White smoke and heavy vibration - 1.4 tdi ATL

Don't forget the difference in compression ratio between the AMF/BHC and ATL. I believe there are three headgaskets to choose from and marked at the tab. Verifiy which one is used for future referrence.
 
Definitely no turbo bits ingested, it broke off exhaust end and made quite a chunky indent on exhaust end housing though, intake side was in one piece with no broken fins.
If the exhaust end failed, fragments can enter the inlet via the EGR. The intercooler would probably prevent fragments entering from the compressor end.

RAB
 
Bit bummed out with this.

If anyone has top half of BHC or AMF I'll be quite interested. Not really sure what involves rebuilding actual cams?

@[email protected] AMF/BHC have higher compression ratio from memory, i believe the 3 different head gaskets are only different in thickness, in case parts were machined?

Will try and plan out a plan of action and source a replacement head, unless there are any shops nearby that are happy to rebuild (SW London) but messaged some and not heard back, so could be closed due to lockdown still.

would rather be 100% sure but I don't see what else it could be other than bent valve, engine runs alright otherwise just wobble as hell.

on the bright side i have been through in and out the engine bay multiple times now, getting to know the A2 quite intimately now :D
 
Can you borescope the piston heads and bores and valve bases? Remove the manifolds to try to see if damage to the upper ends of the valves. You are 100% sure the belts are correctly timed and the belt does not have any damage? My early suggestion for the compression check and other damage to the engine when the turbo failed is looking stronger all the time.
 
Can you borescope the piston heads and bores and valve bases? Remove the manifolds to try to see if damage to the upper ends of the valves. You are 100% sure the belts are correctly timed and the belt does not have any damage? My early suggestion for the compression check and other damage to the engine when the turbo failed is looking stronger all the time.

borescope wont fit through glowplug hole nor injector, really should invest in a better one... It does indeed seem valve is bent or broken, considering havoc top half of my old motor had when timing tensioner bolt snapped off and that pistons seemed to not have a scratch I am hopeful pistons are fine, especially as engine runs just fine as a lawnmower twinair? just wobbly.

Timing is definitely spot on.

Will be easier to split the engine and take top off than remove manifolds with engine in car I reckon so will probably go with that, taking top off is just removing the timing belt and then removing some hoses and bolts holding it together...

I remember seeing someone selling ATL near Manchester I think but that was a while ago...

Fun and games, though I might need to get a temporary run about until I finish with the A2.
 
Righto finly gotten around to it! It did suck in bits of turbo after all and my replacement engine is b****red... And old engine got nicked by metal thieves from back garden... Wish I knew more at the start and just went for a new top engine as there are a few on sale that way I would've had it running by now and even if engine was on way out it'd last long enough for my needs to proceed with something more interesting.

Now then the question is will amf of bmc (I think was the later engine code?) engine be same and all the bits just bolt on if I get just the complete engine without extra gubbins? Would that be same for amd block from polo, I could just use intake exhaust turbo etc. Without issue as lump is same? I would assume as atl and amf have different compression ratio button is not entirely same and piston travel is slightly different?

Fairly confident is doing this yet again as everything is spot on other than engine at this point so need some guidance on finding me a motor...

Attached for findings, intake valve on cyl 2 was also bent so was not sealing fully.

Bummer but having this much already might as well go a bit more.

Cyl 2 reminds me of deadpool. It would probably run for a while with a good head being put on and straight valves but getting it this far done, might as well finish it properly.

Any advise on suitable engines or if anyone has a decently low mile suitae motor not too far away from London for reasonable money do let me know.
 

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Oh F£*%, I did fear the problem was linked to the original turbo failure. Are the bores scored?

As far as compatibility between engine codes and models, I am really not sure. You would have to check each part number individually and see if it is compatible. Would removing the engine and having it repaired be an option? May be a better option than the lottery of used engines / non atl parts. It will ultimately come down to cost and how much you want the car. Not suggesting that it is broken for spares and indeed could make an ideal parts car if you decide to get another A2. Those are decisions that only you can make. Not all that many atl engined A2s out there but you may have to be prepared to wait / travel a long distance / gamble...... Remember it may also need more parts if not an atl donor such as manifolds, ECU, mounts, wiring, turbo etc.

Here is 7zap to check various models etc..

 
Perhaps @Weetank2 MAY be able to help you out IF he ends up breaking the tdi 90 he recently got. No promises and certainly nothing to do with me.
 
There’s an ATL on eBay I think
One in the south is one I got it from as a running motor...

There is another near Manchester and it is bit high miles but if nothing comes about might go for it, though need to inquire if still available.

See one for sale that was rebuilt also for 800 that I am considering and shorter drive too drive.

Would rather spend 1-200 on a good running engine than the extra on rebuilt, but at this point feels like I might end up in a spot of paying thrice for being cheap.

Recall someone listing one for sale on forum but cannot find the thread, unlikely to still be available I'd guess.

Would be nice if amf block was indeed same for bottom half, however I doubt it'll be that simple. Will go have a look over the parts to see what differs bit later

Edit:

Looking through 7zap, seems they share most of parts, pistons themselves are different, piston rods are same part number, but there are a few internal bits that are different as well, though some seem to just be different revision of part potentially with only letter at end being different, though crankcase itself seems to be a different part.

https://audi.7zap.com/en/rdw/audi+a2/a2/2001-248/1/103-103015/ - cylinder block and bits
https://audi.7zap.com/en/rdw/audi+a2/a2/2001-248/1/107-107010/- cylinder itself.

Running ATL turbo on AMF might cause different issues, though in my mind it should be fine, it is not massively higher compression ratio in AMF, so more compression with more boost would probably be just fine, potentially producing more torque thanks to higher compression and seemingly piston travel being same looking at the parts.

Top of engine appears identical which is nice.

actual cylinders are not expensive and walls are not scored, however I'd need a shed to hibernate in with the engine for a fair while to do a proper full rebuild...
 
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Hi tdi engine vibration check the balance shaft timing as the guides wear and the chain slips it happened to me balance shaft on examination was 180 degrees out but all the sprockets were ok but guides very worn
 
One in the south is one I got it from as a running motor...

There is another near Manchester and it is bit high miles but if nothing comes about might go for it, though need to inquire if still available.

See one for sale that was rebuilt also for 800 that I am considering and shorter drive too drive.

Would rather spend 1-200 on a good running engine than the extra on rebuilt, but at this point feels like I might end up in a spot of paying thrice for being cheap.

Recall someone listing one for sale on forum but cannot find the thread, unlikely to still be available I'd guess.

Would be nice if amf block was indeed same for bottom half, however I doubt it'll be that simple. Will go have a look over the parts to see what differs bit later

Edit:

Looking through 7zap, seems they share most of parts, pistons themselves are different, piston rods are same part number, but there are a few internal bits that are different as well, though some seem to just be different revision of part potentially with only letter at end being different, though crankcase itself seems to be a different part.

https://audi.7zap.com/en/rdw/audi+a2/a2/2001-248/1/103-103015/ - cylinder block and bits
https://audi.7zap.com/en/rdw/audi+a2/a2/2001-248/1/107-107010/- cylinder itself.

Running ATL turbo on AMF might cause different issues, though in my mind it should be fine, it is not massively higher compression ratio in AMF, so more compression with more boost would probably be just fine, potentially producing more torque thanks to higher compression and seemingly piston travel being same looking at the parts.

Top of engine appears identical which is nice.

actual cylinders are not expensive and walls are not scored, however I'd need a shed to hibernate in with the engine for a fair while to do a proper full rebuild...

I’m sure Tom is running an ATL turbo and ancillaries on an AMF block. The Tdi120 project thread had a lot of info on the hybrid.


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From memory Tom had a custom impeller made


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I believe it was a hybrid or uprated turbo, when he retrofit bose/cruise he said he wanted the reliability of the older style turbo over VGT for a reliable workhorse A2, which I can relate to right now :D
 
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