Swapping build engine and Stage 3 DSG Clutch Pack (VIDEO)

[UkuRiSh]

Hi guys,

I will post every day of work on my engine and installation of fully build block/head with Stage 3 DSG Clutch Pack. Each day of work on my car will be recording for you. That way you will see how much work it is. Sorry very long video but with good info. I hope you guys like it otherwise I spend my time for nothing



Part 1



Part 2



Part 3




Part 4

[4Rings3Liters]

Sweet!

[S4AvantGuy]

Holy ambition, Batman! Nice work!


2011 S4 / Stage II EPL + TCU / CAI / B&O / Sport Diff / AWE Track Exhaust

[UkuRiSh]

Video was blocked by YouTube, I'm uploading new one w/o music

[03redgti]

Video was blocked by YouTube, I'm uploading new one w/o music

LoL youtube is ridiculous.

[UkuRiSh]

LoL youtube is ridiculous.

They used to allow before with warning of copy rights but I guess not anymore!

[UkuRiSh]

Uploading should be ready shortly

[UkuRiSh]

This is good time to make it single turbo piping kit with downpipe and external wastegate piping, I'm doing only one set because I don't want to spend my time for nothing! Lot's of people asking but no serous buyer! Here is your chance to get one, I will record vid of making and installation of everything on my car.

[UkuRiSh]

Ok, YouTube video is back online ! Sorry ….

[cspcrx]

props to you. No fancy shop just a guy in a garage making it happen! Hats off man!

[UkuRiSh]

props to you. No fancy shop just a guy in a garage making it happen! Hats off man!

Thank You buddy, that's why I'm doing this video to show people it's not that bad as looks ! If you have small garage and some tools it's easy to pull and install performance parts like me. I'm not a mechanic.

[UkuRiSh]

Here is the Part 2, now I have to wait for my clutches and 034 Billet Engine mount

[RWD2quattro]

Damn dude, good job documenting your build . Can't wait for this beast to hit the streets.

[UkuRiSh]

Damn dude, good job documenting your build . Can't wait for this beast to hit the streets.

Thank you, just wanna show to people that, this car needs more love

[Big_Joe]

Where did you get the liners and pistons from I was looking at rebuilding my engine as well but I only seem to be able to get parts from the dealership , does not seem to be any aftermarket support for Audi engines. I had some light scrapping in my cylinder walls and some on the skirts of the pistons, if I can install liners that be better than throwing in a used engine.

[UkuRiSh]

Where did you get the liners and pistons from I was looking at rebuilding my engine as well but I only seem to be able to get parts from the dealership , does not seem to be any aftermarket support for Audi engines. I had some light scrapping in my cylinder walls and some on the skirts of the pistons, if I can install liners that be better than throwing in a used engine.

I can build your engine if you interesting ! All parts was custom ordered by my machine shop and you need someone who knows how to do liners ! Not many shops can done this correct way.

[Big_Joe]

I can build your engine if you interesting ! All parts was custom ordered by my machine shop and you need someone who knows how to do liners ! Not many shops can done this correct way.

I can build the engine, I just didn’t think there was liners. Are the pistons custom as well? They look to be different from stock and would increase compression due to the dome shape because the stocks are more dished

[Whitee]

I can build the engine, I just didn’t think there was liners. Are the pistons custom as well? They look to be different from stock and would increase compression due to the dome shape because the stocks are more dished

Wouldn’t he want lower compression as it’s a turbo build? Supercharged guys would benefit from higher CR tho.


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[sbw]

Wouldn’t he want lower compression as it’s a turbo build? Supercharged guys would benefit from higher CR tho.


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It’s not supercharger or turbocharger specific. The operator just needs to run the right fuel with a higher CR and certain amount of boost.

[UkuRiSh]

I can build the engine, I just didn’t think there was liners. Are the pistons custom as well? They look to be different from stock and would increase compression due to the dome shape because the stocks are more dished

You will not able to find any parts and there is no way you can do sleeve work by yourself! Pistons design was created by JE engineers. My machine shop provided all information of combustion chamber value of the head if I not mistaken our head is around 43cc and plus head gasket thickness! Due this information and smaller bore, original is 84.5mm and my is 81mm JE create the piston with compression 9.3:1 with same style of dome because of direct injectors and velocity


Edit : I had optional with flat style piston but choose it Dome

[Big_Joe]

You will not able to find any parts and there is no way you can do sleeve work by yourself! Pistons design was created by JE engineers. My machine shop provided all information of combustion chamber value of the head if I not mistaken our head is around 43cc and plus head gasket thickness! Due this information and smaller bore, original is 84.5mm and my is 81mm JE create the piston with compression 9.3:1 with same style of dome because of direct injectors and velocity


Edit : I had optional with flat style piston but choose it Dome

I know i cannot sleeve an engine with a 20v DeWalt in my garage. I was curious to how and where you were getting the parts as I could not find any aftermarket support for this engine (internal wise). The amount of work that's going into the engine for the time,labour and parts I think there is better options. Just the cost in new timing chains and tensioners, pistons, gaskets, o rings, hardware and main and rod bearings is the price of a used engine, for my purpose is not worth it.

I've been noticing with these engines they seem to be failing when people start throwing big numbers at them. Usually due to lack of lubrication. If your running a turbo set up now, probably a good chance you could be starving your bottom end as well due to the extra oil usage in the turbo as the supercharger is internally lubricated by a sealed system. Might be worth modifying a oil pan to hold some extra oil.

Did you have any wear on your bearings or build up in your pan?

Good luck with the build, be interesting the see for sure.

[Nollywood]

This is going to be a monster once completed.

[Nollywood]

So, new cylinder displacement is 2752 cc / 2.7L.

[UkuRiSh]

So, new cylinder displacement is 2752 cc / 2.7L.

Yes sir . back to old school 2.7t

[UkuRiSh]

So, new cylinder displacement is 2752 cc / 2.7L.

Next block I would like to use bigger stroke 92.8mm vs original 89mm and custom wet sleeve with 86mm pistons or just swap 4.0T

[friskuh]

I know i cannot sleeve an engine with a 20v DeWalt in my garage. I was curious to how and where you were getting the parts as I could not find any aftermarket support for this engine (internal wise). The amount of work that's going into the engine for the time,labour and parts I think there is better options. Just the cost in new timing chains and tensioners, pistons, gaskets, o rings, hardware and main and rod bearings is the price of a used engine, for my purpose is not worth it.

I've been noticing with these engines they seem to be failing when people start throwing big numbers at them. Usually due to lack of lubrication. If your running a turbo set up now, probably a good chance you could be starving your bottom end as well due to the extra oil usage in the turbo as the supercharger is internally lubricated by a sealed system. Might be worth modifying a oil pan to hold some extra oil.

Did you have any wear on your bearings or build up in your pan?

Good luck with the build, be interesting the see for sure.

I think Oleg stated before the bottom end has little wear. he changes his oil every 4-5k miles! he said his block glitters with little wear on it. also these internals are very strong out the box, hes been beating the car hard at over 600whp. we also carry alot of oil too, double than most import cars that run turbo setups as well.

[Big_Joe]

I think Oleg stated before the bottom end has little wear. he changes his oil every 4-5k miles! he said his block glitters with little wear on it. also these internals are very strong out the box, hes been beating the car hard at over 600whp. we also carry alot of oil too, double than most import cars that run turbo setups as well.

Even still if these engines run with more oil than most imports doesn't make a difference if it hold 6 qts but when running hard its pumping 6 through the system faster than it can pick it backup and lubricate the bottom, as the oil is being pumped and sprayed around the engine it takes some time to get back to the bottom again and if the oil is being aerated can also lead to wear When these engines are designed they are specd within a certain limit. They are not intended for 600 whp, They can handle it sure, with supporting mods, some people seem to forget with more power is more, fuel, air, cooling, lubrication. etc Start your car run it to temp shut it off and check your oil, let your car sit for 15 mins check it again check it 60 mins later, see what the difference is. and that's from an idle.

[Whitee]

Even still if these engines run with more oil than most imports doesn't make a difference if it hold 6 qts but when running hard its pumping 6 through the system faster than it can pick it backup and lubricate the bottom, as the oil is being pumped and sprayed around the engine it takes some time to get back to the bottom again and if the oil is being aerated can also lead to wear When these engines are designed they are specd within a certain limit. They are not intended for 600 whp, They can handle it sure, with supporting mods, some people seem to forget with more power is more, fuel, air, cooling, lubrication. etc Start your car run it to temp shut it off and check your oil, let your car sit for 15 mins check it again check it 60 mins later, see what the difference is. and that's from an idle.

There aren’t many people running around with 600whp on these forums. Oleg has stated several times how much he beats on his car and the engine has held up completely fine with stock bottom end and internals. Still confused at what point you’re trying to make to Oleg....pretty sure he knows these motors better than most tuners know them...


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[Big_Joe]

There aren’t many people running around with 600whp on these forums. Oleg has stated several times how much he beats on his car and the engine has held up completely fine with stock bottom end and internals. Still confused at what point you’re trying to make to Oleg....pretty sure he knows these motors better than most tuners know them...


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1)I m not trying to make any point to him. I m asking questions because I m interested. I have not said he is wrong
2) I m stating facts about when modifying you need supporting mods. When you add more air you at more fuel. Etc he stated that he added an upgrade oil pumping system, with the larger pump demanding more oil your going to need to more oil supply or you will start getting cavatation in the pump and airate the oil.
3) An engine is an engine, they all operate on same basic principles. If a tuner says they don’t know a certain engine then they ain’t much of a tuner. Knowing software is one thing.

I’m only making suggestion, his engine, his money. Would hate to see a build like this fail due to something as simple as not adding a larger oil resivior

[friskuh]

Wouldn’t he want lower compression as it’s a turbo build? Supercharged guys would benefit from higher CR tho.


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not our platform, we run high boost on supercharger. high boost with high compression = prone to knock. big v8's can get away with high compression because they always run <10 psi to get 700+ whp.

[friskuh]

I missed the part about the pump, but with increased capability, you should also add more supply, considering its going to flowing more at a higher pressure.

Well I will definately be watching this build and see how it comes along, because I was going to scrap my old block but if it works out I might just have to get it sleeved and build an engine with it. Best of luck!

When i brought up our engine has a big oil supply, you brought up that the pump won't flow for the needed amount of lubrication. hes put in a pump that pumps wayyyyy more oil at the most important RPM range where stock oil pump actually pumps lowest. now you go back to talking about adding more oil supply. the 3.2 pump actually makes it able to fill about a quart more (?) i think Oleg said it in the 3.2 pump video, idk you can ask Oleg. but what more do you want? a 10 L oil supply? We have 7 L capacity. like i said earlier, imports have smaller oil supply. GTR has a 5L capacity.

[Big_Joe]

When i brought up our engine has a big oil supply, you brought up that the pump won't flow for the needed amount of lubrication. hes put in a pump that pumps wayyyyy more oil at the most important RPM range where stock oil pump actually pumps lowest. now you go back to talking about adding more oil supply. the 3.2 pump actually makes it able to fill about a quart more (?) i think Oleg said it in the 3.2 pump video, idk you can ask Oleg. but what more do you want? a 10 L oil supply? We have 7 L capacity. like i said earlier, imports have smaller oil supply. GTR has a 5L capacity.

I have never said the pump can’t supply, I said the supply can’t keep up with the pump. The 3.2 has the same capacity as the 3.0T.’ 6.2L. With a redline of 6500-7200rpm trans dependant, now that pump with the new new build is going to be running at 8000 rpm. The pump is going on to pumping 11.11% more oil at 8000RPM. Just because you add a bigger pump doesn’t mean you can add more oil to the same resivior because if the crank is splashing in the oil it will start to airate and lead to lack of lubrication due to air bubbles in the oil and also cause drag. I m just giving advice. He said he was not a mechanic, I am a dealer trained diesel mechanic, it does not mean i know every thing, but I think I have an idea what I m talking about. Again his engine his money. Just giving insight

[UkuRiSh]

I have never said the pump can’t supply, I said the supply can’t keep up with the pump. The 3.2 has the same capacity as the 3.0T.’ 6.2L. With a redline of 6500-7200rpm trans dependant, now that pump with the new new build is going to be running at 8000 rpm. The pump is going on to pumping 11.11% more oil at 8000RPM. Just because you add a bigger pump doesn’t mean you can add more oil to the same resivior because if the crank is splashing in the oil it will start to airate and lead to lack of lubrication due to air bubbles in the oil and also cause drag. I m just giving advice. He said he was not a mechanic, I am a dealer trained diesel mechanic, it does not mean i know every thing, but I think I have an idea what I m talking about. Again his engine his money. Just giving insight

The main reason I'm swapping 3.2FSI Oil pump is, Better pressure at low and mid rpms range, we talking about 3.5 bar by 2k rpms on 3.2FSI vs 1-2bar+ at 1k-4krpms 3.0TFSI. Then the problem would be high rev of my engine 8k+ Stock 3.0TFSI variable pump doesn't looks safe for those rpms this is just my thoughts. If you work for audi could you please explain how 3.2FSI engine flow oil true the block and how oil pressure controlled ? Seems like only two check valve and oil return back to pump also over pressure relive valve in the pump 11 bar. I can't find more information about

[Big_Joe]

The main reason I'm swapping 3.2FSI Oil pump is, Better pressure at low and mid rpms range, we talking about 3.5 bar by 2k rpms on 3.2FSI vs 1-2bar+ at 1k-4krpms 3.0TFSI. Then the problem would be high rev of my engine 8k+ Stock 3.0TFSI variable pump doesn't looks safe for those rpms this is just my thoughts. If you work for audi could you please explain how 3.2FSI engine flow oil true the block and how oil pressure controlled ? Seems like only two check valve and oil return back to pump also over pressure relive valve in the pump 11 bar. I can't find more information about

I do not work for Audi, I work for Volvo Trucks. So I cannot give you an example, but im sure there is a flow diagram somewhere. From what you are saying sounds like the pump will have no problem supplying the oil and pressure, my concern is I think your "supply" oil pan might not hold enough oil when you start getting onto the throttle and have that oil flowing through out the engine, it will not be returning quick enough to keep the pump supplied and the pump will start sucking air. I have the audi workshop manuals and I will look through them, but I only have it for our engines not the 3.2

[UkuRiSh]

I do not work for Audi, I work for Volvo Trucks. So I cannot give you an example, but im sure there is a flow diagram somewhere. From what you are saying sounds like the pump will have no problem supplying the oil and pressure, my concern is I think your "supply" oil pan might not hold enough oil when you start getting onto the throttle and have that oil flowing through out the engine, it will not be returning quick enough to keep the pump supplied and the pump will start sucking air. I have the audi workshop manuals and I will look through them, but I only have it for our engines not the 3.2

3.2 and 3.0 is should be the same oil value and capacity! I'll this time I was talking about oil pressure but value of the flow is very important too. Let's think logically, same block ! same oil channels , just a different style of the pump..... Audi engineers did variable oil pump to make engine more efficient and they save some mpg due low pressure true 1k-5k rpms so this is the main reason why they did variable oil pump. Cut oil pressure to save gas so stupid! I just not getting how pressure is controlled in 3.2 Engine, there is no pressure control in then pump except over pressure relive valve! By pictures I posted, oil pressure control by two check valves on then top, same as I posted in video at FB grope. btw I opened my group called " Boosted world " I will post ill my data and progress there as well video.

[UkuRiSh]

Newest boosted engines is runs higher or lower then 10.5:1 because of the new technology, good safety futures controlled by ECU’s combined with direct fuel injectors. Some people runs High compression 11.0:1 / 12.0:1 on full E85 and high boost with out any issue, High compression will have better respond at lower rpms and helps to spool up the turbo. Currently my car at 28psi E20 and ECU is happy with.

[sbw]

Newest boosted engines is runs higher or lower then 10.5:1 because of the new technology, good safety futures controlled by ECU’s combined with direct fuel injectors. Some people runs High compression 11.0:1 / 12.0:1 on full E85 and high boost with out any issue, High compression will have better respond at lower rpms and helps to spool up the turbo. Currently my car at 28psi E20 and ECU is happy with.

agreed, which is why i disagreed with what Whitee said. Its not supercharger or turbocharging specific. You can absolutely do it as long as you have the right knock detection, fuel, and timing/tune...

There's a lot of talk about 'higher boost' but thats all relative also and not supercharger or turbocharger specific.

[friskuh]

I have never said the pump can’t supply, I said the supply can’t keep up with the pump. The 3.2 has the same capacity as the 3.0T.’ 6.2L. With a redline of 6500-7200rpm trans dependant, now that pump with the new new build is going to be running at 8000 rpm. The pump is going on to pumping 11.11% more oil at 8000RPM. Just because you add a bigger pump doesn’t mean you can add more oil to the same resivior because if the crank is splashing in the oil it will start to airate and lead to lack of lubrication due to air bubbles in the oil and also cause drag. I m just giving advice. He said he was not a mechanic, I am a dealer trained diesel mechanic, it does not mean i know every thing, but I think I have an idea what I m talking about. Again his engine his money. Just giving insight

I understand what you're talking about now. maybe he has it sorted out, we'll see if he responds

[friskuh]

3.2 and 3.0 is should be the same oil value and capacity! I'll this time I was talking about oil pressure but value of the flow is very important too. Let's think logically, same block ! same oil channels , just a different style of the pump..... Audi engineers did variable oil pump to make engine more efficient and they save some mpg due low pressure true 1k-5k rpms so this is the main reason why they did variable oil pump. Cut oil pressure to save gas so stupid! I just not getting how pressure is controlled in 3.2 Engine, there is no pressure control in then pump except over pressure relive valve! By pictures I posted, oil pressure control by two check valves on then top, same as I posted in video at FB grope. btw I opened my grope called " Boosted world " I will post ill my data and progress there as well video.

where's your group?

[UkuRiSh]

where's your group?

(BOSTED WORLD) on FB , I will post all my data and video by the time , this way much easy for me to share with pictures and video. YouTube upload and then post on AZ takes lots of time FB much easy and instagramm ..