How much damage could an undershield cause if it came adrift at 65mph? (Read & weep!)

Jeff Sutcliffe

A2OC Donor
Hello All,

I'm a new A2 owner, having picked up my 2001 TDI 75 SE only on 1st April this year. Although there was no service history, the car was reasonably priced and drove better than I'd expected; it is also remarkably dent free with an almost unworn interior (apart from the driver's electric window switch) despite having covered almost 127,000 miles.

The car's MOT certificate was due to expire on 19th April and so, on 2nd April I took the car to a local Audi specialist that I'd read of on this forum to have it MOT'd, serviced and fitted with a new cambelt and water pump (better safe than sorry!) - I'd arranged this in advance as I'd bought the car several days before I collected it. I waited at the garage whilst the car was taken to the MOT test centre that the garage uses so that I'd be aware of any other work that proved necessary. In the event, the car only needed new tyres, which I'd anticipated, and, because the handbrake was ineffective, new brake shoes (which the helpful private seller had left in the boot.)

It was agreed that I'd take the car to have its new tyres fitted and then return it for the garage to fit the brake shoes, carry out the service and change the cambelt and water pump before taking it for re-test.

I had four new tyres fitted on 3rd April and then dropped my car off at the specialist on 4th April. I collected the car on 7th April, the garage having carried out the work as requested and also refitted a heat shield which had been in the boot when I bought the car and fitted a new clip to a CV joint (I think they said) which had had one missing. The car seemed quieter than when I'd dropped it off on the previous Friday and drove without incident for the first 7 miles of my 10 miles journey home.

At the 7 miles point, on a National speed limit dual carriageway where I was travelling at about 65 mph, it seemed that I'd driven over an object in the road. There was a 'graunching' noise from the nearside front wheel arch area followed by a sound as though the car was driving over something below the floorpan. I saw nothing via the rear view mirrors and was unable to stop to look for evidence on the busy, fast-moving road and so continued home, where I examined the car to look for any sign of impact/damage. There was nothing untoward and so I put the 'incident' down to having possibly run over, say, a cardboard box that I'd somehow not seen.

On the following day, I drove the car locally for around 10 miles, feeling quite pleased that it now had over a year's MOT and was serviced and unlikely to need any major work for several thousand miles.

However......on the morning of 9th April, I went to the car and noticed that there was a patch of oil underneath it, along with a line of oil drips marking the path I'd taken when reversing into the parking slot in the dark on the previous evening. I attempted to open the inspection flap in order to check how much oil remained in the sump but wasn't able to do so - I've since been shown the trick of putting a piece of folded paper into the space at the top of the flap before pulling the release handle - and so rang the specialist garage and agreed to drive there so that the source of the oil leak could be identified. I was reassured that the oil warning light would come on if the level became dangerously low.

After about 4 miles of the journey to the garage, as I travelled downhill on the same stretch of dual carriageway where the 'cardboard box incident' had occured, the engine note changed and, when setting off uphill from the next junction, it was obvious that the turbo had 'blown'. I made it to the garage anyway and left the car to be examined.

I received a 'phone call from the garage on the afternoon of 14th April, confirming that I needed a rebuilt turbo and asking me to take £350 + VAT to the garage before 4.00 pm so that the cash could be banked and the part ordered. (I assume there were cash flow problems rather than a lack of trust in me as I'd paid the £670 for the MOT and cambelt etc after the work had been carried out.

When I was at the garage delivering the cash, I was told that the cause of the oil leak was that a set screw had come out of an oil gallery (where an oil pressure gauge could be fitted if required) that was hidden behind the cambelt cover. I was shown the (damaged) offending set screw along with a bottom (crankshaft?) pulley that had a chunk missing, caused by the aforementioned set screw and also damage to the new cambelt and the cover of the oil pump - these would also need replacing.

I authorised the work and subsequently was telephoned to say that the car, along with a bill for just over £600 - a price discounted by over £300 - would be ready for collection at 5.00 pm on 17th April.

In the event, when I arrived at the garage, the work hadn't been completed and so I 'hung around' in the workshop whilst the proprietor and his mechanic finished off the job. As my car was up in the air on a ramp for some of the time, I took the opportunity to have a look at its underside, which I hadn't done pre-purchase or at any stage before that moment. I immediately noticed that the rearwards facing edge of the front bib - below the bumper/spotlights - was 'rough'; there were screws through the metal that weren't attached to anything and the edge would best be described as 'tatty'. I asked the proprietor about this and he told me that Audis have an undershield but that my car's had been taken off at some point.

The work on my car was completed by about 7.00 pm and, after the proprietor had driven it around the block to make sure all was well, I was able to set off for home, the proprietor saying that I should take the car back early this week so it could be checked after having so much work done to it. I did notice, before I got into the car, that it seemed noisier than I'd remembered, but put that down to not having driven it for a week or so.

Since then, the car has performed perfectly, I have driven about 100 miles, including approximately 70 miles of fast motorway work, and it seems that I'm back in the position of having a car that I'll be able to drive for several thousand miles without any major work being required - albeit over £1000 poorer than I'd expected to be!

However, after searching these forums (fori?) for information about the undershield that ought to be on my car, and particularly Sarge's guide to its removal with his comment that it includes sound insulation on diesel models, I had a 'lightbulb' moment that made me think that the 'cardboard box incident' after the service/cambelt work, might in fact have been the sound of my undershield coming adrift - possibly because it had been insecurely refitted after the cambelt change - which would explain why the car had sounded noisier when I collected it after the turbo/oil pump etc job.

Would any reader like to comment on my speculation and also, assuming I am correct, whether the cause of the oil leak and the consequential damage might have been attributable to the demise of the undershield rather than simply an unfortunate coincidence.

As I said, I'm due to take my car back to be checked over in the next couple of days, so I'd like to be in a position to offer other members' opinions to the proprietor if that's appropriate.

Thank you in advance for any replies (and I hope you all had a happy Easter break with your A2s.)

Jeff
 
Hi Jeff,

Sorry to hear of your bad luck, it seems it could be possible but you would need to prove this is the case,I am no mechanic but some other expert members may reply soon,hope all goes well.

Regards
Colin
 
Would any reader like to comment on my speculation. I'd like to be in a position to offer other members' opinions to the proprietor if that's appropriate.
Thank you in advance for any replies (and I hope you all had a happy Easter break with your A2s.)

Welcome to A2OC, and a happy easter to you too.

The fixings on the undertray are known to be flimsy and prone to failure as was discussed on the forum recently by members in mainland Europe ( Bret & JohnL) who drive on harsh winter roads ( in some cases having to replace the undertray several times).

You have done your homework I see and have quoted Sarge's 'how to'.

I had my service done last year by Sarge and he is meticulous about every nut, bolt and clip on the car being OE spec. The Audi dealer he buys his parts from poke gentle fun at him where he is affectionately dubbed 'restoration man' ( or something like that) He replaced many of the non-original self tappers and a couple of missing fixings on my undertray at the time of the service.

When I had the gearbox oil replaced last week locally, the mechanic noticed one of the fixings was missing on the undertray, so this was replaced using some improvisation.

My point here is, that if a fixing comes away after being in the safe hands of someone like Sarge - it's either because of a flimsy design or some impact damage has occurred since last October when the service was done.

Unfortunately, I think you may have to notch this one up to experience, as its almost impossible to suggest that the tray wasn't correctly replaced by the garage doing your cambelt and servicing work. The timing is very coincidental - that's a given; but equally you stated the underside of the bumper was rough - therefore the undertray may have been missing or in pretty poor shape anyway? Plus you said you hadn't given the underbody of the car any inspection prior to purchase or having the work carried out.

Maybe the one thing you would have some argument over would be why you wouldn't be advised of this if the garage had to improvise some fixings to relocate the tray when they worked on it, or if the part had been in poor condition. You'd expect an advisory on that from a thorough mechanic?

Good luck with everything.
 
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Thanks Murdo,

I appreciate your comments and good wishes. The specialist never even mentioned that the undershield was missing when I collected my car after the cambelt/service work, let alone give an advisory on the point; his only reference to its being a standard part that was missing from my car was after my question about the state of the underside of the bumper when I was looking under the car whilst he finished the turbo job - hence my suspicion that it had disappeared during the two days between my visits to him.

But, as you remark, I'd never be able to prove that there was an undertray on my car when I first took it there. It looks as though I'll just have to put it down to experience and buy a new one and fitting kit from the main dealer to get my car back to OE spec. From my research on the forum it seems that the cost will be about £100 so not too costly in the scheme of things, especially if I can fit it myself using Sarge's 'how to' guide.

And, despite the set back, I'm still delighted with the car. It's hard to believe it's 13 years old given the way it performs and looks. My only planned 'improvement' so far is an A2 personalised plate so it can fool its admirers!
 
Thanks for your sympathetic reply Colin.

As you'll see, one of the experts has replied and he thinks it'd be impossible to prove my suspicion.

As somebody once said, "if it wasn't for bad luck, I wouldn't have any!"
 
The undertray has 'legs' which project up into the front wheel arches. These are taller than the car's ground clearance so I believe that if the tray had dropped down it would wedge under the car and have been dragged along for a considerable distance before being ground away and eventually breaking up. On this basis, it's likely there was no undertray on the car

As indicated you can't prove the case either way but if my theory is right, it's is one less thing to fret about.

Cheers Spike
 
... except that the tray keeps the plastic inner arches apart and the front bumper from waggling, so I'd consider it a matter of priority to get it replaced. Not an emergency, but get it done sooner rather than later.

And yes, I'm agreeing that it would not be un-obvious were you to lose this during a drive.

- Bret
 
Hi Jeff

I found my undertray held by three cable ties at the rear - someone had actually prized-out the snap-in rectangular shaped threaded 'nuts' (for want of a better description) to get the ties in. The raised leg sections that Spike and Bret mention are not bolted in on mine as both sides are broken around the mounting hole + the bolt on one side has the nut seized and the other side the bolt is loose (just turns).
I suspect many A2's are in a similar condition!
Fixing the legs is a job I intend to tackle soon, I'm just pondering on the best way to do it.

I hope this hasn't tainted your brief ownership too much - they are very good cars once sorted.

Kevin
 
Hi Kevin,

Thanks for your input. It appears that I've just been unlucky as far as the oil leak/turbo failure/oil pump damage saga was concerned and the undertray is simply something I need to get sorted asap.

I've not been put off the car at all. It's perfect for my twice daily trips to take my non-driving wife to work and back (200 miles per week) and, simply on fuel and servicing cost savings, even including the unexpected early repair costs, it'll pay for itself in about two years; I've been driving a 3.9 litre V8 Land Rover Discovery for the past couple of years and, even though it runs on LPG, I've been spending £70 a week on commuting fuel - which I expect will reduce considerably!

Jeff
 
Thanks Bret,

I'll be ordering a replacement undertray and fitting kit as soon as the main dealer's parts department re-opens after the Easter break.
 
Thanks Spike,

I've been humbled by the number of replies on a Sunday evening; it says a lot about the membership.

It might have been that the tray had dropped earlier than when I actually heard the graunching noises as I was listening to the radio at fairly high volume (Simon Mayo on Radio 2!) and travelling quite rapidly uphill to the point when I heard it, but, as you say, I'd never be able to prove what actually happened.

I won't fret about it; I'm looking forward to many years of happy A2 driving now that it's had so many replacement parts!

Jeff
 
The undertray seems to be prone to breaking where each "arm" of it is and the front centre/front half and the wheel arch extensions seem fairly solid.
I suspect that the back becoming loose would not rip the rest of the undertray off.

Certainly from mine that have been destroyed the rear is the weakest section.

I have found that typically the dealers are a bit slack in bolting the under wheel arch sections back in. I suspect that it is because it is awkward to access when compared to the under car fixings. Unless the wheel is removed the fixing is not the easiest to get to!

John
 
Just a quick update on my saga! I picked up my new undertray (pics below) from Blackburn Audi yesterday (along with a new -full length - dipstick and two wheel centre caps) and took it to a different local VAG specialist this morning to have it fitted. I told the mechanic who was working on my car about my experiences with it to date and he was genuinely baffled by the explanation given to me by the original Audi specialist about the bolt/set screw that had come out of the block and caused the oil leak which led to the turbo failure; he said he was unaware of any such bolt/set screw. Does anyone here have any knowledge of it?

He then called me over to the car and pointed out that the offside bottom engine mounting bolt was missing - presumably having been left out by the original specialist after carrying out the cambelt/water pump/turbo etc. work - and, that the turbo did not appear to be a re-conditioned one - on the basis that the case was not as clean/polished as would be expected after only two weeks and that it had rust on the external cover.

I've brought my car home as there is no point in having the undertray fitted at this stage and am going back on Thursday to have the engine mounting bolt replaced (the garage didn't have one in stock) and the undertray then fitted.

And, since they currently have an 'offer' on re-mapping, I'm getting that done at the same time!

It looks as though my attempt to cut my motoring costs by buying the A2 (as with reducing my fatty food intake!) is another of those good intentions that fell by the wayside!!!
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Jeff
 
Hi Jeff. Hope it all goes Ok for you. It does sound like the repairs done to your car were not up to scratch. If they have put on a used turbo from a breaker or similar, but have sold you the part as reconditioned surely you could seek recourse for this unless you'd prefer to notch it to experience for a quiet life!

Ref your new undertray - it looks a bit different from the one on my TDi. Same shape etc so it's definitely right, but the underside of mine has some grey foam type sound deadening material on it. Maybe worth checking this out or perhaps a member with access to ETKA can confirm?

Hope the costs have plateaued and you now have a super reliable car to enjoy.
 
The under tray looks to me as being a petrol one -as they don't have the sound deadening. Cheers Mike
 
Thanks Murdo,

I was surprised that there wasn't any sound deadening material on the undertray too. I'd looked at a second hand one that was for sale on ebay before ordering the new one and that, like yours, did have them. The parts chap at Blackburn Audi took my chassis number before ordering the new undertray so I must assume it's the right one.

I'm sure that you're right about having recourse to the original 'specialist' regarding the turbo (and the missing engine mounting bolt) but, at least for now, I'll put it down to experience rather than get into an argument. I was assured that the turbo was guaranteed for two years and have the invoice so could always change my mind if there's a problem with it in the future. I'll try to get a picture of the turbo on Thursday so that I have evidence of its current condition, just in case there is a Court case.

As for my spending - these brand spanking new A3 15" 'five hole' wheels were too much of a bargain to miss last Friday (but at least I can wait a few months before I buy the winter tyres for them!)

$_12.JPG
 
Hi Jeff,

Sorry you've had bad experiences so far - but to confirm, it appears Blackburn Audi have either ordered the wrong undertray, or it's incorrectly labelled.

The parts are as follows:

Petrol - 8Z0 825 235 E - Approx. £90 inc VAT
Diesel - 8Z0 825 235 F - Approx. £118 inc VAT

Sorry for more annoying news.

Cheers

Jeff
 
Hi Jeff did you confirm that those wheels are 5X100MM PCD as they look like a more modern design and be 5x112mm PCD. I hope I wrong. Cheers mike
 
Thanks Jeff,

I've arranged to return the 8Z0 825 235 E to Blackburn Audi in the morning and they've now ordered a 8Z0 825 235 F for me, which I can collect at 9.00 am on Thursday so that I can get it fitted that day as originally arranged. That wasn't annoying at all compared with my earlier experiences!

Cheers,

Jeff
 
If it helps with costs, the threaded slip-on nuts that another poster earlier referred to are more commonly called "Spire Clips", when my local garage couldn't refit my tray because they had lost the screws I went into a nearby fastener shop and bought a small selection with the appropriate self-tappers, worked out at about £1 for 10 of each. I fitted them myself and they never budge...until a "trained mechanic" takes the tray off and doesn't refit them. I keep hoping that one day I will find a garage that doesn't let me down or treat me like a fool. I have the wife for that job.
 
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