V8 head refurbishment
 

As most of you will know I trashed my AHC lump a few months ago. I have finally got round to stripping it down and inspecting the damage. I knew I had 16 bent inlet valves but needed to ascertain whether I had bent any conrods. The consensus of professional opinion is that it is unlikely. :)

So this is what the garage looks like atm.........

http://i25.photobucket.com/albums/c7...F1574small.jpg

The piston crowns look like this...........

http://i25.photobucket.com/albums/c7...000/Piston.jpg

You can see where the inlet valves impacted on the piston crowns and made some small indents. Here they are on a de-coked crown......

http://i25.photobucket.com/albums/c7...F1569small.jpg

I have now de-coked all the piston crowns.............

http://i25.photobucket.com/albums/c7...F1577small.jpg

Pretty pictures! Mmmmmmm Shiny...........

The heads look like this.........

http://i25.photobucket.com/albums/c7...F1571small.jpg

http://i25.photobucket.com/albums/c7...F1572small.jpg

I'm going to get them done professionally as I don't have the skills needed to rebuild them. +++
Next up pumping volume check. Have to find a dial gauge.

Come on Mike even I managed to rebuild the heads on my spare engine, your letting the side down now :D

:p

Did you have 16 bent inlet valves to remove first! A! A! A!:-(

Well I had 16 inlet valves to remove they just werent bent

So far so good!
After Botang's ridicule I decided to continue stripping the heads...

http://i25.photobucket.com/albums/c7.../picture-1.jpg

One head's worth of valves
And one very bent valve..... :eek:

http://i25.photobucket.com/albums/c7...ar/picture.jpg

More to follow
:(

Ouchy... Still it'll be worth it when you get it in your A8 :)

lol, it can be a pain at times getting the valve spring compressor to work but its amazing how much work has gone into the heads from the factory.

Pistons don't look bad at all really. Though if rebuilding some nice lightweight ones and some new lightweight rods too? Bit higher RPM then!

Whilst the engine is apart port your exhaust outlets and your intakes. Buy a porting and polishing kit and flow your heads mildly, don't go too extreme as it will have the opposite effect.

A fully rebuilt 4.2 V8 with flowed heads and lightweight pistons would be veeeeeery nice. Some mild cams for sir and a remap over the top would be a nice increase.

A thought.... If there are any kicking around and they fit is the later S8 cams into the engine?

Early engine = 32v late engine= 40v so I don't think that will work :D

Definetely not, I forgot about that.

Oh well, send them off to Kent Cams and get them machined :)

The heads are ported and polished as standard!

Really? Any pics of a standard head?

I'm amazed!

So was I when I took it apart, the effort that they have gone to is incredible they had even removed any finishing marks from the oil pickup.

The strip down continues....

Current state,
http://i25.photobucket.com/albums/c7...r/DSCF1629.jpg

The heads are strip down and ready to go to AVP,
http://i25.photobucket.com/albums/c7...r/DSCF1628.jpg

The Crank Shaft drive for the cambelt came today and you can see the missing key!

http://i25.photobucket.com/albums/c7...r/DSCF1627.jpg

So that confirms what happened. Why? Doesn't do to dwell.........

Next back to the starting problem. I still love my car! +++

Rebuid...
 

Could you provide the amount of time and $Money that your rebuild took? We saw one bent valve....it's cost?

Your supplier for the parts? via the mechanic or the machine shop?

Is this rebuild now a spare or are you going to sell it?

I am in a similar situation, I have a used 4.2 L as a swap and therefore the original engine is up for "re-conditioning" or rebuild if I find that more than a few valves are bent.:o

Thanks

Cam shaft drive sprocket
 

Looking @ your photo...it appears that the old sprocket has lost it's interior "key lock"? ... & the "gears" appear to be worn down compared to the new sprocket. Would this be the reason for any (your) timing skip?

To me, it appears that it's very possible cause/effect for timing issues on high milage engines.

Thanks

I have had a quote of approx £23 per valve x 16, £3 approx per seal x 32 from Audi. I have not had it done yet. Still saving up, but have found and independent mechanic to do it. hoping to get it done in the next few weeks.

I intend to fit this AHC into and A8 in place of an ABZ. +++

Yep, key-way has gone completely so timing went out and bent all 16 inlet valves! :(

Actually, not true! :eek:

We gave the heads a good inspection when I dropped them off and AV Performance and they definately have casting and machining marks on them. So added to the list of work is a polishing. +++

Oh, how I would love to do something like this :)
But unfortunately my S is the only vehicle I own that has a roof.
So I had to go for weeks by bike again and in these awful winterdays it's not the way to go..
But your pics give me much passion to do this, at a time far far away.. :ROFL:

Pictures to follow


With the heads now with AVP I have started work on the recipient car. A 1997 A8QS i picked up for £500 from North Wales. It had oil in the water and a suspected blown head gasket. As it has turned out it has a blown heat exchanger in the oil cooler. This has turned out to be a 'Part not recognised' by the Audi parts system and is causing a bit of fuss. So out with the ABZ and in with my AHC.
http://forum.a8parts.co.uk/attachmen...0&d=1250706601
The offending article.....
http://forum.a8parts.co.uk/attachmen...9&d=1250706601

I started work before I had my camera so here are a few on the phone.

Front end off
http://forum.a8parts.co.uk/attachmen...6&d=1250706601

Some of the muck that came out as I drained the rad.
http://forum.a8parts.co.uk/attachmen...8&d=1250706601


Radiator off and the first problem anyone notice anything missing.
http://i25.photobucket.com/albums/c7...50-resized.jpg

http://i25.photobucket.com/albums/c7...52-resized.jpg

Stripping of the plastic I came across a small horror story.......
http://i25.photobucket.com/albums/c7...51-resized.jpg
Going to have to get that welded up!

I think this engine has been out to change the gearbox and has not been put back at all well. Nothing we can't fix.

So after 6 hours today we were at a natural break point so off for a beer.

http://i25.photobucket.com/albums/c7...54-resized.jpg

For those that saw the last one I have a fetish for looking up my tunnel!!! :) +++

http://i25.photobucket.com/albums/c7...53-resized.jpg

Engine porn at its best...!! +++ :love:

Hi Mike,

Sorry if you already mentioned it but why are you getting another 8?...and why would you put yourself through all that again?...you have a sick fetish indeed! ;-)

Looks great though!...i love seeing these sorts of threads! :D

The S8 will go to full project car status once I have this one running as my daily driver. :)

You can never get enough 8's LOL :D

We all need to have 2 in the drive :)

hey mike does "full project car status" mean something like these add on's or maybe more powerful rs4 lump ,on ebay.de for £6k. complete s'charger's ready now for the s8 $8500. tubular headers $2500, both from usa. will send you the links.john

http://forum.a8parts.co.uk/attachmen...1&d=1250792986

http://forum.a8parts.co.uk/attachmen...1&d=1250792986

http://forum.a8parts.co.uk/attachmen...1&d=1250792986

http://forum.a8parts.co.uk/attachmen...1&d=1250792986

http://forum.a8parts.co.uk/attachmen...1&d=1250792986

more pics and company details, if not fast enough for you, go for the 5.2 v10 from the d3 s8, these are about £5000 on ebay.de, and run with the kms stand alone ecu, as on this ultima. will look good in your s8 at next years a8oc meet.
kms.vankronenburg.nl , pes-tuning.com , vf-engineering.com , novidem.ch , jhmotorsorts.com . nice winter projects, john

http://forum.a8parts.co.uk/attachmen...1&d=1250793132

http://forum.a8parts.co.uk/attachmen...1&d=1250793132

http://forum.a8parts.co.uk/attachmen...1&d=1250793132

http://forum.a8parts.co.uk/attachmen...1&d=1250793132

http://forum.a8parts.co.uk/attachmen...1&d=1250793132

OMG where is my sock! :D+++

How much would I get for one of my children I wonder!!!

Droooooooolllllllllll.

couldn't resist posting a few more audi engine porn pics for you guys. the 5.2 v10 from s6/s8 with the kms intake, the underside of the mtm supercharger for the audi 4.2 v8 showing that it is made by mercedes specialist kleemann !,the new kleemann merc unit, the new eaton tvs1900 on an r8 by vf. and last, of audi things to come, the '09 s4 tfsi3.0 v6 with twin intakes and rated at 408hp+, to appear soon in ? mike all you have to do is get promoted to admiral and then take your pick.

http://forum.a8parts.co.uk/attachmen...1&d=1251100351

http://forum.a8parts.co.uk/attachmen...1&d=1251100351

http://forum.a8parts.co.uk/attachmen...1&d=1251100351

http://forum.a8parts.co.uk/attachmen...1&d=1251100351

http://forum.a8parts.co.uk/attachmen...1&d=1251100351

http://forum.a8parts.co.uk/attachmen...1&d=1251100351

Lovely engines but all the work for putting in the Audi S10 5.2 FSI into a kit car? I would go for the BMW V10 5.0 Litre anytime..... Running either Pectel or Haltech management.

Oh wait.... I did!! :D

:love: do tell and let's see some pictures! ;)

As I contemplate the possibility of the therapeutic use of any payout I get for injury and distress threads like this are very nice. This will sound a little weird but what puts me off modding my new one is that it isn't black. Silver just doesn't do it for me. if I get a little payout then heated seats and wheels will get done, anything over £5k and a black S8 may come into my life. Hmmm, at least I have something to think about when I can't get back to sleep at 3am.

Bill

I think that was Matt getting a bit excited! The heads are very well ported as standard and come with 3 angle valve seats as standard (on the engine we took apart), If you compare them to a standard car the ports look like someone has spent a lot of time on them.


It was the oil pump pickup pipe that had been ported out and polished, That one reason why it might cost £590+vat for the pump

of mice and men
 

Plans are a bisis for change. Believe that as it's true. I dropped the AHC off to AVP on Monday with the plan of rebuilding the engine with the parts supplied by the Volkswagen parts department. except they didn't. While I was there the parts started to dribble in. After several months waiting some gaskets and bits arrived then 3 valves and the head bolts. Given that the heads need 16 valves, a pretty pathetic show. So after 36 hours, nothing was rebuilt! Bummer :( .

When I got home however, this was in the kitchen....

http://i25.photobucket.com/albums/c7...Z/DSCF0179.jpg

Not a lot of use without an engine to sit on, but nice to stoke.

For the techies it's an Eaton 112 for a Jaguar.

From a Jag... or For a Jag? :D

Is it going to your '8???

Hmmmmmmmm maybe! :rolleyes:

one of the best superchargers mike, from the xjr, i just hope your going to do a better install than this m112 in the pic.

http://forum.a8parts.co.uk/attachmen...6&d=1260726075

Hmmmmmmm That'll be hard! :ROFL:

Cool I have an M112 just like that, Toby has obviously confused me enough as explianed above, perhaps its just that I don't understand the difference between a much better than regular to ported and polished!

Wait till you try fitting that in the V of the Audi engine, it very tight!