My 3B Coupe project - Total rebuild

[jogi730]

I was following this thread with some awe at the fact everything was just so right and all being done by your own hands. Somehow missed the problems you encountered and I can't tell you how gutted I am this happened. I can well imagine how you felt.
Really glad you have got her up and running agian so quickly Hope the engine now delivers as you had hoped and will give you thousands of miles of trouble free and pleasurable miles.
Well done and best of luck with her

[add]

excellent work getting it sorted so soon
look forward to seeing the end results

[newsh]

Well done mate! Looking good in the countryside there

Maybe best to get a belt cover on there though, one little stone in the belt..

[AndyP]

Well I made it past 275miles today so it's doing better than last time I was hoping to get some miles piled on this weeked but the roads in Derbyshire are still quite bad ( snow ) so that has limited me a bit.

I'm taking it up to 5000rpm on about 3/4 throttle and the boost is set to spring pressure so I'm seeing about 2-3psi. Feels really strong, can't wait to get it mapped now, it's going to fly! I'm really pleased with the exhaust, when you get you foot down it has that authentic 5cyl quattro roar, but sitting on the motorway at 70mph it's really quiet and not boomy at all. The perfect all-rounder.

[s2_bo]

great news Andy!

[Error404]

sounds good Andy, are you booked in for mapping just yet?
was it a twin box setup you built in the end?

[newsh]

Are the system details in this thread? Sounds like what I want from mine, to get rid of the drone..

[s2_wot]

Andy, great thread, pity about the extra rebuild work, as above I hope you get many 000's of satisfying miles out of the car now.

[AndyP]

Are the system details in this thread? Sounds like what I want from mine, to get rid of the drone..

Yes, somewhere. It's basically 3" from the turbo back, no cats, a small ( 12" ) straight through silencer just before the rear drive shaft, then at the driveshaft it drops to 2.75" where it joins a Jetex 'off the shelf' back box. T2Andy has a similar system on his car only he's using the Supersprint 2.75" downpipe. He has similar results re noise. I think it's all in the backbox.

[Error404]

Cool. So no droning around 2.5 - 3.5k rpm Andy? I'll be building my own and if I can avoid a resonator it really helps round clearance
We need vids

[AndyP]

Up to 600miles now so I think it's pretty much run in now. I did a compression test today which showed a very healthy 14bar across all cylinders

There are a couple of issues that will need to be addressed before it's mapped though, first one is a small oil leak. As far as I can tell it's leaking from the oil pump bolt that holds the cam belt tensioner roller on, if it this then the oil pump gasket will need to be replaced and that means removing the sump
The other is the 3B oil cooler, even with the modest boost I'm using at present ( 0.3bar ) it only takes a brief period of 'spirited driving' to get the oil temp over 100°C. I'm looking at a 13row 235mm wide cooler as I want it to go in the std location.

[Error404]

great news Andy
did you use RTV sealant on the gaskets? I've heard they can be a PITA to seal properly as apparantly the castings on the oil pump housing are not always very flat
RE: the 3B oil cooler, I think the stat doesn't open till around 100deg, but your beast will undoubtedly need a bigger cooler anyway I'd have thought

[A80Avant]

isnt there an oil pump gasket there? i remember using one on the ADU.

for the oil cooler also check the check valve which is located on the sanwitch plate that connects the oil cooler to the engine and the oil filter. Sometimes it can get stuck or the thermal sensor there that allows the oil to go through the cooler can get stuck, so the oil is not flowing through the cooler at all.

[AndyP]

great news Andy
did you use RTV sealant on the gaskets? I've heard they can be a PITA to seal properly as apparantly the castings on the oil pump housing are not always very flat
RE: the 3B oil cooler, I think the stat doesn't open till around 100deg, but your beast will undoubtedly need a bigger cooler anyway I'd have thought

When I build the first engine I did use sealant, but when I took the block to JP for him to rebore he told me not to use sealant, so I didn't
The stat is definatley opening as the cooler is getting hot, I think it's just not big enough as the 3B is smaller than the ABY. I've not heard that Jamo is having any problems with his, so going to a 13 row should fix it.
As usual with the S2, nothing that can't be solved with a large injection of cash It's a good job I love this car!

[Error404]

Don't forget Jamo drives Miss Daisy

I suppose you could skim a couple thou off the pump housing and the block face to true it all up? I'm sure the water pump gasket would benefit too.
Might do that when I build my engine up