TDi 75 AMF coolant leak from hoses tandem vacuum/fuel pump seals?

D

Deleted member 16918

Guest
Interesting bodge on your fuel filter. Looking around on the internet for my own, I noticed that a lot of modern filters have no drain plug. Perhaps just shoving silicone sealant into the drain hole for an airtight seal is perfectly acceptable?
BTW we are both using Mannol 5 30.
 
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froggy

Member
We must be due an update on progress now?
You are indeed @audifan. The car is still at the garage. After fitting the replacement drain screw and bleeding the fuel through properly, the little A2 fired up on the first turn of the key and even better, all of the work I had carried out passed with flying colours - no leaks whatsoever - thank you a2oc!!

Unfortunately that is where the good news ends and we move on to the bad. After 10 minutes idling, she dropped onto 2 cylinders. A scan showed the typical TDi injector wiring harness issue. In my haste over the weekend I sourced a used loom from the incredibly helpful @Clackers without considering my mechanic who is not happy at all about using old parts. He reluctantly agreed to fit it, but after a lengthy discussion about possibly doing the job twice, we decided to go the darkside developments route and ordered a new loom. It is very possible the connections to the injectors have simply come loose and after my tandem pump experience I felt confident about tackling this myself. Without a garage and winter weather on the way, for the sake of an hour or so labour I gave him the go ahead to do this for me, hopefully by Wednesday. My battery is shot (probably killed it trying to prime the fuel system) so a new one from Tayna batteries (thanks again @Clackers) has been ordered.

On top of this we had combustion gases in the engine bay. My money was on the dodgy looking egr, however it turned out to be a hole in the exhaust flexi. Thanks to @depronman excellent fix for this, a new flexi and 50mm joiner will arrive today or tomorrow. Just need to find a welder to get that job sorted. Weighing up wether or not to still do a smoke test 🤔

The suspension as expected is in a terrible mess. Front driver side top mount and shocker are done for and the coil spring is snapped at the top (Q. How the hell did this pass an MOT?!). The rear shocks look like something that has been recovered from the Titanic (or is it the Olympic 🤔😜) but amazingly are not leaking. Pictures to follow of those. I’m trying to at least get them fitted this week and get the front sorted when funds allow. KYB or cheaper recommendation anyone? The driver wishbone looks particularly bad and at least 1 alloy is buckled.
Fingers crossed though I will be up and running by the weekend, after Liverpool’s fabulous win at the weekend nothing can dampen my spirits!!

A massive thank you once again to all that helped in this process, I think probably anybody else would have walked away and this car would have been scrapped in the future if not for your amazing help and patience.

I will update once the car is running, on how the temperature is once the engine is properly warmed up and any other work that is carried out 👍🏻
 

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audifan

A2OC Donor
That has turned into quite a saga. KYB springs are fine.. I think you have made the right choice in having the garage replace the parts. Not because you are not capable. They have suitable location, all tools to hand, will be quicker due to experience and if something gets broken in the process they can sort it. All work listed would have been a steep learning curve - perhaps too steep at this stage.
At least now when done you will have confidence in the car and can then think about little jobs that you may wish to tackle in the future.

As always keep us in the loop and any questions just ask.
 
D

Deleted member 16918

Guest
Is this thread an additional means of advertising paid services of members?
 

froggy

Member
Sorry Rod if you feel this thread is some kind of advert for other members services - absolutely not my intention at all. Just wanted to thank everyone who has helped. Looking back at my posts I’ve only really mentioned clackers who is not far from me. Any other members mentioned were just links to their threads to show how they solved the issues I was struggling with and my thanks to them - they do not provide any services as far as I know? I did also mention depronman but the fuel screw is something many people have already bought and needs no advertising from me! Also mentioned him above in relation to my exhaust leak, but this is not a service he provides, just a guide on how he solved the same issue cheaply. Happy to edit anything you feel is advertising?

Anyway, update from my mechanic, new loom fitted but unfortunately still an intermittent cylinder issue. I’m picking the car up tomorrow and fingers crossed it just needs a good run. These are the figures from the live data that I received in a message from him - does anybody know if such a large deviation could indicate serious injector issues?

Cylinder 1 = 2.9
Cylinder 2 = -2.5.

Then after a few minutes all injector values are around (I think) 0.5, - 0.5 and it idles sweet. He has used a very good injector cleaner on it and for now it is running fine on 3 cylinders. He does not understand why cylinder 1 is being intermittently fuelled like that, without spending more time on it. He thinks it’s been running like that for a while so suggests driving it to see if it settles. I’ve probably wasted money on fitting the new loom already so worried about going any further - would a scan reveal more details?
 

audifan

A2OC Donor
As you have said this car has had work done on multiple areas and really needs to get to know itself again. I would suggest bar any serious issues to try to run the car for a month as your daily driver. Then have a VCDS scan done on the car. Be aware even VCDS does not show everything as not all components are part of the Can Bus. There has also been a lack of use with this car and the cobwebs need to be blown off. Preferably before Halloween!!! You are also new to the car so may be expecting something that just is not there or could be experiencing something you are not expecting.
Check the fuel trim in the next scan after the car has been run with a couple of tanks of good fuel and a good fuel system cleaner. Remember the new tandem is providing a far more consistent fuel supply to the injectors that may have carboned / coked up or partial spray patterns due to poor fuel supply in the past.
I do not believe you have wasted your money on a Darkside Developements injector loom. It is one component that has a really hard life.
 

kp 115

Member
Sorry Rod if you feel this thread is some kind of advert for other members services - absolutely not my intention at all. Just wanted to thank everyone who has helped. Looking back at my posts I’ve only really mentioned clackers who is not far from me. Any other members mentioned were just links to their threads to show how they solved the issues I was struggling with and my thanks to them - they do not provide any services as far as I know? I did also mention depronman but the fuel screw is something many people have already bought and needs no advertising from me! Also mentioned him above in relation to my exhaust leak, but this is not a service he provides, just a guide on how he solved the same issue cheaply. Happy to edit anything you feel is advertising?

Anyway, update from my mechanic, new loom fitted but unfortunately still an intermittent cylinder issue. I’m picking the car up tomorrow and fingers crossed it just needs a good run. These are the figures from the live data that I received in a message from him - does anybody know if such a large deviation could indicate serious injector issues?

Cylinder 1 = 2.9
Cylinder 2 = -2.5.

Then after a few minutes all injector values are around (I think) 0.5, - 0.5 and it idles sweet. He has used a very good injector cleaner on it and for now it is running fine on 3 cylinders. He does not understand why cylinder 1 is being intermittently fuelled like that, without spending more time on it. He thinks it’s been running like that for a while so suggests driving it to see if it settles. I’ve probably wasted money on fitting the new loom already so worried about going any further - would a scan reveal more details?
I would also check the glow plugs as they play an important part of the running of these engines not only in the starting .
Both Bosch & Beru have information regarding this.
Hope that helps you
Keith.
PS running the Darkside supplied genuine Audi loom!
& new Beru glow plugs.
 

froggy

Member
I would also check the glow plugs as they play an important part of the running of these engines not only in the starting .
Both Bosch & Beru have information regarding this.
Hope that helps you
Keith.
PS running the Darkside supplied genuine Audi loom!
& new Beru glow plugs.
Yes thanks for that, I found a couple of intersting threads on glow plugs causing misfire issues and will change them as a precaution. Could you PM me a link to your Beru plugs if you get chance?
I only know they have to be 11v for the 75 tdi.
Cheers
Rob.
 

philward

A2OC Donor
Flood the base of the plugs with penetrating oil then run the car for a week. Only attempt plug removal on a hot engine.

A tiny amount of ceramic grease on the new ones makes sure they come out easily next time
 

kp 115

Member
Yes thanks for that, I found a couple of intersting threads on glow plugs causing misfire issues and will change them as a precaution. Could you PM me a link to your Beru plugs if you get chance?
I only know they have to be 11v for the 75 tdi.
Cheers
Rob.
Darkside have them
 

froggy

Member
Got the car back today and I drove for about 12 miles, temperature rock steady just before 90 mark. Coolant level is low so I will do a few more flushes, then replace the tank so I can see what I’m doing. It’s VERY early days but…..I LOVE IT WOO-HOOOOOO!!!!!

For anybody of a nervous disposition - do not click on the link, the full horrors will be revealed, from the dodgy engine cover, to the ruined bodged fuel sensor wiring, smoke from the blown exhaust flexi, unreadable coolant tank and many more - you have been warned!!!

If your eyes can handle it though, considering what its been through it’s ticking over ok?!


 

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audifan

A2OC Donor
Glad you realise the pain is worth it.

Right, the engine cover will respond well to a dusting of paint, the wiring is easily tidied up and wrapped in Tesa tape to look more OEM, the coolant tank I have seen far worse so as long as it is functional and holding the coolant that can be a lower priority to replace although it may even clean up. The worst is the blowing exhaust and you already know what to do to fix that.
I think you have already done wonders on this car and you should be both happy and proud of the progress that has been made. You have a good attitude and realised quickly that best practice not to just jump in but ask for advice on various jobs. You listen and ask further questions if still not sure. So I for one am happy to see the car progress and happy to be assisting you.

Now after you make sure your wipers are good, go and drive your new best friend and get to know each other. Literally your journey is just beginning.

After you can make a list of everything you want to fix, improve or replace. You then break the list down into three categories.

1. Safety critical.

2. Repairing /replacing to bring the car up to your standard.

3. The little extras to either lift it to a higher status or to your personal taste.

ENJOY.

Graham.

P.S. You will now need to reset the clock and date. Ignition on and pull the left little stalk on the instrument panel. Each time you pull it it cyles through the different parts of the display, just twist the stalk left or right to adjust the displayed value up or down. When you reach the end and all are flashing pull once more to store the values.
 
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@froggy well done you!!! Not only for tackling this and saving the car but also for cataloguing all you’ve learned and the help Graham @audifan and others have given you.

Not only will you have a car you can be proud of having basically saved it yourself, you’ve also created a resource for others in future to use. 👏👏👏
 
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