2.0 Tdi running like a tractor

[The Bear]

Hi everyone, its my first time posting here and i was hoping you guys can help me.

I have a 2005 A4 2.0 Tdi that has never given me an ounce of trouble in the 5 years ive owned it, that is until i decided it was due a timing belt (90k miles) I enquired around and found a guy that came highly recommended to do the job. Once the job was done i noticed the front rhs indicator wasnt working and i reckoned he didnt reconnect the wire, so i tried to lift the bonnet to connect it myself and then i noticed the bonnet catch wire wasnt connected. I called him and he said hed sort it out, he took the car and said hed be back in 20 mins with the problem fixed . . . . . 4 hours later the car arrived back farting and spluttering, he said the EGR cooler blew on the way back so he returned to the workshop to fix it. He tried to MIG weld the cooler, but only managed to blow holes in it, then covered it in chemical metal trying in vain to block the hole. When i looked at the part it was covered in dents as if he was trying to lever against it. I bought a new EGR cooler off Audi and fitted it, but it seems to be blowing exhaust gas out of the top of it (also seems like its running on 3 cylinders) im wondering is the EGR valve stuck shut and not allowing the gas to circulate ?? Could some of the slag or snots of weld get sucked into the EGR valve or even into the engine ???

Any help at all would be greatly appreciated.

 

[rowdyboy]

Hi everyone, its my first time posting here and i was hoping you guys can help me.

I have a 2005 A4 2.0 Tdi that has never given me an ounce of trouble in the 5 years ive owned it, that is until i decided it was due a timing belt (90k miles) I enquired around and found a guy that came highly recommended to do the job. Once the job was done i noticed the front rhs indicator wasnt working and i reckoned he didnt reconnect the wire, so i tried to lift the bonnet to connect it myself and then i noticed the bonnet catch wire wasnt connected. I called him and he said hed sort it out, he took the car and said hed be back in 20 mins with the problem fixed . . . . . 4 hours later the car arrived back farting and spluttering, he said the EGR cooler blew on the way back so he returned to the workshop to fix it. He tried to MIG weld the cooler, but only managed to blow holes in it, then covered it in chemical metal trying in vain to block the hole. When i looked at the part it was covered in dents as if he was trying to lever against it. I bought a new EGR cooler off Audi and fitted it, but it seems to be blowing exhaust gas out of the top of it (also seems like its running on 3 cylinders) im wondering is the EGR valve stuck shut and not allowing the gas to circulate ?? Could some of the slag or snots of weld get sucked into the EGR valve or even into the engine ???

Any help at all would be greatly appreciated.

Are you sure he's not got the timing a tooth out whe he's changed the belt, if it's running that rough??
I'd hand it back to him till it's sorted or take it somewhere to diagnose the problem, then go back to him.
The blobs of weld won't just get stuck in the EGR, they'll be in your engine.
If your EGR valve was stuck, you'd have a light on the dash.

 

[The Bear]

Hi Rowdyboy

We took the cover off the timing belt and checked, the marks line up, so im pretty sure its not that. The engine management light is on and when diagnostics is plugged in it shows an EGR valve fault. Reset the fault and it just reappears. Ive got a new EGR valve and will fit it today, im just praying that snots of weld hasnt got sucked in and has bounced off all the valves.
I guess my frustration is that i think he was trying to lever against the EGR cooler trying to open the bonnet and ripped the thin metal on it, thats bad enough, but doing a half assed repair looks like it cost me a new cooler AND a new EGR valve, and possibly thats not the end of it, the head might have to come off.
If some snots of weld did get sucked in, worse case scenario, would it cause a misfire ? And how big a job is it to repair ?

 

[ukdan]

If you got weld spatter into the engine it could have damaged the valve seats, piston and rings or something like that causing a compression drop in one or more cylinders.
Put your new egr valve on and see how it runs after.

 

[hades-]

id make the idiot repair it

 

[ukdan]

id make the idiot repair it

After what he's done, I wouldn't let him anywhere near the car again!

 

[The Bear]

Hi guys,

Fitted the EGR Valve today but alas no joy, the engine is still running like a tractor and im pretty sure now its after chewing up some internals, going to get a compression test done on monday then whip the head off. Also i noticed the new EGR cooler isnt working and upon closer inspection it seems the diaphram at the end of it is bent and the shaft going into it is seized, this is where the exhaust gas is escaping, the part came like this from Audi so ill be on to the parts department on monday looking for a replacement.


Fun times ahead

 

[The Bear]

Did the compression test on Monday. It confirmed there was no compression on cylinder 3 so the head had to come off. Once it was off it was very apparant why, the valves were bent, valve seats were damaged and the piston looked like the surface of the moon. The head was sent off for skimming and new valves etc. The top of the piston was machined flat again and the reassembly began.
Got it all back together and held my breath as the engine turned over, success ! She's running well now, firing on all cylinders.
I reset all the fault codes (EGR valve, Heater plugs) but a new one keeps re-appearing "Feul temperature sensor" fault.

Anyone any ideas on what this could be ???