random oil consumption more recently. I also had aspr crankcase breather pipe split indicating crankcase preasures being to great. So there has been an indication of somethng still being up for a while.

Seat were useless as usual and compression used to drop and then come back so there was no grounds to investigate further and I pushed them as much as possible. I resigned myself to the fact that at some point I was going to need new pistons as my suspicion was cracked rings/piston.

My radiator sprung a leak at xmas not through puncture but from the core, indicating high preassure in the system which could be related to cylinder head/gasket probems.

I have lasted it out now until 45k but after a few aweeks of the exhaust smoking after letting off the accelerator and re-applying, I pulled up after a long drive today to have plumes of white smoke coming from the exhaust, only at idle though.

MY REBUILD PLAN

1. Forged Arias pistons(Already aquired).....2mm oversized

2. Rebore which will give 1.5 liters

3. Forged 1.8t rods modified to fit (very similar design)

4. Port and polish

5. Uprated valve springs as there are suspicions that these may be causing high rpm misfires.

#I will then fit the loba hybrid thats begging me for months

I have contacted TSR as they have prior experience with this engine and are recommended.

 

[lucifer666]

Pistons

 

[lawrieIbizaMk4]

So so so excited about this!!! Please keep us updated!

What are your projections for overall cost?

 

[lucifer666]

TSR are not cheap, but I need this done 100% correct. Personally Im dreading it because of the hassle and unforseen problems but I cant keep driving this car with a black cloud above my head.

Cost wise, labour is the biggest thing. Estimated £900 for fitting pistons plus £180 for removing block all together, then £150 for re-bore. Then its the parts which come to around 1k so we are looking at 2k minimum.

 

[Law121]

does the injection/fuelling stay the same i no if its injecting to much fuel you will loose compression there for overfueling will cause cat damage ect just mite need fuel trimming sorting out

 

[lucifer666]

im running a revo map, think theyr map is a bit rich but I assume revo know what their doing with the mapping

 

[Law121]

theres always room for error specially with maps just a thought what colour are the plugs ?? are the bores washed get a scope in there see whats happening

 

[lucifer666]

usually a brownish redish colour, AFR is s 14.4ish at idle, requested is 14.7 and they arnt ever too far off what is requested. Problem is the bores rarely get scored from what I have seen with these engines, you might see a scorched cylinder head but that was more than likely from the early mapping. Its the part of the cylinder between the two rings that tends to crack and fail.

The only real symptoms are
1. random occurances of misfiring
2. sudden drop in oil
3. excessive crank preassures......oil in intake
4. smoking exhaust at idle only and only when engine is warm

 

[ibizaracebrake]

While my car was there I got the Forge water hose set and the oil catch tank as they are easier to fit when the engine is in bits. good luck.

 

[lucifer666]

Cheers. Did you get any hidden bits done with the block like porting or balancing. If you had to give overall summery of tsr and how they were to deal with what would it be

 

[Big-Pete]

gearbox!?!?!

 

[ibizaracebrake]

Cheers. Did you get any hidden bits done with the block like porting or balancing. If you had to give overall summery of tsr and how they were to deal with what would it be

I got the forged pistons/rods + head rebuild. Porting on a turbo car not important, nothing needed balancing. Main issue was getting pistons from Germany as they were a new design copied from one of my pistons and the cracked turbo which the company who tried to rebuild it twice failed to spot. Lucky TSR got a new one to try as a last resort.

 

[lucifer666]

where was the crack in the turbo? did they think it was a problem with the turbo cooling too quickly or even a piece of piston going through it? Were the bearings ok?

I have the loba hybrid off hurdy which has done 5k so im covered if there are any issues with the turbo, pistons Im due to pick up next week and the rods are just 1.8t ones modified so are readily available.

Just a case of taking the plunge now.

 

[Big-Pete]

where was the crack in the turbo? did they think it was a problem with the turbo cooling too quickly or even a piece of piston going through it? Were the bearings ok?

I have the loba hybrid off hurdy which has done 5k so im covered if there are any issues with the turbo, pistons Im due to pick up next week and the rods are just 1.8t ones modified so are readily available.

Just a case of taking the plunge now.

seriously tho

gearbox??
wont it go well over the 250bhp max of the dry box?

 

[lucifer666]

its the torque thats the main issue not bhp. The dsg limit is down to software, this can be upped through mapping.

I have a dyno of revo stage 1 giving 198bhp, then stage 2 with 3" decat downpipe, twintercooler, itg intake on setting B at 233bhp.

At this state of tune I have been having dsg issues when accelerating from 0 where it short shifts, or when using kickdown and you feel it bite and start to pull then power is almost feathered before it continues to pull.

Although I have had less problems lately with this. Boost seems ok so no reason to think its turbo related unless Im loosing compression slightly which from data logging is likely. A few misfires on cylinders 1 and 4 detected per trip although no lights or warnings appear.

I would be happy with a nice 260bhp without the dsg limiting power which is doable with the loba. APR are currently mapping a specific map for it which I believe is pushing 270 in highest state of tune.
I would like a tractable and RELIABLE 250 more than anything

 

[duzza90]

Good luck with it mate, looking forward to seeing how it comes along

 

[Big-Pete]

its the torque thats the main issue not bhp. The dsg limit is down to software, this can be upped through mapping.

I have a dyno of revo stage 1 giving 198bhp, then stage 2 with 3" decat downpipe, twintercooler, itg intake on setting B at 233bhp.

At this state of tune I have been having dsg issues when accelerating from 0 where it short shifts, or when using kickdown and you feel it bite and start to pull then power is almost feathered before it continues to pull.

Although I have had less problems lately with this. Boost seems ok so no reason to think its turbo related unless Im loosing compression slightly which from data logging is likely. A few misfires on cylinders 1 and 4 detected per trip although no lights or warnings appear.

I would be happy with a nice 260bhp without the dsg limiting power which is doable with the loba. APR are currently mapping a specific map for it which I believe is pushing 270 in highest state of tune.
I would like a tractable and RELIABLE 250 more than anything

id be happy with a reliable 220bhp i think

is it possible to change the box to wet clutch? ie out of a mk5r32/somthing bigger?

best of luck with it buddy!

 

[lucifer666]

Good luck with it mate, looking forward to seeing how it comes along

Thank you. You all will be the first to know all the info on here. Its the kind of thing I would like to stand and watch them do.

 

[lucifer666]

Dont think theres a need for wet box. Would be a massive headache too. This is as far as Im going to go with this car. Maybe some anti roll bars and brake upgrade and thats me done.

 

[ibizaracebrake]

where was the crack in the turbo? did they think it was a problem with the turbo cooling too quickly or even a piece of piston going through it? Were the bearings ok?

I have the loba hybrid off hurdy which has done 5k so im covered if there are any issues with the turbo, pistons Im due to pick up next week and the rods are just 1.8t ones modified so are readily available.

Just a case of taking the plunge now.

Don't know where crack was but it only opened up when hot so was not seen during rebuild, not debris damage. Crank etc bearings were changed as they were worn.