Help Needed,TDI wont run properly!!!

Hi All, this is my first post so hello to all!

Im really hoping that someone maybe able to shed some light as to my problem.

I found my Mum a nice 2004 A2 TDI done 64,000 with full history. For the first year it has been good as gold and she loves it, but last summer time around august it started to run very rough.

She had filled the car up as normal and used it though the week, she does very little miles to probably only 30-40 during the week, which it ran fine on. Then she made a trip to Gatwick (about 45 miles from us) and on the way up (30 miles or so into the trip) she said it started to make a funny noise and also lose some power and feel alot of vibration through the car and gear stick, unfortunatly she continued there and back with it running like this, she said it seemed to get worse (but not a great deal) by the time she was back.

I went and had a look and it sounded like the car was running a cylinder down, so having only 3 to start with made it sound pretty rough, it also caused alot of vibration through the engine and you could see it moving around and this is also felt through the gear stick.

We took it to our Mechanic and he had found that there was petrol in the system even though we have no idea of how it got there as even traced back the last time it was filled up and that was with deisel.Because it was found with petrol running through it the injectors were thought to be the problem, they were sent away and tested and were all found to be 30% down so we had the injectors changed (best part of £750!!!) but it has made little to no difference, we then have also tried another pump (as this was suggested as a problem area if petrol had gone through it) from another A2 TDI and this made no difference, the car has even gone to Audi (not the main door but a friend) on there diagnositcs and they cannot find anything out either and their only suggestion weas to start replacing parts (which is not what we wanted to do as the cost would of been massive!), everything elcetric has been checked over and all the sensor's has been tested and belived to be ok.

The Turbo also seems to be fine with little play, but it was suggested they had a funny set up on them with the veins and the way they work but this all seems to be ok.

It has now been going on for over 8 months and we just dont know what to do, the car will start first time everytime and will also drive but just sounds like a bag of nails and lacks power!

We have spent over £1000 on it and still have no idea so are getting to the point that we either cut out loses and get what we can for it or maybe buy another engine and hope that this will solve the problem.But the last thing we want to do is fit another engine and then it be the same!

The engine code is bhc if that makes any difference.

Because there are not many of the cars my mechanic is having trouble finding anyone with any experience with them.

Please please can anyone suggest anything or have had a similar thing happen.

We just dont know what to do?
 
Hi and welcome to the A2oc
Not sure if its the cause of your problem but a couple of club members have had issues with faulty injector wiring looms which can cause intermittent misfires. The wiring loom runs through galleries inside the cylinder head and costs about £40 for the part.
Let us know how you get on

Cheers Spike
 
Hi Spike

Thanks for the reply, i did read that on a few other treads, have not had a chance to let my mechanic know yet but he did seem to know this early on when he had it and did check it all and said it was all ok but for the sake of £40 i am going to suggest he change it just to see what happens.

Anyone else have any suggestions?

Regards

Mark
 
You say there was petrol in the system, so I guess the obvious question is; was the tank and fuel system drained to get rid of it all? You don't say it has been, and contaminated fuel could easily explain it. Could there be some petrol floating on top of the diesel in the tank, that's still there after 8 months because it's always in the last few litres when it gets filled up? If so, the symptoms could be worse when the fuel runs low. A bit of a shot in the dark, but worth eliminating, and low cost.

Also, did you take it up with the garage that sold the fuel? Surely they should be covering the cost of fixing it.
 
The whole system and tank has been drained before the new injectors were fitted and it still runs the same.

We are now getting to the point where the head is going to come off as the noise seems very top end, but if the head comes off then we will be past the point of no return!

Hopefully there will be something obvious wrong with the head and then we can go from there but if there is nothing to be seen then i think we will go down the route of just changing the engine!

The Engine is a BHC code which seems to be less common and so have not had much luck on ebay and the net.

Does anyone know where i might get an Engine, any good breakers? Or anywhere that will have a recon head incase we can see that it is the head.

Does anyone know the difference between the engine codes, can a head from another engine or another engine be used or are all the electrics different?

Any help would be appreciated as this is turning into a real headache!

Regards

Mark
 
Hi there
i had a similar problem and the engine was running very rough
and i had the injector wiring harness changed

thi fixed the problem i woul recommend you do the same
as it sounds pretty much the same problem i had the wiring harness
costs around£40
 
hmm.... Sorry to hear your first go with an Audi's not a good one!
When the injectors were fitted, were they installed correctly? Just asking as they must be set at an installation angle measured from the front of the cylinder head, they also need their rocker's setting up for correct clearance. If either of these is wrong then you can have issue with fuel delivery.
Also, the pump you said you tried, was it the tandem pump (the big alloy on the back of the head)? These dont like petrol either!

Failing that, check to see if the engine is using any coolant. I have had a few cases where the 3-pot heads can grow a hairline crack in the inlet port that allows coolant into the combustion chamber. Very difficult to spot as no gases get back into the coolant and nor does any oil! If you get stuck and need help I am happy to give you my nukber for advise. If I can help I will - I dont have an A2 but I do a lot of them!
 
I'd say the prime candidates would be a cracked injector wiring loom, or possibly a split intercooler?

By the way if you're interested the "funny vanes" on the turbo - that sounds like the 90PS engine, which has a "variable geometry turbo" - clever stuff to allow the turbo to produce more boost at lower revs.
 
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