JonnyC's Audi S3 Project..

[jonnyc]

Something got a little hot there ! Good luck with the build 

Really need to know why.. Im thinking it could have been a head gasket failure?

[Phil Mcavity]

Does it have a larger Fuel pump already fitted? does look like lean burn issue,

No sign of a cracked block that caused it Jonny? .Water ingress can do the same.

[jonnyc]

Does it have a larger Fuel pump already fitted? does look like lean burn issue,

No sign of a cracked block that caused it Jonny? .Water ingress can do the same.

There was a lot of oil in the cylinder, and it doesnt look like its came from the bottom.. Im thinking that could have been a contributing factor, neat oil in the cylinder would massively lower the octane rating and could make it pink its brains out..

Just worried now about a cracked block now, could be worth having it x-rayed..

[nick-barnes07]

you having anything done to the crank whilst the engine is apart!!! maybe shot peened and lightened and balanced if they can do it, also have the gears in the box cryo treated as it will make them a bit stronger!!!! doesnt cost much to have those little bits done whilst the engine is apart!!! running 550-600bhp will put some strain on the gearbox !!!! you also going for water/methanol kit??? bloke i know put water/methanol on his ibiza and once it was set up correctly he saw between 50-60bhp gain!! integrated engineering are also doing a bigger inlet manifold for it as well i think with a bigger throttle body... http://www.seatcupra.net/forums/forumdisplay.php?f=261

[jonnyc]

you having anything done to the crank whilst the engine is apart!!! maybe shot peened and lightened and balanced if they can do it, also have the gears in the box cryo treated as it will make them a bit stronger!!!! doesnt cost much to have those little bits done whilst the engine is apart!!! running 550-600bhp will put some strain on the gearbox !!!! you also going for water/methanol kit??? bloke i know put water/methanol on his ibiza and once it was set up correctly he saw between 50-60bhp gain!! integrated engineering are also doing a bigger inlet manifold for it as well i think with a bigger throttle body... http://www.seatcupra.net/forums/forumdisplay.php?f=261

Well in an ideal world the crank would be knife edged and balanced along with the pistons and rods.. Just to get it all perfect, I will look into it but I have to be careful it doesn't run away with itself.. Otherwise its not going to get finished any time soon!

Meth is a good idea, but to be honest, I would rather run on straight pump fuel.. Ill see whats involved, I dont think its a particularly hard thing to do so maybes that will go on at the same time.. With the way the car is at the mo (in about a million bits) its the obvious time to do all of this work, but it all adds up!

Just bought this which doesn't help the funds..!



Does look nice though!

[Poppa Dom]

What Manifold are you going for Johnny?

[jonnyc]

What Manifold are you going for Johnny?

AFI/BSH purge welded v-band connectors etc etc.. Apparently it made the same power / torque figures as the ATP manifold running 3/4 psi less..

[Poppa Dom]

What Manifold are you going for Johnny?

AFI/BSH purge welded v-band connectors etc etc.. Apparently it made the same power / torque figures as the ATP manifold running 3/4 psi less..

Ok - looks good, have you not thought about the Eurojet manifold (Stainless stell tubular) - http://www.eurojetracing.com/ProductDetails.asp?ProductCode=MK520MANI



Been getting some really positive press in the US.

[jabbalad]

Well in an ideal world the crank would be knife edged and balanced along with the pistons and rods.. Just to get it all perfect, I will look into it but I have to be careful it doesn't run away with itself.. Otherwise its not going to get finished any time soon!

Meth is a good idea, but to be honest, I would rather run on straight pump fuel.. Ill see whats involved, I dont think its a particularly hard thing to do so maybes that will go on at the same time.. With the way the car is at the mo (in about a million bits) its the obvious time to do all of this work, but it all adds up!

You dont have to use the meth as a fuel all the time if you didnt want to, most kits will use a progressive boost controller and can just be used as an additive for hot days to keep charge temps down, wile everything is off its a well worthwhile thing to do, especially if your doing 1/4 miles where it can get a fair bit of heat soak wile your waiting for the lights.

I will be putting the snow kit on my ED30 just to aid the intercooler if its warm 

[jonnyc]

What Manifold are you going for Johnny?

AFI/BSH purge welded v-band connectors etc etc.. Apparently it made the same power / torque figures as the ATP manifold running 3/4 psi less..

Ok - looks good, have you not thought about the Eurojet manifold (Stainless stell tubular) - http://www.eurojetracing.com/ProductDetails.asp?ProductCode=MK520MANI



Been getting some really positive press in the US.

Also looks nice and I have been in contact with them, they dont have kits ready immediately so not helpful for me really.. Plus, the AFI/BSH kit is the top of the line kit, the way its made, the parts there using, its all the best stuff.. I only plan on doing this once so want to do it right first time! Hopefully I have gone the right route..

Well in an ideal world the crank would be knife edged and balanced along with the pistons and rods.. Just to get it all perfect, I will look into it but I have to be careful it doesn't run away with itself.. Otherwise its not going to get finished any time soon!

Meth is a good idea, but to be honest, I would rather run on straight pump fuel.. Ill see whats involved, I dont think its a particularly hard thing to do so maybes that will go on at the same time.. With the way the car is at the mo (in about a million bits) its the obvious time to do all of this work, but it all adds up!

You dont have to use the meth as a fuel all the time if you didnt want to, most kits will use a progressive boost controller and can just be used as an additive for hot days to keep charge temps down, wile everything is off its a well worthwhile thing to do, especially if your doing 1/4 miles where it can get a fair bit of heat soak wile your waiting for the lights.

I will be putting the snow kit on my ED30 just to aid the intercooler if its warm 

Yeah, suppose I could have the car tuned for straight pump fuel then have the meth there as a back up and not advance the timing at all, that way im not running the risk of relying on the meth injection for the tuning to be correct..

Never a bad thing having everything run cooler!!

[jabbalad]

yep thats how it was on my A3, we didnt see a massive power gain from it, but it made the power dead steady no matter what the temp was on the rollers.

[Ryan_Evo]

You could pressure test the bore but in my opinion you will be ok if nothing visable. I would definetly check your fueling and make sure the new set-up is pukka.Keep your eye on the mapping  
BTW that looks a nice turbo set-up.

[jonnyc]

You could pressure test the bore but in my opinion you will be ok if nothing visable. I would definetly check your fueling and make sure the new set-up is pukka.Keep your eye on the mapping  
BTW that looks a nice turbo set-up.

Injectors are getting bench tested along with the ECU.. Should give some insight, I really hope that we confirm the cause before I start running the car again, not a nice feeling at the moment not knowing why its happened..

Yeah turbo set up is lovely, should be on its way to me by the end of the week, looking forward to seeing it for myself!

[JKM]

Something to keep in mind with the pressure testing result on your FSI injectors (which I presume is just for the purpose of understanding the reason for the failure  and you wont be re-using them) is that no company that I could find in the UK can test FSI injectors under their full rated pressure (say 130BAR).
I looked into this for one of our customers, and every company that I found would only actually perform the testing at 5BAR and then use the calculated flow formula to ‘calculate’ what they ‘should’ be flowing under their full working pressure.
I have found from experience on ASNU injector testing machines on conventional injectors, that the theory and the actual flow can vary quite a bit. Just something to keep in mind.
Are you using RS4 FSI injectors on the new build?

[jonnyc]

Something to keep in mind with the pressure testing result on your FSI injectors (which I presume is just for the purpose of understanding the reason for the failure  and you wont be re-using them) is that no company that I could find in the UK can test FSI injectors under their full rated pressure (say 130BAR).
I looked into this for one of our customers, and every company that I found would only actually perform the testing at 5BAR and then use the calculated flow formula to ‘calculate’ what they ‘should’ be flowing under their full working pressure.
I have found from experience on ASNU injector testing machines on conventional injectors, that the theory and the actual flow can vary quite a bit. Just something to keep in mind.
Are you using RS4 FSI injectors on the new build?

Something to keep in mind with the pressure testing result on your FSI injectors (which I presume is just for the purpose of understanding the reason for the failure  and you wont be re-using them) is that no company that I could find in the UK can test FSI injectors under their full rated pressure (say 130BAR).
I looked into this for one of our customers, and every company that I found would only actually perform the testing at 5BAR and then use the calculated flow formula to ‘calculate’ what they ‘should’ be flowing under their full working pressure.
I have found from experience on ASNU injector testing machines on conventional injectors, that the theory and the actual flow can vary quite a bit. Just something to keep in mind.
Are you using RS4 FSI injectors on the new build?

Im trying to establish why the engine failed.. And I was planning on using the injectors again if they have the all clear..

Im sending them to ADS

Yes, the car was already fitted with OEM RS4 injectors..