BHC tdi - Rebuild ( GULP ! ) Anyone done it ?

A2tdifan

A2OC Donor
Hello everyone,
Im new to the A2oc and have come here from the UKtdi website. Im changing from Golf tdi to my A2 tdi ( as soon as ive rebuilt it )
Purchased my 1 owner A2 a few weeks ago which had been standing since February, apparently needing a new engine.
One of the Bosch glow plug tips had dropped off, putting a hole through the exhaust valve. It also nibbled the crown edges of the middle piston.
HeadGlow.jpg

Me being the ever enthusiast decided, Have the head sorted, remove the sump, replace the piston, and Bobs ya uncle !
So, I bought it,
Blimey was I so wrong,
I never knew there was a balance shaft, Never thought I may have to have the engine out and possibly remove the front end.
I used to have ElsaWin some years ago, so decided I had better purchase an upto date version for Audi, but even that makes it look harder than it probably is.
Ive spoken to a few engine rebuild companies, but got that ( do I trust they're gonna do it right feeling )
So here I am, asking for any advice ( BEGGING FOR !! )
This is where I am.
Ive got a decent head.
Got a decent used piston
Purchased Head gasket, Head set, New bolts, Cam bearing shells, Con rod shells, Piston Rings, Cam belt etc.

As I am replacing the No2 piston, ( and thankfully the bore is good ) I decided to renew all 3 pistons rings, along with the Sputter shells ( may add a chain, as I think its advisable )
When I removed the camshaft, the shells looked slightly worn so decided to replace them too.
If anyone out there has taken on such a job, Id love any advice you may have on things to look out for.
Cheers for now !
Win A2tdifan
 
Last edited:
Spike,
Thanks for the ups on Davids post.
Its the balance shaft assembly that was puzzling me a bit. Getting the sump off seems pretty straight forward as long as you use the correct extra long (9") 6mm ball end hex, for the 2 bolts up in the fly wheel area. ( I know there are 2 windows that give access to these sods at an iffy angle )
I need to get the Balance shaft frame off to get to the conrods, as im replacing piston 2 and putting new rings on all 3, followed by new shells in the conrods, along with a new chain for the pump etc.
Im gonna try and do a photo step by step of the mission, in case someone else needs to do a similar job.
Cheers again,
Win
 
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