[s-cars] COME ON!!!!!! NIGHTMARE!!!!!

[calvinlc at earthlink.net]

This sucks, Jim.  I am so sorry to hear about this.  As someone who has had
to pull two engines after recent rebuilds because of either substandard
machine shop work or bad parts I totally sympathize with you.  I don't know
how the oiling system on the S-cars works since I have never had to take the
I-5 apart, but is the #5 cylinder the last bearing to get oil?

One thing that I have seen destroy a rod bearing before was having the rods
"backwards."  Now since this was on a V-8 with two rods per journal I don't
know if it applies here but bear with me.  If you are looking through the
hole in the big end of the rod there is the front edge of the hole, the one
closest to you, and the back edge of the rod, the one furthest away from you
on the other side of the hole, so to speak.  On V-8s the two edges I have
described have different chamfers on the edges for oil control purposes.  So
if the machine shop puts the piston on "backwards" so to speak, and you
insert the piston so the valve reliefs line up, the rod will have the wrong
chamfer on the wrong side.

Like I said, I don't know if this condition even exists on the I-5 but it
was something I learned painfully a long time ago and it is very subtle.

Other ideas....Did you get the crank turned or is it a turned/polished crank
from a machine shop?  If so, they usually do a pisspoor job of cleaning the
internal crank passages.  Usually a rifle bruch and soap and water followed
by a healthy coating of compressed air through the passages and WD-40 to
avoid rusting of the polished surfaces will clean these out well.

Is this the smae rod as before that cuased the problem?  Did you have the
rods re-sized before re-using them or did you simply pull out the old rob
bolts, put in the new ones and away you go.  Sometimes that procedure alone,
if the rod bolts are press fit, can cause enough warpage to throw the hole
out of round enough to cause problems.

I don't know if any of these are applicable but they were just what I could
think of in a few minutes.  Good luck!

--Calvin


-----Original Message-----
From: s-car-list-bounces at audifans.com
[mailto:s-car-list-bounces at audifans.com]On Behalf Of AUDIJIM at aol.com
Sent: Tuesday, May 30, 2006 5:57 AM
To: s-car-list at audifans.com; Audi5TurboTech at yahoogroups.com;
quattro at audifans.com; urq at audifans.com
Subject: [s-cars] COME ON!!!!!! NIGHTMARE!!!!!


I can't believe this!!!!! I get up at 0430 hrs for work, start the car (93'
S4) and precede as normal. I get onto the highway and cruise along and I
start
 to hear a knocking. It changes with RPM. I pull over and pop the hood and
at
the  same time a tractor trailer almost hit me and the car. Confirmed, I
have
a knock  and it's bad. I limp the car home and pull the oil pan. Number 5
connecting rod  only has a small portion of it's rod bearings!
WTF!!!!!!!!!!!!!!!!!!!!!!!!!!!!  This is not good. I'm burned my hands
taking this apart so
quickly so I need to  address that soon. Too much adrenaline right now. I'm
going
to see if the crank  is OK and run some very fine emery cloth with a cord
and
see how it looks. The  rod end that I took off looks so-so but I will mike
everything and see if this  is OK. I just don't understand how this
happened.
There is only 2000 miles on  this engine since I built it. I miked
everything and
AND used plastigauge to  make double sure this was going together correctly.
I'm totally beside myself  right now.


Angry Jim
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