Nice work! I look forward to seeing how this turns out
was able to get the manifold apart and cleaned, wow this has to be so overly built its mind blowing........spent 8hrs cleaning it and another 3hrs to reseal it.
this stuff fell off while working so its staying off....
not easy using a potato-phone to get detailed photos but the idea is there........... lots of carbon build up. id guess each intake runner was about .250" smaller in DIA due to carbon build up.
the tools i found best to work on getting the carbon out
spent a lot of time looking like this.......
one big problem for this service was moving the motor to close cylinders for the service. solution our team came up with was to make a custom strap wrench to move the crank safely.
hard to see but the tool fits in the limited space and is easy to use
this is the seal for the oil filter housing to the top of the crank case......... it was the main reason for taking the motor apart due to the annoying leak it had become.
once the cylinders were cleaned focused on a few other items like plugs, new coils and some other tweaks.....
while waiting for the chems to soak on the carbon i popped out the HVLP gun and did this since i cant find real OE euro bumper inserts.
final part of the SAI update was to cap the air box.......... turns out a 16oz coors cap fits perfectly...... and its aluminum so the cars keeping true to its roots.
after the test drive last night i cant quiet explain how the car drives aside from its a whole new beast...... this carbon issue really kills these motors performance. car was fast before but now its wild fast..... wish we had dyno time before doing this service as the butt dyno says big change. at some point we will get this car on rollers and see how the Malone Tuning software is doing but i am going to guess its doing well.
cars off to SEMA in a few hours, maybe some of the guys around here will recognize the car and come say hello.
Last edited by carsluTT; 10-30-2017 at 03:19 PM.
over 2 weeks we took the car from LA to Vegas to Phoenix. zero issues and an overall average of 20.2 mpg........... cant call that bad for a v10.
the car has made a few solid dry lake passes and has proven rock solid around 140mph.... after the next round of work the car will be going back to the dry lake/track for more runs. there is a ton of power yet to be let loose.
time to make sure the fuel system is in tip top shape before the next outing......... going to be installing some Autotech Dual High Volume Fuel Pump Upgrade Kit Audi V8 V10 4.0T 5.0T FSI & R8 Lambo V10 5.2L
Malone tuning post #15 talked about getting tuning going. have you dealt with tuning these 5.2 ltr motors?
2004 BMW E46 M3cs.
2012 VW GOLF R, 5 Door, DSG, Euro Spec.
eh......... everything has a cost. the struts are cake to change and really not that much vs. performance struts/springs cost. more a mild sticker shock. our shop truck costs a ton more to keep on the road and its just a big diesel tow rig. struts last what.... 70-120k miles of use.... math says per mile vs. cost no so bad. now the biggest cost so far is me flipping about dings......... that aluminum body isn't going to protect itself!
you had me at m5!......... actually Ive have had a few........ they are great cars! just wanted to do something a bit different this time around. either way your winning! are you finding cars locally in Bahrain or getting them shipped in?
2004 BMW E46 M3cs.
2012 VW GOLF R, 5 Door, DSG, Euro Spec.
really, 5 year cap on import. i helped with sending 2x mk2 golf's to dhahran a while back, i know its not the same area but close. maybe laws are different there. also sold a car/shipped to dubui with zero issues but i really don't know how/if it was setup for street use upon arrival. either way ......... a really neat area to get out and drive!
poor S8's been parked in the shop since X-mas, been busy and the car developed the classic vw/audi "random misfire" code with no time to dig into it . Today the S8 got 2 new Bosch throttle bodies installed along with rewiring cylinder 5 and 10's coil pack plug. the misfire codes are only on 5 and 10 so if the new plugs don't fix the issue next the car will get all new injectors. at this point the car has had a fair amount of new parts so this misfire code is a bit odd but after all its a vw/audi so game on
new spark plugs
new Bosch coil packs
new Bosch throttle bodies
carbon cleaning of intake valves
clean and reseal intake manifold
reseal oil filter housing
new high pressure fuel pumps
new valve cover gaskets
new Front air struts
new suspension air pump
malone tuning software
muffler valve mod
i hope to get time to do a few more test drives but so far all is looking positive. there are plans to take the car out to the dry lake late March/ early April for some runs.
time to open the top of the motor for the 2nd time since owning the car............. new injectors/seals and a few other odds and ends are inbound..... while the cars on the lift tranny service is going to happen. not real happy with the non-existing tranny dipstick or any real solid way to measure oil level aside from the "is it dripping out of the hole" method........ but so goes life.
boy, where has the year gone?...... been collecting parts and finally the S8 got some attention over the week.....
new coil packs
new park plugs
new fuel filter
lots of new gaskets
developed a plug-n-play catch can (pvc dripping into manifold go by-by)
clean all hard fuel lines on motor
new air filters
new maf sensor
new green coolant temp sensor
once the car gets a bath i will have some photos.
also re-placed the plugs for both Throttle bodies and re-placed the plugs for #5 and #10 coil packs. had a few issues over the last year with getting the dreaded EPC light with associated loss of power. Looks like the throttle body plugs where the cause of the EPC light. What a pain to track down but super glad to not have the problem come back since replacing the plugs. best part about the Throttle body plugs, mk4 vw's use the same plug and can be bought much cheaper than D3 parts. think it cost all of 31 buks for 2 mk4 plugs with 6" pig tails installed vs. 50ish for just 1 D3 plug with no pig tail and the plug not assembled.
aside from parts supply issues the car is a well........... not for taking the kids to soccer! ............. yes i owe photos if only i had a way to take photos not from a potato. my webfoo is slipping......... but ideas are sparking so!............
on a side note the catchcat setup is working wonders. pulled the manifold for the previous oil change and everything is 100% clean on the top end. guess the time tig welding and planning and designing parts paid off...........