MTM500+ Engine Conversion

[johneroberts]

As some of you might know id been running the stage 3 458 for some time with good results , would reccomend to anyone with a budget in mind, but at the last Donnington meet i had turbo failure [img]images/graemlins/frown.gif[/img], it got recovered from the track and taken to my local Audi workshop, who diagnosed the said problem, also gave me a quote to replace £4000 [img]images/graemlins/blush.gif[/img]
(Warning dont blow your turbos) obviously i thought that i was going to be covered on the warranty, but alas not, found out that the car had been "Blacklisted" as a modified car and Audi deemed it not a warranty claim..... GULP [img]images/graemlins/crazy.gif[/img]
So i then decided to get QST to quote me, Kim came back with a price which was better and the turbos were Turbo Dynamics Blueprinted hybrids SWEET [img]images/graemlins/grin.gif[/img]
So i said yes fit them, the car BTW was in Birmingham and QST in Haywards Heath, i trailered the car down to QST at a cost of £350, and Kim said 3-4 working days to sort it out.
The turbos were fitted and the car was taken out on test, and it was found that an alien object was in the engine [img]images/graemlins/confused.gif[/img] [img]images/graemlins/confused.gif[/img] [img]images/graemlins/confused.gif[/img] [img]images/graemlins/confused.gif[/img] [img]images/graemlins/frown.gif[/img]
And numbers 6 clylinder was not working, probes were incerted into the engine and sure enough there was somthing in the valve beds, so the engine needed to be stripped down to find out what had got in there, (always make sure that when turbos blow that who ever fits them checks the intake system)Small bits had entered from the failure and had some how got forced into the engine and caused Big damage to the head and the cylinder and the valves, at this point my heart was pounding [img]images/graemlins/033102bad_1_prv.gif[/img]
My Red Beauty was looking sad and at no fault of my own, or anyone elses for that matter, just one of those misfortunate happenings.
So i now had to weigh up the options.
It was simple
MTM 520 upgrade
which included new head exhaust manifolds and turbos.
The price was ridiculous £12000 ish
but Kim was very kind and gave me an accomodation for having the first in the UK.
So all parts were ordered along with the new H&R PSC Coil over suspension again the first on the RS4 in the UK, adapted from the DTN cars in Germany a fully ajustable system with dampening dialers. COOOOOOOOL [img]images/graemlins/nodder.gif[/img]
So i was all ready to go down and collect Misano Mister (my version of Noggy Babe) when i got a call from Kim explaning that number 2 cylinder was showing no compession [img]images/graemlins/jawdrop.gif[/img]Bollocks , this was really getting me worried, the engine had to com out again, the metal 2 layer gasket for the heads had a manufacturing defect, and could not be seen when the engine was re assembled, this was 5 days before i was going to Germany on the RS Challenge, Moday came and Kim said we got the engine back in come down tomorrow and we will see how we get on, most of the day was spent sorting out water and oil leaks due to split hoses and stuff, but by about 11 am we were in a position to go out and test it.
All was fine and the engine was remarkably quiter and smoother than ever before, came back to base and did a couple of tweeks and Kim then said "Go a get some miles on it" and dont exceed 5000 rpm, so there i was up and down the M23 doing test miles, after about 100 miles i went back the cat was prepped for the RS Challenge, and i was sent on my merry way.
Well got to Calais and we started our journey, about 6 miles into the journey, the engine management light comes on, luckly Revo Kev was there with VAG COM and diagnosed banks 1&2 Cat sensors were getting wrong readings, the phone call followed, and the answer was rapidly given, i run 100 cell cats, and on the early models the sensors we put pre-cat and the code which was sent in the 500= CHIP WAS TAKING READING FROM POST-CAT POSTION [img]images/graemlins/tongue.gif[/img]
Phew [img]images/graemlins/033102ass_1_prv.gif[/img]
So i carried on my journey keeping the revs under 5000 until the magic 750 miles arrived.
Driving along on your own you get to realise that the car is different in many ways, the turbos are stronger and car has more power over 120 mph and the car was having to rev less, it felt like it was breathing better [img]images/graemlins/grin.gif[/img].
&50 came and i decide to open her up [img]images/graemlins/clap.gif[/img]
SH1T [img]images/graemlins/jawdrop.gif[/img]This sucker flysand it hasnt even been mapped yet (After the 20 th November it will be done along with the cat sensors being repositioned)
More will follow i am quite confident when all is done lots rides will be in order to all you 458 boys.
Sunday morning blast me and Gav went out south bound on the A% to Baden-Baden a fantastic piece of road, got up to 185 on the clock and 181 on the Sat Nav, and was only revving to 6750 rpm.
The car with the new suspension at that speed was sblime and not as twitchy as before with the GMBH fitted.

More to follow when i get it all done
Cheers
jr [img]images/graemlins/29428-red4.gif[/img] [img]images/graemlins/29428-red4.gif[/img]

[Mo_S3]

Jeez, if i had repairs bills in that region id be having heart attacks! And instead of just getting the engine fixed u went ahead and got the H&R's too. money money money !
Glad u got it sorted and no doubt ur thinking it was worth every penny judging by the way the car has completely transformed.
By the way how much was the total bill in the end? If u want to say that is? So is there a remap to follow to take te BHP up even higher ?

Nice one ! [img]images/graemlins/thumbs.gif[/img]

[wazza]

Why didn't you just go for the MTM600 John [img]images/graemlins/bowdown.gif[/img] [img]images/graemlins/rs4-button.jpg[/img]

[Andiroo]

[img]images/graemlins/smile.gif[/img] Those hybrids are so cool [img]images/graemlins/thumbs.gif[/img] I believe yours are of a newer design than mine as well [img]images/graemlins/clap.gif[/img]

Andiroo

[Taipan]

John,
Following up on our discussion on the digital speed display through the aircon, here's the complete list of info you can collect with the AirCon.
http://www.audiworld.com/tech/int5.shtml

Eric

[wazza]

It's only in km/h though Eric! [img]images/graemlins/033102ass_1_prv.gif[/img]

[Taipan]

Because it's more precise, that's why...
[img]images/graemlins/033102ass_1_prv.gif[/img]
[img]images/graemlins/wink.gif[/img]
Eric

[SimonS4MTM]

John,

that car sound awesome.

That is the first RS4 turbo failure i have heard of, are there any more?

[Nige_RS4]

jr, did QST identify what it was that caused the internal damage to the engine? Was it part of the turbo, or was it a pair of Riz's trainers that got sucked in via the airbox [img]images/graemlins/hoho.gif[/img]

[DavidT]

jr, did QST identify what it was that caused the internal damage to the engine? Was it part of the turbo, or was it a pair of Riz's trainers that got sucked in via the airbox

Come to think of it, where's Riz [img]images/graemlins/blush.gif[/img]

[Nige_RS4]

Come to think of it, where's Riz

I think he's gone to console himself after finding out there's no RS3 [img]images/graemlins/062802drink_prv.gif[/img]

[RobK]

The price was ridiculous £12000 ish

Strewth!! Did you have to sell a couple of metres of speaker wire to pay for that? [img]images/graemlins/tongue.gif[/img]

[johneroberts]

jr, did QST identify what it was that caused the internal damage to the engine? Was it part of the turbo, or was it a pair of Riz's trainers that got sucked in via the airbox [img]images/graemlins/hoho.gif[/img]

All the parts were accounted for apparently [img]images/graemlins/smirk.gif[/img]
but i will take a picture of the piston and head to show you the damage, and see if you can identify what did it.
turbo failures will become more common place is chipped cars around 30k miles and upwards, Carl in Germany has had a couple go on him and his friend even 2 sets and then an engine with abt conversion [img]images/graemlins/shocked.gif[/img]
So expect turbo failures they are looked upon as an expendable item in the car.
Cheers
jr

[sitas3]

So expect turbo failures they are looked upon as an expendable item in the car.

hmmm. A turbo going bust is one thing but if this causes internal engine damage as well - that could be costly as yours has proved. [img]images/graemlins/mad.gif[/img]

just a small question - how much power can the RS4 gearbox take (is it different to the S4 one?)?

[Dippy]

Nice one John [img]images/graemlins/thumbs.gif[/img]