EGR Valve

Posted: Fri Jan 23, 2009 1:17 am

Whats at Telford? Is that a show or something? Embarassed

I have done over 700 miles with it but want to do about 1000, and there is a German car specialist fairly near in Dorset who I have never used but have been recommended to me. I can then get any codes pulled and establish if it is a boost fault or fuel timing. Correct me if I am wrong, but a boost problem would still pull smoothly wouldn't it? I had though the stuttery and sometimes hesitant power delivery is more like to be over/under fueling? I dunno tho, as he said to me "I am just the driver" Rolling Eyes

Posted: Sat Jan 24, 2009 12:16 am

>>> LINKY

Posted: Sat Jan 24, 2009 1:58 am

D'oh! Thanks for that Jas, I am hoping to go to that too.

Posted: Thu Jan 29, 2009 10:15 pm

Done 1000 miles now and booked in at a local independant on Monday to get the fuel pump timing set with VAG-com Cool

Will ring tomorrow with the quote I have received for the interior valet, watch this space Very Happy

Posted: Mon Feb 02, 2009 8:44 pm

Anyone still reading this? Laughing

Or you all as bored as me!

Took the car to Autotechnics in Gillingham today who seemed very professional. The engine was checked on VAG-com with the following results:
- The timing was at the very extreme of its tolerances, this would account for the poor performance and cold starting problems.
- There is a needle valve in one of the injectors which monitors actual fuel delivered against fuel metered by the pump and reports back to the ecu. This is saying there's an open circuit, ie its bust Sad

This valve costs £260 plus vat Shocked

VAG parts where are you? Crying or Very sad

So with the front coming off to retime it it's going cost me a load more. Again. At least I know it should be done properly this time.

Was supposed to be driving to the Alps this weekend, and am now on the Easyjet website Rolling Eyes

Posted: Mon Feb 02, 2009 9:10 pm

Again sorry to hear of the woes James.
Looking hopefully like there's light at the end of the tunnel though.

Also sorry to hear of you contemplating Easyjet Shocked

I used them a couple of years back. We paid to board first, so we could get a good seat. Great idea, all the people who paid for that, were shouted up first to board the bus from the terminal to the plane. On the bus we go, shoved right to the back, where we are the last top get off and onto the plane, where there were no seats left for me and Allie to sit together.
Total croc of crap
Laughing

The head stewardess I'm sure used to be man, when she/he/it came round asking if we wanted drinks or snacks, I bought some just in case she/he/it dragged me into the aisle, beat the sh*t out of me and then threw me out at 35000 feet. Talk about an aggressive nature.

Enjoy Wink

Posted: Mon Feb 02, 2009 9:34 pm

Brilliant can't wait Laughing

They fly from Bournemouth which is less than half an hour away which clinched it, and it's a short flight (I hope Shocked

) I'm not paying the £12 priority boarding cost either, gonna play the screaming baby card Wink

Yeah I do feel the car may be getting somewhere now. Apparently the 2.5 is a very fragile engine, apparently a remapped 1.9 is a better bet. Now he tells me .....

Posted: Tue Feb 03, 2009 9:08 am

James i am still reading obviously!
Spoke to a chap with an A6 180bhp he bought 6 years ago for his wife which is up at.. 210k miles now, it ate a turbo at 160k but thats all the issues he has had other than general servicing. lottery engine i still believe, either that or they were all built on a Friday.

Have a good Alps trip, skiing i assume? If it is supposed to be some of the best snow in 15 years i hear.

Posted: Tue Feb 03, 2009 11:00 am

James - get this last fix done then sell. Your confidence in this car has probably been tested this last few months, so cut your losses. It's difficult when you've invested so much time, money and energy getting it the way you want.

You could lay your hands on a 1.9 TDI QS. Apparently like hen's teeth - but they do come up now and again. Confused

Given the choice again - I wish I opted for one instead of my current car.

Posted: Tue Feb 03, 2009 12:51 pm

Agree with the above, once its started giving problems unfortunately it won't end.

Posted: Tue Feb 03, 2009 12:54 pm

Thats what my dad has.... very nice motor.... that 1.9 redeye pulls like a train Razz

Posted: Tue Feb 03, 2009 8:32 pm

My sister lives out there so going to see here, but yes will be skiing for the odd day too Very Happy

It is a love or hate engine, I am looking forward to leaving the hate stage and going back to the love stage Laughing

There was a Dolphin Grey 2.5 non q there on an 04 (with GMBH kit Evil or Very Mad

) that had just turned 205k in for some work, so they are good for high miles.

Sell or keep is a tough one. I have spent a lot of time and money on it to get it how I want, and am not sure I would want to do it all again, and when it's running right I love it. And looking at the prices they are fetching right now, I'm not sure i would want to sell as I don't have any more money to add to it right now. Better the devil you know maybe? Who knows ... I know there is always something, but given I plan to uprate the suspension anyway, the clutch and engine is good, brakes quite recent, gearbox aside it should be ok. Should Rolling Eyes

Ironically i have seen three or four 1.9TDi Q's the last few days .....

On the plus side The Engine centre are going to send me my old needle valve FOC which will save me £300 hopefully Very Happy

Posted: Wed Feb 04, 2009 10:43 pm

Some poor bu**er on the VWAudi forum could be facing a bill for £15k+ for new S4 engine. Only done 49k. It's enough to make you buy a second-hand Ford Ka.

Audi are looking for £2-3k just to take the old engine out and to diagnose what's happened. Crying or Very sad

http://www.vwaudiforum.co.uk/forum/showthread.php?t=60389

Posted: Thu Feb 05, 2009 7:36 pm

I can't read that as I am not a forum member Sad

Feel for the guy though, but I cant imagine anyone taking a car like that to an Audi dealer, what age is the car? Pretty sure you could get it rebuilt for less than £15k Shocked

Audi Nut Joined: Dec 15, 2006 Posts: 77

hi,the front doesnt have to come off to retime it.the error with the needle motion sensor get the garage to check the wiring isnt fouling the camshaft,there is a guide for the wire if its installed wrong the cam cuts the wire,leading to open circuit.you can repair the wire...tim

Posted: Fri Feb 06, 2009 8:08 pm

2004. Full service history but ouside warranty. Last service done at an independent. Sad

Posted: Fri Feb 06, 2009 8:44 pm

Nightmare

Do they know whats happened to the engine yet? Keep us posted won't you Wink

I found out today that my local garage who did the swap also kept a needle valve thing from the injector, so with the one the Engine Centre are sending down I will now have two Very Happy

Posted: Fri Feb 06, 2009 9:56 pm

Glad you're starting to smile again James, it's been a hell of a journey just reading this thread. Wink

Oh yeah, that white stuff down your way is called 'snow' in case you were wonderin' Laughing

Si.

Posted: Fri Feb 06, 2009 9:58 pm

or

, I tried the latter but it made no difference Wink

I quite like this snow thing, just glad the quattro was back in time to enjoy it! Going to the Alps tomorrow for some proper stuff Very Happy

Posted: Mon Feb 16, 2009 9:09 pm

Car was dropped to Autotecnics today for a couple of days work. They are going to set the engine and fuel timing correctly with VAG-com, swap the needle flow valve and adjust the headlights.

I have a 20v Passat from them on loan, 184k but no complaints from me Very Happy

Inexperienced Joined: Feb 17, 2009 Posts: 27

New to the forum, and just read your post. sorry to hear of the misfortune youve had, bit of a bummer. Any updates?

Posted: Tue Feb 17, 2009 9:00 pm

Thanks mate, it's a sorry saga still ongoing!

Autotechnics rang me today and said that the viscous coupling for the fan is "mullered", and that in their opinion the pulleys on the timing belt didn't look new Confused

So I rang The Engine Centre who told me that a completely new timing kit was fitted to the 1st replacement engine I had and this was transferred across to the 2nd engine. So what to do? The Engine Centre even offered to extend the engine warranty to 2 years and 30k miles.

The viscous coupling was £150 to replace but The Engine Centre are sending a replacement one down, which I though was fair enough.

But I can't take any risks with the timing belt, and as the front is off I have decided that for £160 for a belt kit and pulleys, and £50 for the water pump I have no choice but to get it done Rolling Eyes

So the bill for this is going to be approaching £1k Sad

What choice do I have? The amount I have spent I have no choice but to carry on really to get it right.

On the plus side, loving the Passat, mainly cos its a petrol car that revs to 6000 Very Happy

Posted: Wed Feb 18, 2009 5:54 pm

James,

Is mullered a technical term? Personally I would consider this a side issue unless it is responsible for the engine running problems, first priority is to get the engine running correctly. Has the garage understood what is wrong yet, if they cannot get the engine running right I wouldn't bother with the belt, etc.

As the Engine Centre has provided an extended warranty and stated that new parts were supplied changing the belts, etc is an unecessary expense.

Pete

Posted: Wed Feb 18, 2009 7:36 pm

Hi Pete,

The fan is not responsible for the poor running issues, but as the front of the car is off and it's at the garage then I might as well get it done, I really don't need any more breakdowns for a bit!

It is hoped that when the engine and fuel pump timing are set correctly the engine will be running as it should, but obviously no one can guarantee that until it is tried.

I hear what you are saying that changing the belts is an unnecessary expense given I have a two year warranty, but firstly, I don't want it to breakdown again, under warranty or not. And secondly given the wheel damage and other hassles I don't really want The Engine Centre touching the car again, and what is the warranty going to be worth given that another garage has now worked on the car? I can see lots of small print issues here .....

At the end of the day while the front of the car is off for the timing to be rest it is maybe going to cost me an additional £300 labour and parts for total reassurance - worth the money in my opinion.

Posted: Sun Feb 22, 2009 9:46 pm

I got the car back on Saturday and I was very pleased, it's not there yet but it's hugely improved Very Happy

There are two issues remaining, firstly where the fuel lines have been on and off the injectors so many times, one of them isn't quite sealing and there is diesel weeping out. As you can't order them individually I have to get six Sad

And also the MAF is sticky so a new one of those is on the cards too. Hopefully they will be in stock and fitted later this week.

The car is running better and smoother, going better, and starting and sounding better than it has done since I had my old engine. Performance wise it is still somewhere behind the old engine, but hopefully with the above two issues sorted there will be a further improvement in performance.

Incidentally Autotechnics held on to the timing pulleys that there was some doubt over whether they had been replaced. The fuel pump drive pulley was definitely new, but I have to say the idler and tensioner pulley certainly didn't look as if they had done 1500 miles Confused

Posted: Tue Feb 24, 2009 7:50 pm

The fuel pipes are on back order with Audi until June Rolling Eyes

The search commences.....

Newbie Joined: Feb 23, 2009 Posts: 3

Hi This is my first post)))

sorry about my english ))
I have A4 2.5 TDI v6 quattro year 99 facelift inside is engine AKE(132 kw) with individual chip cca 200 HP
here is my sprint with audi 80 2.8 petrol 24 value
http://www.youtube.com/watch?v=JC1nGc0JtlI

I know engine 2.5 tdi V6 because I change engine (only my self)) because i hated services or garages. And in czech is work to same in english so expensive. I havent EGR 3 years no problem. I put my EGR out and this hole i dazed)))). and this tubule underpressure for control EGR dazed to.

3 years no problem with mess in airsystem in turbo.

system EGR is bad system only for polution but very bad system

Posted: Fri Mar 13, 2009 7:32 am

I am finally in possession of the elusive replacement fuel injection pipes, so the car is off to Autotechnics on Monday for the new MAF and the pipes to be fitted Very Happy

It has been running ok up until the last couple of day even thought the mpg was in the low 20's, but I put this down to the MAF. However it has recently developed an intermittent fault where after about 15 mins of driving it develops a misfire on tickover, I would say it's probably only running on 5 cylinders. This is accompanied by a loud ticking from under the bonnet which is engine speed related, and seems to happen when you stop accelerating and hold the car at a constant or decreasing throttle. Performance is largely unaffected, but it smokes a lot, looks like unburnt fuel from the colour of the smoke.

I am wondering if it is an EGR problem again and the ticking is vacuum related? Confused

Find out Monday hopefully Wink

Posted: Sat Mar 14, 2009 5:28 am

Ok I have a few more symptoms Sad

The problem seems to manifest itself after about 10 minutes driving when the engine is fully warm. The noise is pretty loud, but goes away on hard acceleration completely. At tickover it gives a very faint clicking sound, I have looked under the bonnet and it's hard to pinpoint the location of the noise, it sounds as though it is coming from the head somewhere but hard to say if it's the EGR valve or not. The car is virtually billowing grey smoke out the back which smells like unburnt fuel by this time. It seems to smoke worse on tickover than under load. Could the EGR cause this?

I bought a new EGR for my original engine, but am unable to say whether it ever made it's way onto the new engine the second time around.

I am worried it may be a valve problem. Could this be intermittent as a mechanical problem only coming to light when the engine is warm? Or would a valve problem be there all the time?

Bastard car Evil or Very Mad

Newbie Joined: Jan 27, 2009 Posts: 18

sounds like it could be an injector at fault.
i haven't read the whole thread, but did you replace them?
if it was a tractor ( my usual field ), that's where i'd start.