AKE engine problems - rocker arms keep falling off
Hello Audi Diesel Guru's.
I desperately need your help. My 2002 Audi allroad 2.5TDi V6 (152k miles) has been off the road for some time now. It's suffering from alsorts of problems. The oily bits mainly down to the longlife service intervals. The garage have rebuilt the front end, and replaced the brakes (discs & pads), MAF, turbo, new injectors, new rocker arms, new pressure pads, changed the timing belt, thermostat, water pump, pulleys, tensioner, gas strut damper, auxiliary belt tensioner pulley/bearing and probably a lot more, but didn't replace the camshafts and only changed a few of the damaged hydraulic lifters.
I remember going to pick up my car. It was difficult to start. Cranking, cranking, cranking. It would eventually start in a cloud of blue/sooty smoke and was lumpy as hell to drive, and there was a very loud ticking sound coming from somewhere in the right hand-side head. I shouldn't have accepted the car, but needed it for work. Foolishly i'd paid for the work and drove away.
Two and a bit months ago we went to the Lake District. Something didn't feel right on the way up. At around 2500rpm there was a slight hiccup, almost like a mis-fire. 2 days before we were meant to drive back down the car dropped a bunch of rocker arms and pressure pads. We'd crawled back to the cottage, on what felt like 2 cylinders, so we could get our things ready to be recovered to London. A pool of oil was left infront of the cottage and 8 hours and 3 recovery lorries later we'd made it to the garage in London.
The prognosis is the camshafts were so worn that they couldn't hold the rocker arms in place. Whilst driving back to the cottage 3 pressure pads had also fallen off and were lost in the engine somewhere. They'd later found 2 of them, but there is 1 more in there somewhere.
I'd picked the car up last Friday. It was lovely to drive. Sounded just like any other 2.5 V6 TDi engine i've heard pass me on the road. It was so eager to pull and felt like a different car. The power seemed to come in a lot quicker too. Within 5-10mins it was at 90degrees operating temperature, unlike before when it hardly moved above it's position of rest. The only thing that was different was the oil temperature would always read 80degrees, now it reads 100degrees. And since the recovery service had wrapped the strap around the anti-roll bar and pulled it up on the lorry, something in the n/s/f is clunking and there's a creaking sound with any steering input. I've been told to limit the revs to 2500rpm and allow things to bed-in for the next 1000miles.
2 days ago i was stationary in traffic and the engine cut-out. I'd restarted it and it was lumpy as hell. Here we go again. I'd managed to drive all the way across London to the garage. I've just spoken to the guys at the garage and one of the rocker arms had fallen off. As a precautionary measure they'd ordered a new rocker arm and hydraulic lifter from Audi. Bit of a nightmare getting it sent over, but as they were fitting it they'd heard another rocker arm fall off. As a gesture of good will there's no charge for the labour, but suggest replacing the other 23 hydraulic lifters.
Is there something they're not doing right? Is there something an Audi Master Technician would have a jig or tool for setting everything up? Is there some inside information that i can get to the garage? Or am i just unlucky? I've just read back this post and it seems crazy to have replaced everything but the hydraulic lifters. Tst tst tst. It makes sense that they are the only things that are holding the rocker arms up against the camshaft lobes.
Can anybody help me or do you have any advice? I wish i'd found this forum before i went to the garage as i'd have contacted Adamss24 to do the work. Since the warranty is with them i'm in their hands. Thank you.