2015 S3 Rebuild Project

[AlaskanAudi]

Hey everyone,

I usually hang out on the B8 S4 forum, but recently I’ve added a new vehicle to the stable. I noticed this section is not hugely active so I’ve decided to create a new thread here to tell my story. I plan to update this thread, but I don’t plan on modding the car too much as it needs to be reliable and cost effective.

Backstory:
I live in Texas and work on rotation in North Dakota. Recently, I’ve decided that my life will be better with a car up there, as I have to share a work truck and rent vehicles to take to the airport. I needed a car that was primarily cheap, new(er), and reliable. These criteria brought me to Copart where I created a watchlist for these cars:

Golf Alltrack
Audi Allroad
Golf Sportwagen 4Mo
Audi Q3
Audi Q5

After looking at the ones for sale, many of them had airbags blown, axles torn out, the like. I knew that any of these issues would require a lot of work; which I was planning to do myself to keep costs down. I then found this ‘15 Audi S3 with very promising damage; front end crash, fenders untouched, no blown airbags, and runs and drives, with 54k miles, PA salvage title. The only problem was that it was located in Philly, and I was in Houston, so I’d need to figure out a way to get it down to me.

Enter my new to me, crashed Audi S3. These are the auction photos and how the car arrived to me.

Note: I’ve never worked on salvage title vehicles before, so this experience is new to me.

Stay tuned for more updates!




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[AlaskanAudi]

The tear down and evaluation project began. My biggest concern was the frame rails. Buying the car sight-unseen and seeing that aluminum crash bar bent to unnatural positions, I was afraid that the frame rails would be busted up as well. After receiving the car and taking it apart, I saw that the crash bar only slightly bent the frame mounting points, and it actually broke off from the frame rails at those mounting bolts. That was the biggest relief.

Also, the auction photos didn’t have a picture of the engine bay, which was concerning. After receiving the car, I realized why. The hood latch was bent up in a position that did not allow the hood to open. I made quick work of that but using a sturdy flat-head screw driver to bend the latch out of the way. After opening the hood, I was able to take in all of the broken pieces. The biggest issue was that the motor was pushed in on the passenger side, and it appeared to be hanging there. The reason for this was that the passenger side engine mount broke (quite easily it seems). This also caused the serpentine belt to pop off. Obviously all of the coolant was gone, but there was oil in the reservoir, which was a relief. The whole radiator support including the AC condenser, intercooler, radiator and fans were destroyed. I was able to save one fan, though.

Although I had already sourced some obvious parts, it was time for me to create a list of everything I needed. The plan was to buy as many OEM parts as possible, although some aftermarket parts would have to do.




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[AlaskanAudi]

Here are my notes from everything that I needed to replace, and I’m sure some pieces are missing. I ordered an aftermarket radiator support, along with the radiator and AC condenser. ECS Tuning has an aluminum kit for all charge piping, so I decided to go with that as many OEM bits were plastic and broke in the crash. This was many hours of scouring Audi USA parts websites and comparing broken pieces to what they’re supposed to be, then seeing if there were any used ones for sale. Some parts I was able to scavenge locally from awesome Audi/VW club members in Houston.

Hood: eBay - $300
Front bumper:
Aluminum reinforcement: eBay - $200 (250 with shipping)
Radiator: OEM Audi - $200
Condenser: $80
Intercooler
Thermostat
Serpentine belt
Turbo inlet pipe
MAF sensor

Ordered:
Radiator support
Radiator
AC condenser
grille
crash bar
hood
bumper clip and BOV
Bumper
VCDS
Plastic bits
Motor mount
Belt
Sensors
Battery
Thermostat

Engine code CYF


Parts needed:

Lower coupling - 5q0-122-291
5q0 122 291 B

Left air pipe -
Lower radiator hose - 5q0-122-051AF
Hose from thermostat down- small to block on right side


To order:


Fluid washer reservoir-5q0-955-453-AK
Washer nozzle pass side
5q0-820-741Ac hose
5q0-816-721-AGDischarge hose
4D0-260-749-BOring
3D0-260-749-COring
4e0-260-749-AOring
Hood hinges
8v0-823-301-G (left)
8V0-823-302-G (right)
Release cable - 8V0-823-531-A
Intercooler piping (ecs tuning)
Left - 5q0-145-840
Right- 6c0-145-770-A
Intercooler insulator left - 1k0-121-367-F
Intercooler insulator right - 1K0-121-367-F

Radiator piping
Hose assy- 5q0-122-058-Q
Lower radiator hose - 5q0-122-051AF $71 (aup)
Passenger fog grille 8v3-807-682-k-9B9
Audi logo-8T0-853-605-2ZZ
S3 badge- 8P0-853-736-A-2zz


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[AlaskanAudi]

Reassembly started. I used a big pipe wrench to bend the frame rail mount plate back in place so the new crash bar can mount on. Also used an engine hoist to put the new motor mount back on. After all the coolant lines came in, I was able to fill the system up with water to look for any leaks, before pouring expensive oem coolant inside.

This was finally the time I was able to start the car up and drive it around. I immediately heard some periodic scraping under the car, as if something was stuck in the wheels. After finally getting the car to a garage, I was able to get under the car to see if there was any damage or loose plastic around the wheels/axles that would cause this noise. Unfortunately, it was the prop shaft above the exhaust and below the exhaust tunnel. Currently waiting on that to come in.

This was especially apparent when I accelerated the car to above 45 mph, the car started shaking violently because of the imbalanced prop shaft. I guess when the engine got pushed in, it buckled the prop shaft.




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[bakedcorn]

Looking forward to updates, I love this kind work


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[AlaskanAudi]

Looking forward to updates, I love this kind work


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I know right, it's so rewarding and I haven't had any of the usual headaches with this. I will say though; the previous owner of this car (female) smoke like a chimney and there were countless matches and lighters left between the seats, etc. The interior also smelled like an ashtray. Mind you, there were scuff marks on the back seats, with glitter and greasy small fingerprints in the back, which means kids were also in the car. How you can introduce your young kids to that kind of air is beyond me.

This thread is a bit backdated though, 96% of the work is finished, and I have tons of photos from the project, so I figured I would share em here for you special people . More updates to come!

[AlaskanAudi]

The car is back in one piece!

Installed OEM mudflaps while putting everything else on. Bumper is out for paint now while I am away at work.

A few little things missing still:
Passenger headlight washer
Prop shaft
Lower windshield washer reservoir
Front Audi rings
Fog light grilles
OEM fog lights (retrofit coming soon)
Tint
Black roof wrap

Stay tuned!


Brought out my actual camera for these shots, car is dirty as hell, before it ever got washed. Peep my S4 in the background





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[AlaskanAudi]

It’s been documented before where weird lights start appearing when the battery is old or dead. It was the same case with this car, as the battery was dead and the car sat for a long time. After replacing the battery, the specific lights I had were (can’t remember if there were more now):

TPMS error
Airbag light (which really worried me as the car was clearly in a crash)
Steering angle sensor
Check engine light

As soon as I drove the car around in the new battery, all the lights disappeared. Literally the first two feet of the car moving. I was left with a very nice (although dirty) cluster.

Hope this helps anyone with this issue




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[rdf5186]

Awesome job!!! Thanks for sharing this!!


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[ENV²]

I like how you roll man! You ust gave me the idea of doing something like this. I was considering a rebuilt or salvage car anyway as a track/project.

[AlaskanAudi]

Awesome job!!! Thanks for sharing this!!


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Thank you!


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[AlaskanAudi]

I like how you roll man! You ust gave me the idea of doing something like this. I was considering a rebuilt or salvage car anyway as a track/project.

Doooo it. As well as this went, I’m thinking of buying a salvage R8 or something in the future with the hopes of values going up


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[ENV²]

Doooo it. As well as this went, I’m thinking of buying a salvage R8 or something in the future with the hopes of values going up


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A salvage value wont really climb. I would buy one for my own enjoyment. Especially if gated 6 speed.

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[acase]

I'm in the works of the exact same thing. Bought mine from Copart in Philly a few months ago. What is your enhanced inspection process like with the salvage title in TX?

[AlaskanAudi]

I'm in the works of the exact same thing. Bought mine from Copart in Philly a few months ago. What is your enhanced inspection process like with the salvage title in TX?

It was really weird. I called a place near me ahead of time and made sure they knew this is a salvage vehicle. I brought it in and did an inspection just like any other car. I showed them the receipts and they didnt even wanna see them. Really odd.

Anyway, do you have any pics of your project?

[acase]

Yeah both curtain airbags deployed & all the belts were locked up. Did they pass your inspection without small items like the lower grill covers & stuff? I was told it had to look like it came out of the show room to pass. Not sure if that was your case or not. Were you able to get full coverage with collision after??

It was really weird. I called a place near me ahead of time and made sure they knew this is a salvage vehicle. I brought it in and did an inspection just like any other car. I showed them the receipts and they didnt even wanna see them. Really odd.

Anyway, do you have any pics of your project?

IMG_9458.JPGIMG_9465.jpg




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[AlaskanAudi]

Yeah both curtain airbags deployed & all the belts were locked up. Did they pass your inspection without small items like the lower grill covers & stuff? I was told it had to look like it came out of the show room to pass. Not sure if that was your case or not. Were you able to get full coverage with collision after??



IMG_9458.JPGIMG_9465.jpg


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Looks like a solid project. Undercarriage damage primarily, i assume? I'm jealous that you got the prestige package with the LEDs. Also looks like those northeast salts got to it. Have you ran a carfax on it before purchasing?

And yes, i brought the car just like the photos above, no fog light grilles, unpainted bumper. From my understanding, they're looking for all major components, especially safety stuff; so airbags, belts, body panels, headlights, turn signals, wipers, mirrors, etc. they shouldn't care about random moldings missing as they serve no purpose in terms of safety.
Make sure to keep your receipts with you in the car while you go through the process.

As far as insurance, I used geico with basic coverage, and it was only a few dollars more than my moms clean title 18 S3. i think some insurance companies do provide full cover (from what i've read online) but not all.

[acase]

Interesting, and the damage was not bad at all. The front passenger side knuckle was completely busted, that’s why it was listed as running, not driving. The aux radiator on that side was bent too, but nothing cooling, engine, or drivetrain wise in damaged.

And it was only covered in crap because I trailered it home in a big snow storm the week before the photo. I washed and waxed it since then it looks a lot better now! I’ll post more pictures in this thread as I progress!

Also debating on starting my own YouTube channel on it since I’ve filmed a majority of all the work.


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[AlaskanAudi]

Interesting, and the damage was not bad at all. The front passenger side knuckle was completely busted, that’s why it was listed as running, not driving. The aux radiator on that side was bent too, but nothing cooling, engine, or drivetrain wise in damaged.

And it was only covered in crap because I trailered it home in a big snow storm the week before the photo. I washed and waxed it since then it looks a lot better now! I’ll post more pictures in this thread as I progress!

Also debating on starting my own YouTube channel on it since I’ve filmed a majority of all the work.


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Hell yea, I’ll watch if you do. I love stuff like this! How many miles on the car, any backstory to it?


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[Pete6641]

Awesome dude so entertaining! can't wait to see it all finished up!

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[falcones]

Well done....

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[acase]

IMG_0080.JPGIMG_0088.JPGIMG_0089.JPG

Got the front end torn down last night. Planning on using JB plastic Weld for the core support since it broke off really clean. Plus the price for an OEM one is upwards of $400. Anyone know if the 8V A3 and S3 have I interchangeable intercooler? The part no. Is different but they look identical

[mto925]

I did this with a 04 Jetta GLI back around 2008 and it was a blast. I ended up fixing it for around $2900 total. In PA the do "enhanced inspection" to go from a salvage to rebuilt and I was sure they would find a bunch of stuff. I was pissed when they called and the only thing they said was the tint needed to come off.

[AlaskanAudi]

IMG_0080.JPGIMG_0088.JPGIMG_0089.JPG

Got the front end torn down last night. Planning on using JB plastic Weld for the core support since it broke off really clean. Plus the price for an OEM one is upwards of $400. Anyone know if the 8V A3 and S3 have I interchangeable intercooler? The part no. Is different but they look identical

I bought mine from rock auto. It costs like $79. Although not OEM, everything bolted up perfectly. Plus it’s very much buried under everything else so it’s hard to tell


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[AlaskanAudi]

I did this with a 04 Jetta GLI back around 2008 and it was a blast. I ended up fixing it for around $2900 total. In PA the do "enhanced inspection" to go from a salvage to rebuilt and I was sure they would find a bunch of stuff. I was pissed when they called and the only thing they said was the tint needed to come off.

GLI's aren't what they used to be. I actually just put tint on mine, i'd also be pissed if they tell me to take it off. Got any pics of it???

[mto925]

GLI's aren't what they used to be. I actually just put tint on mine, i'd also be pissed if they tell me to take it off. Got any pics of it???

MK4s, in general, are showing their age but I feel like the GLI, 337, 20ths and R32 of that area made it out much better. Thankfully I did not put the tint on it myself but it was such a dumb thing to ding me for. What was I suppose to do, go over, grab it and drive it back home? Technically it wasn't legally able to be driven at that point so I had to pay for them to remove it and they did a garbage job too. I do actually have a few pictures on my instagram, potato quality from 10 years ago. Unfortunately after I sold it the new owned didn't change the timing belt and it went boom. https://www.instagram.com/p/Bv4OO0mn7Oy/

[AlaskanAudi]

MK4s, in general, are showing their age but I feel like the GLI, 337, 20ths and R32 of that area made it out much better. Thankfully I did not put the tint on it myself but it was such a dumb thing to ding me for. What was I suppose to do, go over, grab it and drive it back home? Technically it wasn't legally able to be driven at that point so I had to pay for them to remove it and they did a garbage job too. I do actually have a few pictures on my instagram, potato quality from 10 years ago. Unfortunately after I sold it the new owned didn't change the timing belt and it went boom. https://www.instagram.com/p/Bv4OO0mn7Oy/

You did a great job with the car. I used to have a 2001 mk4 GTI 1.8T in high school and I was always drooling at the 2004/5 GLIs. I also put on a front mount intercooler and had it peeking out of the grille, touche

[AlaskanAudi]

So I got home from working two weeks out of town and I’m excited as ever for car parts. The elusive fog light grilles was what I was most waiting for. I found these ones in China and I guess there was a misunderstanding....


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[acase]

So I got home from working two weeks out of town and I’m excited as ever for car parts. The elusive fog light grilles was what I was most waiting for. I found these ones in China and I guess there was a misunderstanding....


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OEM Grill & bumper? I’ve been looking at the RS3 grill & bumper from eBay for around $630 unpainted


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[AlaskanAudi]

OEM Grill & bumper? I’ve been looking at the RS3 grill & bumper from eBay for around $630 unpainted


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Oem bumper cover, eBay grille. Got the grill for 190 and the bumper was straight from Audi


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[AlaskanAudi]

Everything is back together. Got the bumper back from paint and the car is once again in one piece. Obviously missing the fog light grilles




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[AlaskanAudi]

As mentioned in previous posts, the car was making a loud banging noise from under the center of the vehicle. I suspected that it was the prop shaft and yesterday I realized why. The prop shaft is two separate pieces, the weird thing was, the rear part was freely spinning and jumping around, not connecting the rear wheels to the engine. I suspect this happened because the car was towed as a FWD car at some point (keeping the rear wheels on the ground and lifting the fronts off the ground). As a result, the rear part of the prop shaft sheared from the front. There are ball bearings in there and they all fell out when I pulled the drive shaft. Let’s just say that if you plan to do this, get access to a car lift because it was very uncomfortable rolling around on the garage floor.

For the mean time, I’m driving around with no prop shaft while I wait for one in the mail and I’m happy to announce that the car doesn’t care whether there’s a drive shaft or not, no faults or warning lights of any kind, and the traction control works as it should on a FWD car. Let it be known that you can mod your car to be FWD if that floats your boat.




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[AlaskanAudi]

I’m still laughing that the front of my car says “QUATTRO” hahaha


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[PINGERS]

Maybe this was covered already, how much are you all in now?

[AlaskanAudi]

Maybe this was covered already, how much are you all in now?

About $17k. Admittedly not the greatest potential profit


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[Dubfound]

Nice! On my previous 2015 S3 I had I rear ended a truck with a trailer hitch going like 10-15mph and had similar damage. No bags went off and it was all cosmetic for the most part. Intercooler, radiator, throttle body we replace and so were the headlamps. All the rest was bumper, hold, grill, bumper support. No fender damage though. The insurace bill was $14k!! Out of curiosity what has it cost you to fix this one back up?

[AlaskanAudi]

Nice! On my previous 2015 S3 I had I rear ended a truck with a trailer hitch going like 10-15mph and had similar damage. No bags went off and it was all cosmetic for the most part. Intercooler, radiator, throttle body we replace and so were the headlamps. All the rest was bumper, hold, grill, bumper support. No fender damage though. The insurace bill was $14k!! Out of curiosity what has it cost you to fix this one back up?

Yikes, that’s hefty! My total parts bill was $5-6k, but I did all the work myself (except for bumper paint), which I assume saved quite a bit of change. Obviously parts weren’t brand new direct from Audi, and I’m assuming yours were?


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[bakedcorn]

As mentioned in previous posts, the car was making a loud banging noise from under the center of the vehicle. I suspected that it was the prop shaft and yesterday I realized why. The prop shaft is two separate pieces, the weird thing was, the rear part was freely spinning and jumping around, not connecting the rear wheels to the engine. I suspect this happened because the car was towed as a FWD car at some point (keeping the rear wheels on the ground and lifting the fronts off the ground). As a result, the rear part of the prop shaft sheared from the front. There are ball bearings in there and they all fell out when I pulled the drive shaft. Let’s just say that if you plan to do this, get access to a car lift because it was very uncomfortable rolling around on the garage floor.

For the mean time, I’m driving around with no prop shaft while I wait for one in the mail and I’m happy to announce that the car doesn’t care whether there’s a drive shaft or not, no faults or warning lights of any kind, and the traction control works as it should on a FWD car. Let it be known that you can mod your car to be FWD if that floats your boat.




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I get the impression that these vehicles can be towed from the rear not that I’d be the lab rat to prove that theory, lol.
Kudos to see you work through this project and how it’s turning out. Given the pics the lines look pretty clean.
What’s your impression on parts removal from this car compared to others? I know my Acura was a complete pain in the ass to even remove the battery.

Looking forward to seeing the entire package and price breakdown for this work


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[bakedcorn]

Nice! On my previous 2015 S3 I had I rear ended a truck with a trailer hitch going like 10-15mph and had similar damage. No bags went off and it was all cosmetic for the most part. Intercooler, radiator, throttle body we replace and so were the headlamps. All the rest was bumper, hold, grill, bumper support. No fender damage though. The insurace bill was $14k!! Out of curiosity what has it cost you to fix this one back up?

Yep, something similar on my end with the wife’s A3, all cosmetic but the final price was around 7k for a new bumper, grill, drivers headlamp, rad support and some paint work on the bumper (s-line).
I believe the parts were roughly 2.7k and the rest labour and paint etc.


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[AlaskanAudi]

I get the impression that these vehicles can be towed from the rear not that I’d be the lab rat to prove that theory, lol.
Kudos to see you work through this project and how it’s turning out. Given the pics the lines look pretty clean.
What’s your impression on parts removal from this car compared to others? I know my Acura was a complete pain in the ass to even remove the battery.

Looking forward to seeing the entire package and price breakdown for this work


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Thank you! It’s been a journey for sure.

And based on what I’ve seen with this prop shaft, I would absolutely recommend against having your car towed with the back wheels on the ground.

Speaking of prop shafts, my car is back to “Quattro” status.



And now that the project is complete, it was time to get rid of the boxes. A homeless man could build himself quite the mansion out of these.




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