URS4 Disaster

[Rejmow]

Some backround on the project: The UrS had been sitting for a while so when we got some snow in sweden I decided to take him out for some Quattrofun™. After a couple of laps on a empty parking lot I heard like a poof and then the car died instantly. At first I noticed 2 drops of what I thought was oil on the spot I stalled. but turned out to be dirty water. But because of these drops I thought for sure I had blown a gasket. And the 2nd update picks up from here.

Some info on the car
94 with 6speed manual. 140.000 kms (87.000miles) on it

2.2t AAN
1.8t coils
Stainless exhaust maifold
1.5bar WG spring
sms Revo303 chip
3" turbo back with 1 muffler(way waaay too loud)
boost at about 22psi according to factory trip computer

EBC discs front/back
EBC calipers
and redstuff pads

To do list.

Get him running, and full service [x]
Re do the intake/IC plumbing [x]
Find a headliner(Mine is missing for some reason) []
S6 bumpers and exterior trim []
Paint damage fix []
Need a new left-hand mirror [x]
Steering servo(got a fresh one at home just need to replace it [x]
Complete reconditioning interior/exterior []

At first this is just gonna be a fix-up to get him to the interior and exterior standards I want. After that im gonna pull as much streeet friendly power as possible


Older summer pic, sits on 18" M3 CSL reps


Current pic, very dirty

[pilihp2]

You're not the only one in love with that thing..

wow..



right. uh.
good luck with the project!

[s6sputnik]

Looks like a great project!!!

[Rejmow]

Thanks guys!

If you want more on the other S4 http://www.garaget.org/?car=168069 great car and great guy :)

[nnnick]

Wow, I love your plans and the car you're aspiring toward. Good luck with the build & repair!

[Rejmow]

Todays update, just spent 10-20 minutes in the garage and i didn't like what I saw. As I started to remove the valve cover since I thought it was the gasket, i hade to remove the drivebelt, surprise surprise the drivebelt had like 2cm slack(half a inch). I have no idea what this might be, have to get it to the big garage next week and lift it up and remove the front.. Anyone knows what might have been the cause ? the drivebelt is not old changed 2000km(1200mi) ago.

came right off..

[Rejmow]

Done some research now and the lower cam pulley seems to be a weak point on the AAN. Just hoping the internals aren't salad now.

[loxxrider]

Don't get your hopes up for the internals

There are a few things that could have happened. Something got in like a rock and cut the belt (probably not if you have the covers on there), the cam pulley key sheared off, the crank cog broke. The crank cogs are known to fail over time because of crap design. There are variants made out of hardened steel if you are interested in one.

[Rejmow]

Don't get your hopes up for the internals

There are a few things that could have happened. Something got in like a rock and cut the belt (probably not if you have the covers on there), the cam pulley key sheared off, the crank cog broke. The crank cogs are known to fail over time because of crap design. There are variants made out of hardened steel if you are interested in one.

Ok, how much of the internals do you think have gone ? I was guessing head and valves, worst case maybe pistons. If more i have to re-think the whole thing..

[loxxrider]

It all depends really. If you were at lower RPM and it immediately shut off you might by some miracle not have bent anything. Being realistic, I'd say there is a good chance that you can just replace some valves (probably not all of them, but have them all checked). Pistons could certainly be just fine. You'll know when you see them. Could just be valves so keep your fingers crossed and get to work!

[Rejmow]

I got it to the big garage today and worked on it for a while, didn't take long for me to realize it wasn't the crank pulley cog. Turns out it was the waterpump that threw in the towel, so equal damage as if it was the pulley.
Ordering a timing belt kit from 034, also getting a reinforced pulley while im at it so I don't have to worry about that.

some pics.



I don't know if you can see but the waterpump wheel is slightly bent and completely stuck.

[loxxrider]

well at least you know what happened.

Where did you get the hardened cog? I got mine from EFIexpress

[Rejmow]

well at least you know what happened.

Where did you get the hardened cog? I got mine from EFIexpress

ooh, I was actually planning on buying the cog from 034 "super torque" but looking at the price from EFIexpress the one from 034 can't be much better than stock. Thanks will probably go with the one from EFI :)

[loxxrider]

Awesome, you'll like it. Never have to worry about it again. Marc (the owner of EFIexpress) is a really great guy too, so try and give him any business you can! He's got the good stuff :)

[urs4kid]

yup. water pump was my guess

I got it to the big garage today and worked on it for a while, didn't take long for me to realize it wasn't the crank pulley cog. Turns out it was the waterpump that threw in the towel, so equal damage as if it was the pulley.
Ordering a timing belt kit from 034, also getting a reinforced pulley while im at it so I don't have to worry about that.

some pics.



I don't know if you can see but the waterpump wheel is slightly bent and completely stuck.

[Rejmow]

Awesome, you'll like it. Never have to worry about it again. Marc (the owner of EFIexpress) is a really great guy too, so try and give him any business you can! He's got the good stuff :)

Great:) Quick question, did you have to change the nut/bolt when you changed to the hardened cog ?
And I also removed the waterpump today, plastic wheel was in 4 pieces. Is there anyway to get one with a aluminium wheel ? or should I be fine with a OEM plastic ?

[loxxrider]

I personally have never heard of an aluminum wheel version, but if I did I'd love to have one.

I changed the crank bolt when I did mine; its a stock item though. I'm really not sure if its torque to yield. I spose I could figure it out, but I just replaced it regardless.

[Rejmow]

I personally have never heard of an aluminum wheel version, but if I did I'd love to have one.

I changed the crank bolt when I did mine; its a stock item though. I'm really not sure if its torque to yield. I spose I could figure it out, but I just replaced it regardless.

Cool, I ordered one from my local VAG dealer. And I got my 034 package today. And wow did those guys deliver, I was worried that waterpump was gonna be the same crappy plastic as the old one, but no it was solid metal. Feels like it won't break in a thousand years, I really hate the guy that cheaped out and put that thing on my car.


Now im just waiting for the cog wich i ordered from a swedish company, I has a separate wedge and better material than stock.

[Rejmow]

Havent updated here in a while, just waiting for parts now.



Resting under the dust, ready for operation.


Heres the old waterpump, wich i realized was a stock pump made in 92!! Guessing it has never been changed.


Exhaust manifold removed, lets do this.


Voila :)


.


.


For sale! anyone? ;)


Ill update again later today!

[Quattro Krant]

Who the fuck does a timing belt on an AAN and doesn't do the waterpump while they are in there?????????????????????????

[Rejmow]

Who the fuck does a timing belt on an AAN and doesn't do the waterpump while they are in there?????????????????????????

Tell me about it..


Didn't have much to do in the garage today since im waiting for parts to arrive, so I did some cleaning :)

Before


After


Wonderful thing this is :)

[Scotty@Advanced]

Cool, I ordered one from my local VAG dealer. And I got my 034 package today. And wow did those guys deliver, I was worried that waterpump was gonna be the same crappy plastic as the old one, but no it was solid metal. Feels like it won't break in a thousand years, I really hate the guy that cheaped out and put that thing on my car.


Now im just waiting for the cog wich i ordered from a swedish company, I has a separate wedge and better material than stock.

That looks like a stock part with a seperate key... Pretty cool.

[Rejmow]

That looks like a stock part with a seperate key... Pretty cool.

Yup thats pretty much it :) im very pleased with it

[Rejmow]

Got me some of these in the mail today :)


Havent placed the order for the ARP studs and the other stuff yet, but i'll probably get that done later today!

[dogbntyhntr]

sweet project

[dogbntyhntr]

i will be keeping an eye on this, i love it

[Rejmow]

[Rejmow]

While im waiting for the parts to arrive ill keep the thread alive with some older pics. Also the head is being resurfaced.

Back in 2008


Older summer pic without the trim


I miss you summer </3


From the front

[Rejmow]

Didn't realize it was so long ago I updated this thread, and since this part of the forum is pretty much dead I thought i'd help out reviving it :)

Let's start with how the rebuilding of the head went.

Washd'


dat ass

Also need a new muffler, I want something that looks kinda like Magnaflow 14816 but with shorter tips, any suggestions?

putting the head back together


more putting together, list of some stuff that came on that day.
*Changed lower pulley(new one with the separate key)
*MLS gasket
*ARP bolts
*Waterpump
*Timing belt
*serpentine belt
*Changed steering servo pump since the old one had some leakage

[C4.Style]

Its a bit hard to find the muffler with shorter tips like you want. I believe magnaflow has one but I forgot the part number of that muffler or you could just slice off the tips a bit to make it shorter From what I know the common good exhaust system on such urS cars is Stromung however its rear muffler is very identical to 14816. I got 14815 on my C4 and I'm happy with it still till today.

[Rejmow]

Its a bit hard to find the muffler with shorter tips like you want. I believe magnaflow has one but I forgot the part number of that muffler or you could just slice off the tips a bit to make it shorter From what I know the common good exhaust system on such urS cars is Stromung however its rear muffler is very identical to 14816. I got 14815 on my C4 and I'm happy with it still till today.

The stromung is nice but 1500$ is crazy since I won't be using the whole system.


First start after rebuild, lot's of oil in the engine and rough idle.

[C4.Style]

Nothing like nice rough morning idle. Sounds kinda like mine even though mine is a 12v V6.lol. But mannnn its smoking like diesel!!! What happen at the end, died? It was working fine the whole time you were driving.

[Rejmow]

Nothing like nice rough morning idle. Sounds kinda like mine even though mine is a 12v V6.lol. But mannnn its smoking like diesel!!! What happen at the end, died? It was working fine the whole time you were driving.

Yeah it couldnt keep itself alive on idle but that fixed itself after a couple of runs. The smoke is because of all the lubricants being burnt in the engine after the build :)

[Rejmow]

Replaced the broken rearview.



New lower trim, sorry for rocking the winter wheels


Now we're pretty much up to dat on the car, 1 or 2 updates and then the real project starts :)


Heres a video when I stretch the legs on the sedan :)

(Sorry for the way im holding the steering-wheel, I don't know what the fuck was going on there)

[Jim Hef]

Yeah it couldnt keep itself alive on idle but that fixed itself after a couple of runs....

Was the battery pulled when you were doing the work? Most computer systems, when drained, need a few miles or more to reset the engine parameters, and then will settle into a decent idle. Until then, you need to keep the revs up using the accelerator.

[Rejmow]

Was the battery pulled when you were doing the work? Most computer systems, when drained, need a few miles or more to reset the engine parameters, and then will settle into a decent idle. Until then, you need to keep the revs up using the accelerator.

Yeah the battery was pulled, might have had something to do with it

[Rejmow]

So, lets get this shit up-to-date. This is what happened like 2 months ago.. just my luck huh.







This happened after quite a violent downshift, probably my own fault for not rev matching the engine.


So lets tear this shit down.




And now for the goodies :)

I will be building a B.A.T machine, the turbo im most probably gonna go with is the GTX3582R with a Tial GT35r Stainless hotside. Full 034 Stage IIc package, KW spec 2 coils, STaSIS center diff, fully built head and internals you name it. This is gonna get done right and expected build time is 1 year+ and when the car rolls out it is gonna be lika a brand new car except eveyrthing is bigger, better and a hell of a lot more expensive.[:d]

Oh and i forgot, this will be a stroker. This arrived earlier this week.
AJA eurovan bottom, crank, tray, 7a head, cams and cover. Not sure if I will bore the block yet, but the head will get some better airways.


Thats it for now, gonna save up a couple of months salary so I can order a big ass box from 034 and get started, I'll post a complete setup list lasterz.

[Dagi]

Oh.. I was happy seeing the car been driven. Now I just got sad..

What turbo did you run before it broke?
Where are you buying the KW coils?

Hilsen nabolandet Norge :p

[loxxrider]

I want to suggest VEMS, but you seem like an 034 nutswinger so its probably no use. (no offense)

Should be nice when finished regardless. Just don't bash your head against the wall too many times over the terrible user interface and lack of features on the 034 system ;)

[Rejmow]

Oh.. I was happy seeing the car been driven. Now I just got sad..

What turbo did you run before it broke?
Where are you buying the KW coils?

Hilsen nabolandet Norge :p

The car was pretty much stock so K24 :)
And the coils will be bought from 034.

I want to suggest VEMS, but you seem like an 034 nutswinger so its probably no use. (no offense)

Should be nice when finished regardless. Just don't bash your head against the wall too many times over the terrible user interface and lack of features on the 034 system ;)

Really? I've been around for mapping Vems and it's very popular in Sweden but I always felt like it's missing something?

And non taken, I diden't think a 034 nutswinger could be a bad thing ;D
But it's definetly not no use since I havent decided on anything except block and head etc, but that might change aswell, so stuff like this is always welcome.