80V6 Engine Rebuild

[geryS2]

Nice work man !

[s2_wot]

Angle Grinder

1 - I wrongly assumed it would have been easy to buzz off the crank bolt with the locking tool while engine on the stand, but it wasn't possible so I had to resort to desperate measures - safe in knowledge that bolt & washer would be replaced anyway. The clue is on the floor... LOL. Interestingly - I got about half way thru the cutting operation and went to spanner the engine round to a new position to finish the cut and to my amazement the bolt was now loose.
!

Great choice of weapon there Paul, If all else fails eh??? Thats a great bit of restoration work, fair play to you.

Shane

[S2central.net]

Some more pics of progress...

155 - engine mounts cleaned up not too shabby. Might paint them.

156 - cam covers after a few nights dunked in neat degreaser... still far from clean - going for industrial power / chemical wash this week

159 - one of the heads in similar yucky state - not as bad as covers with glar

[S2central.net]

And onto the heads for the usual fun and games - anyone want to guess how many EM studs will be broken ?

165 - off with the cam pulley first... buzz gun and counterhold worked well. Exposes a locking plate on the end of the camshaft.

157 - I used a 3-legged puller to remove the pulley. No drama. Only odd thing of note was the lockplate is clearly marked 'FRONT' but was oriented with that side to the pulley which isn't what I expected. Same on both heads...

160 - Off with the EM... Only one stud sheared here but it was otherwise straightforward. However - the subsequent attempt to remove the old studs with good ol' two nut method has not worked - maaaaaan are they tight.

[S2central.net]

161 - Close up of the offending sheared EM stud... Where is that dremel ?

163 - Tother head with EM still attached - it removed easily but I haven't tried to remove any studs yet

164 - Inlet side of one head... perdy boggin huh

[S2central.net]

Both heads in zee bath for a degrease... getting very bored of this cleaning nonsense - but is a necessary evil with engine rebuilds I suppose.

[S2central.net]

I just got some insight on the stupidly high prices that Audi wants for bearing shells and piston rings on this thing... To the tune of £400 plus VAT with a good amount of discount. Thats just crazy, so I'll have to go elsewhere on those bits.

Who can help shortcut the search for a reputable source - preferably in UK ?

[S2central.net]

I have found this nice reference guide in multiple languages on the subject of piston rings... I have never heard of that company before - but there is lots of data across the Audi range (including S2/RS2 as well)...

http://www.allautoparts.ru/closed/alex/HTML/files/cats/engine/KS/%D0%9A%D0%BE%D0%BB%D1%8C%D1%86%D0%B0.pdf

[S2central.net]

KS = KolbenSchmidt... a seemingly very reputable of source of rings, bearings, valves and other internal bits... I've located a UK distributor (Elring Parts) who I assume supplies the general motor factor marketplace.

[S2central.net]

Another possible outlet... more recent catalog and online shop too - maybe trade only though.

http://www.ms-motor-service.com/index.asp?cls=02

[S2central.net]

Amongst others... MS supply ECP and GSF in the UK so thats a good start

[Error404]

Good find on the KS catalogue Paul, they do a really good range of OE engine parts by the look of it

[S2central.net]

There is a whole range of downloadable catalogs at the MS site - quite chuffed with that find alright... lots of good reference material for installation of rings, bearings and such... Also recommendations about 'sputter' bearings for higher performance applications.

[S2central.net]

I see that their bigend bearings (PL) are sputter type upper shells for 20VT applications - see page 154 of bearing catalog

[S2central.net]

Been making very slow progress unfortunately here but I was out there again last night but I need to fill in the story of where I left off from last time. Firstly I have made no attempts to buy bearings or rings yet. Must try to find time for that next week...

Up to last night I had spent some fraught hours trying to remove the remnants of studs from one of the exhaust manifolds. Application of heat, penetrating oil and 'easy out' tools was just a waste of time... I blunted several drill bits, broke two so called 'easy out' things and more annoyingly destroyed a nice tap wrench - too much torque / aggression.

Here's some pics of the carnage... despite me sawing off stud remains, filing nice and flat and drilling as carefully as possible. This disaster from 2 weeks ago is why I couldn't be arsed for a while.

187 - as things started with remains of studs in one EM
188 - after sawing them off and filing flat, ready to be drilled
189 - destruction of 1st 'easy out' - what kak waste of money those are