New TFSI owner woes and query

[antwan64og]

Bought a 2006 BUL TFSI last night and Oil pressure light came on on the way home so coasted and got a lift on a flat bed. Top end sounds ok, with likely culprit being the oil pump at 99k.

Engine is coming out this weekend to inspect and see whats what.

Other than a new cam lobe, a HPFP upgrade and cleaning the inlet valves is anything else worth doing now along with the oil pump and maybe a clutch?

Is the balance shaft delete oil pump kit on ebay any good?
Is a sachs Xtend clutch strong enough for the torque from mapping or is the sachs SRE organic needed?

TIA

 

[RichMk3]

Hi.

I'd check the oil pickup in the sump, sometimes can get blocked and cause oil pressure issues, or as you say the oil pump.

Water pump and cam belt worth doing while the engines out. Check the dmf when you change the clutch also.

With regard to tuning, STD clutch will be okay, especially if 2wd, upto 270bhp... Some people have run much more without problems. That's the practical limit with the standard turbo anyways.

 

[antwan64og]

Thanks.

Cambelt, water pump and timing chain were done 6 weeks ago so thats a bonus.

I’ll always change a DMF with a clutch, previous owner of my A3 just changed the clutch and the bad DMF killed the clutch within 5,000 miles.

Good to know on the clutch, it’s quattro but as you say the small turbo limits the torque output anyway.

 

[antwan64og]

Erm..... a picture says 1000 words. Low oil pressure culprit identified.

The metal filings are a bit worrying but see what I find next.

The motor is on an engine stand anyway

 

[antwan64og]

Oil pump doesn’t look to healthy

 

[antwan64og]

Turns out oil pump bolt had snapped.

Is any big end play acceptable?

 

[antwan64og]

Friday night the 1.8t pump on, fitted a new CHRA to the turbo while it was out and noticed that the DMF and clutch was goosed so had ordered replacements.

Sump back on and was ready to throw the DMF and clutch on for the final stretch home.
Clutch pilot bearing did not want to come out at all, oh buggery.

Ordered an inner bearing puller kit on Amazon prime today so should be here Sunday (tomorrow).

I need the car ASAP since I spun and crashed the A3 in heavy rain last Sunday so been borrowing various cars to get about for the last week.

I know I shouldn’t of but in my haste to get it on the road I took the gamble of not changing mains and big end bearings since it was another £200 and I figured if the bottom end was toast then the head/cams probably were too And I’ll get a refurbed engine if it does go to save messing about.

 

[antwan64og]

Well the inner bearing tool pulled the inner race out of the pilot bearing leaving the bearing housing siezed in place.

6 hours of trying every tool I could find and reverting back to patiently hammer and chiselling (which was fun) the bearing finally came out.

Turns out I had ordered the wrong replacement, most B7 pilot bearings are 24mm except the 2.0 TFSI which is 22mm and 1.8t which is 21mm.

 

[antwan64og]

I thought getting the engine in and running would be about 4 hours. It took more like 8hours inishing at 2am last night.

The downpipe flexi disintegrated upon reinstall but at least she runs. Good excuse for a new one and decat really

 

[antwan64og]

The saga continues.....
At low load under 2000rpm the low oil pressure warning comes on sometimes. I felt like burning the car when it first happened!

Spoke to the company who provided the 1.8t oil pump and they said oil pressure can be bumped up with a quarter turn of an allen key.
(The 1.8t pump flows more than the TFSI pump so they dump the excess pressure with an adjustable valve.)
That means the sump has to come off again, muda f@*%#$.

Hopefully it’s an easy fix

 

[antwan64og]

Just to complete the story.

I picked this out of the sump with my fingers through a window in the block.....
In hindsight getting the crank polished and all new bearings might of been a good investment if that was the weak point.

 

[antwan64og]

So the saga if the cursed A4 continues, the night before it was due to be picked up for the engine transplant a kind person smashed the windscreen and stole the SE wheels.
Got wheels from the scrappy and autoglass sorted the windscreen.

Onto the engine transplant the only good news was theSB clutch was ok and the CHRA survived but i’d already Bought an uprated bearing version with billet wheel for £250.

The 500 mile old DMF was FUBAR so another £400.
2 injectors where stuck in the old head so another £220 there.
The flying rod had Cracked the oil filter housing another £189.

Got it started and its leaking oil like mad, the oil cooler had warped from the heat so another £85.

Car was finally running sweet and I put 300 miles on it breaking the engine in.

Next thing low coolant pops up, she’s dumped all her coolant from a leak by the radiator and off the road again.

So in 10 months I’ve done 800 miles, threw 2 rods, refurb engine spent a fortune and still have no running car.
Gotta love the TFSI

 

[Charlie Farley]

time to walk away from it chap, clearly a problematic car.

 

[antwan64og]

Turns out the coolant drain plug had undone itself slightly and let the coolant out, easy fix.

The car runs as smooth as silk, did the first oil change at 300 miles and will do them every 2500 miles.

Fitted an Xtrons single din stereo so now have google maps, youtube and Amazon Prime Video