Stubborn AUA engine fitted to a 1.4 petrol BBY car refuses to start

[rotifer II]

The vehicle is being shipped from Coventry to Huddersfield and will arrive on Monday, December 2, 2024.
The car is described as being spotless on the inside and out, and it passed all MOTs prior to 2017. However, it did not receive another one until 2023. Both the car and the used AUA engine have a complete service history.

15 August 2023 MOT​

Repair as soon as possible

• Front Outer Drive shaft joint constant velocity boot severely deteriorated Both Sides (6.1.7 (g) (i))
• Front Suspension arm ball joint dust cover severely deteriorated Both Sides (5.3.4 (b) (i))

Monitor

• Nearside the Anti-roll bar ball joint has slight play (5.3.4 (a) (i))
• Nearside Front Play in steering rack inner joint(s)

MOT 26th October 2017​

Advisory

• Rear Direction indicators slightly discoloured (1.4.A.2f)
• Nearside Front Anti-roll bar linkage has slight play in a ball joint (2.4.G.2)
• centre rear exhaust clamp broken
• Nearside Front Play in steering rack inner joint(s)
• Offside Front Suspension arm ball joint dust cover damaged, but preventing the ingress of dirt (2.4.G.2)
• Nearside Front Suspension arm ball joint dust cover damaged, but preventing the ingress of dirt (2.4.G.2)

The vehicle received a number of advisories in 2017, most pertaining to the running gear, some of which were carried over to the 2023 MOT.

This historic thread has been used to discuss the car.
Injectors wont fire; no signal

The things I took away from that discussion are as follows.

Fuel	Air	Electric
Tank: cleaned	Compression test 135 lbs	ECU/Immobiliser
Filter - new	Evap-canister solenoid	REV counter
Injectors—spraying ok		Crank Sensor - new
Fuel: new (2023?)		Fuse 18, 20 - ok
		VCDS - stored misfires
		Wiring Harnes not checked
		VCDS - J285 comms
		Earth, cam cover, ok
		Earth starter motor, ok
		Coil Packs: new
		Ignition Barrel
		Spark plugs: new
		Injectors—ok
		Crank sensor, new
Fuel checks​	Air checks​	Electric checks​
4​	2​	13​

Do you know why this vehicle will not start?

• One tooth out of the timing belt
• camshaft sensor
• The oil filler tube cracked.
• AUA components installed on a BBY

Given that it passed the MOT, it must have run in 2023 to pass an emissions test.

 

[Little Dog]

Start by putting fresh fuel in it a build up from there.

Shame the collapsible spare wheel has gone.

 

[PlasticMac]

I spent ages on this, with Azim, on WhatsApp, but the conversation stopped when his cloned VCDS crashed, neverf to work again.
Sadly all the conversation is now dissapeared, as he has time limited settings on his messages.
Start with a scan, that's where we left off. Can't remember the DTC we were following up, related to ignition switch, maybe. Hopefully, it's still there.
It went well past fresh fuel, believe me.
Mac.

 

[rotifer II]

Hello @PlasticMac,
Just the single 01206 VCDS DTC and an illuminated EPC light displayed on the dashboard were spoken about in the previous thread.

01206 - Signal for Duration of Ignition Off Time​

Possible Causes​

• Ignition Switch faulty
• Wiring between Instrument Cluster (J285) and Climatronic Control (J255) faulty
• Instrument Cluster (J285) faulty
• Climatronic Control (J255) faulty

Possible Solutions​

• Check Ignition Switch
• Check Wiring between Instrument Cluster (J285) and Climatronic Control (J255)
• Check Instrument Cluster (J285)
• Check Climatronic Control (J255)

Special Notes​

• If this fault doesn't clear with the key on and the engine off, try clearing it while the engine is running.

Let's hope the wires in the dash are not damaged.

 

[PlasticMac]

The original engine was a BBY. The current engine is an AUA with several parts from a BBY, including coil packs, fuel rail, (I think), to make it compatible with the BBY ECU and wiring.
Mac.

 

[rotifer II]

Hi @PlasticMac
The block, sump, cylinder head, and camshaft cover of the AUA engine have been mixed with the BBY auxiliary parts. It remains to be seen if the blending process was carried out successfully. It was more serious than that the the cars engine was a non runner due to catastrophic piston and bore damage

 

[PlasticMac]

Hello @PlasticMac,
The car was showing an EPC fault on the dashboard and a single VCDS DTC.

01206 - Signal for Duration of Ignition Off Time​

Possible Causes​

• Ignition Switch faulty
• Wiring between Instrument Cluster (J285) and Climatronic Control (J255) faulty
• Instrument Cluster (J285) faulty
• Climatronic Control (J255) faulty

Possible Solutions​

• Check Ignition Switch
• Check Wiring between Instrument Cluster (J285) and Climatronic Control (J255)
• Check Instrument Cluster (J285)
• Check Climatronic Control (J255)

Special Notes​

• If this fault won't clear with key on, engine off, try clearing it while the engine is running.

Let's hope the electics in the dash are not damaged.

Because the engine hasn't run in a while, and DTCs have been cleared previously, there won't be any engine related DTCs, until it runs. Chicken and egg.
Mac.

 

[Little Dog]

I still say put fresh fuel in and take it from there. There could be absolutely nothing wrong with it.

 

[Howey]

Reading the previous linked thread it would seem the spark plug being changed has generated a non start situation. This would be my first check along with fuses and anything that potentially could have been connected incorrectly during the engine change. Years since I have worked on these petrol engines so very rusty myself. Hopefully it's something silly!

 

[rotifer II]

Thank you very much for the excellent recommendations. Since there will not be a working battery in the car, I will start by fitting a new one before running a VCDS scan.
Once the new plugs are out of the way, I can take some new compression readings and check for spark.
Prior to replacing the old fuel with new, I would like to inspect the newly installed fuel pump and check the tank for debris.

 

[rotifer II]

Links​

If you're experiencing similar engine issues, please attempt to get the error codes using VCDS. Click on the links provided above the image of the old computer if you are unable to access a diagnostic tool.​

• Print out post #2
• List of checks @ end of post #1

EDIT (02/12/24)
@PlasticMac has provided a printable document of the 1.4 petrol VCDS label file below.
EDIT (05/12/24) thanks, @Andrew
Do not upload this label file to VCDS (use Mac's one below)
I have condensed the document from 8 to 6 pages if folk would like to print it off for reference.

EDIT II (02/12/24)
uploaded the 1.4 engine parts checklist in PDF format.

EDIT III (02/12/24)
I have finally completed getting the diagnostic paperwork ready.

 

[PlasticMac]

Until the engine runs, there will no engine DTCs, they were cleared long ago, and the engine hasn't run since.
Get the biggest battery you can find, to allow an extended cranking session.
Connect VCDS, and log Groups 002, 003, & 004, while cranking. You will then see what's happening while it's cranking, which may give you a clue as to why it doesn't start.
There are other groups that might help too, but I'd start with those.
I've attached a PDF of the APE label file, (used for AUA and BBY), so you can see what each groups monitors, and choose groups that you think might help identify the problem.
Mac.

 

[rotifer II]

Hi @PlasticMac,
Excellent information; many thanks for sharing it. I printed it off after saving it to the computer. ⁣⁣
Rosstech has developed a webpage that explains the functions of label files. Would you kindly assist me with this query? The document you mentioned above was obtained from where?

NOTE:
I was unable to locate the 1.4 petrol APE label file when I searched on Google, but I did find the FSI label file.

 

[PlasticMac]

Hi @PlasticMac,
Great stuff, thanks for the information. Saved it to the PC and printed off
Rosstech has created a webpage that describes what label files accomplish. Could you please help me out with this question? Where did you get the document that you mentioned above?


EDIT
When searching A2OC in Google I found the FSI Label file but not the 1.4 petrol APE label file.

The FSI label file was created by A2OC because there was no label file compatible with the FSI engine. All other A2 engine options are already in the Label folder of VCDS on your laptop.
Those that have the .lbl suffix, like the APE, can be opened as a txt file, which is what I did to give you the pdf.
Later label file, with a .cbl suffix are encrypted.
Mac.

 

[PlasticMac]

When you use Measuring Blocks, you'll see the name of the label file being used, top left.
Just look for that file in the Label folder, make a copy, save it, rename it as .txt, and Bob's your Mother's Brother.
Mac.
Edit: Only works for .lbl files, (which all Lite labels are).
Later label files, in Full VCDS are usually encrypted.
I've also posted A2 specific HVAC and Instrument label files.

 

[Andrew]

Links​

If you are reading this and have similar engine troubles, please try to get those error codes read. But if a diagnostic tool is not available, the thread below provides a list of perishable engine parts to check.​

• Print out post #2
• List of checks @ end of post #1

View attachment 132296

EDIT (02/12/24)
@PlasticMac has provided a printable document of the 1.4 petrol VCDS label file below.
I have condensed the document from 8 to 6 pages if you would like to print it off.

EDIT II (02/12/24)
Uploded the PDF list of 1.4 engine parts check list

EDIT III (02/12/24)
Finally finished preparing the necessary documents for diagnosis.
View attachment 132300

Good Afternoon,

In your label file attachment the double semi-colon that top of Group 001 needs removing or the heading text will not display or possibly worse.

Andy

 

[PlasticMac]

You

Good Afternoon,

In your label file attachment the double semi-colon that top of Group 001 needs removing or the heading text will not display or possibly worse.

Andy

@rotifer II
Also, I'd omit Group 001, as the data it provides is not really relavant to starting, (coolant temperature, Lambda etc).
Groups 002 & 003 are, I think, and, perhaps 010?
The data from the first cranking log, may well hint at what to look at next
Mac.

 

[Robin_Cox]

I've tried reading this from the top several times to a answer question arising from what I've read, and I can't see the info required to clarify this point.

[Removed text as it wasn't adding anything to the discussion and could have caused confusion]

Edited to add - having read down the pages of the earlier thread on this vehicle the question had been asked long ago .. bit late to the party!

 

[PlasticMac]

When I was in contact with the original owner, I believe the engine is an AUA, with BBY parts, including, (but not only), the coil packs and fuel rail, (I assumed from the original BBY). The car originally had a BBY engine from new, and the BBY loom and ECU were still present and in use.
Mac.

 

[rotifer II]

This vehicle has a BBY harness and coils.



I am not positive, but I think the engine is an AUA.