Strange metallic/hissing noise. HELP!

[slepy]

Car is a 2007 2.0Tdi 170PD with 85k miles on the clock.
There is a really weird noise coming from the engine bay. I can clearly hear it inside the car on idle.
It is a hissing but metallic sound coming from the turbo side of the engine.
Noise isn't regular and doesn't change at increased rpm.
Have a look here: 10sec, 12sec and further.


I scanned the car today. Bear in mind that I had it only few days.
It came up with loads of engine errors. Cleared them and after running the engine for few minutes, it came wit no
errors at all. There are no lights on the dash. I can't drive it at the moment because it isn't taxed and doesn't have and mot.

These are the errors for engine, but after clearing them nothing comes back:
I really don't think this issue is related to DPF. Any ideas?

008194 - Particulate Trap Bank 1
P2002 - 006 - Efficiency Below Threshold - Intermittent
Freeze Frame:
Fault Status: 00100001
Fault Priority: 1
Fault Frequency: 17
Reset counter: 16
Mileage: 0 km
Time Indication: 0

Freeze Frame:
RPM: 2112 /min
Torque: 144.0 Nm
Speed: 50.0 km/h
Pressure: 0.0 mbar
Text: 0 mbar
Text: 312 C
Temperature: 22.5°C

001137 - Exhaust Pressure Sensor 1 (G450)
P0471 - 006 - Implausible Signal - Intermittent
Freeze Frame:
Fault Status: 00000001
Fault Priority: 1
Fault Frequency: 16
Reset counter: 40
Mileage: 0 km
Time Indication: 0

Freeze Frame:
RPM: 0 /min
Torque: 136.0 Nm
Speed: 5.0 km/h
Pressure: 0.0 mbar
Text: 21 mbar
Text: 272 C
Temperature: 16.5°C

001137 - Exhaust Pressure Sensor 1 (G450)
P0471 - 006 - Implausible Signal - Intermittent
Freeze Frame:
Fault Status: 00000001
Fault Priority: 1
Fault Frequency: 5
Reset counter: 40
Mileage: 0 km
Time Indication: 0

Freeze Frame:
RPM: 0 /min
Torque: 136.0 Nm
Speed: 5.0 km/h
Pressure: 0.0 mbar
Text: 268 C
Temperature: 16.5°C
Text: 0 mbar

009299 - Diesel Particle Filter; Differential Pressure Sensor
P2453 - 006 - Implausible Signal - Intermittent
Freeze Frame:
Fault Status: 00000001
Fault Priority: 1
Fault Frequency: 5
Reset counter: 40
Mileage: 0 km
Time Indication: 0

Freeze Frame:
RPM: 0 /min
Torque: 136.0 Nm
Speed: 5.0 km/h
Pressure: 0.0 mbar
Text: 0 mbar
Text: 272 C
Temperature: 16.5°C

000665 - Boost Pressure Regulation
P0299 - 006 - Control Range Not Reached - Intermittent
Freeze Frame:
Fault Status: 00000001
Fault Priority: 5
Fault Frequency: 2
Reset counter: 40
Mileage: 0 km
Time Indication: 0

Freeze Frame:
RPM: 2112 /min
Torque: 144.0 Nm
Speed: 30.0 km/h
72.93 %
Voltage: 13.56 V
Pressure: 1831.8 mbar
Pressure: 937.2 mbar

001026 - EGR System
P0402 - 006 - Excessive Flow - Intermittent
Freeze Frame:
Fault Status: 00000001
Fault Priority: 1
Fault Frequency: 2
Reset counter: 37
Mileage: 0 km
Time Indication: 0

Freeze Frame:
RPM: 2048 /min
Torque: 144.0 Nm
Speed: 30.0 km/h
0.00 %
4.68 %
Mass Air / Rev.: 550.5 mg/str
Mass Air / Rev.: 397.9 mg/str

000258 - Mass Air Flow Sensor (G70)
P0102 - 007 - Signal too Low - Intermittent
Freeze Frame:
Fault Status: 00100010
Fault Priority: 5
Fault Frequency: 9
Reset counter: 39
Mileage: 0 km
Time Indication: 0

Freeze Frame:
RPM: 0 /min
Torque: 0.0 Nm
Speed: 0.0 km/h
99.45 %
Voltage: 11.75 V
Mass Air / Rev.: 850.2 mg/str
Mass Air / Rev.: 0.0 mg/str

000801 - Engine Speed Sensor (G28)
P0321 - 006 - Implausible Signal - Intermittent
Freeze Frame:
Fault Status: 00000001
Fault Priority: 5
Fault Frequency: 1
Reset counter: 40
Mileage: 0 km
Time Indication: 0

Freeze Frame:
RPM: 160 /min
Torque: 0.0 Nm
Speed: 0.0 km/h
Time: 0.02 s
Angle: 0.0 °
Bin. Bits: 00000000
Bin. Bits: 00000001

 

[slepy]

Started the car today to try and locate the noise. Revved it to 2k rpm and it threw an oil pressure light on dash. Looks like balance shaft failure and the noise is coming from inside of engine. ****** marvelous. I really hope the engine isn't gone.

 

[T!M]

Hi slepy,
my first thought was a slipping oil pump drive when I watched your video, which you then confirmed.
It sounds like it's a chain driven one and the teeth are worn/ stripped.
What's your engine code and what part number sump have you got fitted?
Tim

 

[slepy]

Hi slepy,
my first thought was a slipping oil pump drive when I watched your video, which you then confirmed.
It sounds like it's a chain driven one and the teeth are worn/ stripped.
What's your engine code and what part number sump have you got fitted?
Tim

Hi Tim. It is a BRD. Gear driven engine.

 

[Steaudi]

Did you switch the car off straight away mate, and do you have full Audi service history?

 

[slepy]

Audi service history means nothing with this issue as they don't want to do anything about it. There are hundreds of cars with this issue. Dropped the car off at MB services in Sheffield today for balance shaft and key change. Will find out what other damage it caused.

 

[Steaudi]

If you switched off straight away mate, engine should be sound, happen 7 weeks ago to mine, and with having full Audi service history, Audi did good will for me, I know others who have had good will done too mate, don't get me wrong they didn't pay it all but they paid hell of a lot of it, that's using the upgraded parts too

 

[slepy]

Well, you were the lucky one. In my case they didn't want to know. Will see how the engine and turbo are.

 

[Steaudi]

Fingers crossed mate, I switched mine off straight away, and got it recovered, and they said to keep an eye on the turbo but they said it looked ok, and that was 7 weeks ago, so fingers crossed it should be ok

 

[slepy]

So I had the balance shaft and key changed today and engine seems fine. Turbo on the other side not so much . I got quoted over £800 for fitting a refurbed turbo by the garage that did the shaft. I refused because I believe it is a bit steep price.

I will be probably changing the turbo myself but the question is where do I get the refurbed turbo from? There are couple of companies on ebay with prices around £300, but never heard of them and don't know what quality it will be. Turbodynamics can refurb my turbo but it would mean that I would have to wait for over a week to get it back.

Also, what else other than the exhaust gasket and oil feed pipe I will need?
Anyone knows if I will need to remove the manifold as well or the turbo can come out on its own?

 

[T!M]

Hi Tim. It is a BRD. Gear driven engine.

That's interesting, in all the threads I've read about oil pump failure it's only been the chain driven ones that people have heard it coming, my interpretation of what I've read is that the hex shaft failure just creeps up on you!
Do you think the noise from your engine was the hex shaft chattering about in the balance shaft?

I also read that the oil pressure warning light comes on at 0.2 bar and that the engine can tolerate that for a very short time if you shut it down straight away. The problem is that with a slipping hex shaft or chain drive the car could have been running at well below the 2 bar required to keep the turbo heathly for quite some time. Which is why they tend to get mangled by the time the low pressure warning comes on.
I'm reading up on turbo rebuilds at the moment, you can get new cartridges relatively cheap, use your old housing and a new gasket set.

http://www.ebay.co.uk/itm/AUDI-A4-A...749V-717858-/380821720799?hash=item58aabe4edf

 

[T!M]

Forgot you've got a 170, you'll probably need a different cartridge

 

[slepy]

Forgot you've got a 170, you'll probably need a different cartridge

I believe that this was the sound. The shaft/key was worn out and was rattling. Gear driven engines are affected by the same issue. I will get the car back tomorrow morning. I was told that the turbo has a massive shaft movement and I should not start the engine to avoid turbo breaking and having pieces getting inside the engine. I will take off the TIP and check for myself.

I am thinking that i could disconnect the turbo outlet pipe on cold side and start the engine to make sure that the rattle is gone before I put a new turbo on. I know that I would have no boost pressure but at least it should stop from pieces of turbo getting inside the inlet?

 

[slepy]

Oh, and I'm not sure if I'm up to diy refurb on a turbo myself to be honest.

 

[T!M]

If you disconnect the hot or cold side the shaft will still spin up to about 100,000 rpm from the exhuast manifold and risk stuff flying out at high speed. Sounds risky to me!

http://www.qualityturbos.co.uk/audi...er-bv43-0109-turbo-engine-brd--bva-2099-p.asp

 

[slepy]

If you disconnect the hot or cold side the shaft will still spin up to about 100,000 rpm from the exhuast manifold and risk stuff flying out at high speed. Sounds risky to me!

http://www.qualityturbos.co.uk/audi...er-bv43-0109-turbo-engine-brd--bva-2099-p.asp

Thanks for the link Tim. I've seen this website and couple of others. Just never heard of them and wonder how long their recon turbos last for. There is also one company in Huddersfield and Manchester that do them on exchange basis.

 

[T!M]

I suppose that's always a risk. A friend of mine use to use a company called Turbo Technics back in the late eighties and they're still going today so they must be doing something right!

 

[slepy]

Yup.
From what I can find on forums:
- turbo technics
- turbo dynamics
- midland turbo
are those that people rate high.

I will give them all a call tomorrow afternoon to get quotes. First, I need to take the inlet pipe off and see how bad it really is.

 

[slepy]

Got the car back from garage in the morning. Went on to removing the turbo. This is how it looks like after the balance shaft failure:

I will send it to turbodynamics tomorrow for a rebuild.

Have a question about priming the turbo. Does anyone know what I can disconnect to stop engine from starting, but to be able to turn over couple of times and build up oil pressure and prime the turbo? Normally on petrol I would pull the coil packs, but on a diesel?

 

[T!M]

I think you have to use a syringe!
There's a "how to" on the turbo technics web site from their homepage

 

[slepy]

While the turbo is being rebuilt at turbodynamics, I've decided to take the EGR out and clean it as well. Got the 2 gaskets and seal from audi today. Removed the valve and found quite a thick layer of gunk inside. Got a large can of carb cleaner and used old toothbrush and screwdriver to break through the layer. Cleaned up quite well. All in, an hour job.

 

[Pav]

All back in and running?

 

[slepy]

Yes. Turbo came back like new. Had to have the core replaced but now there is no shaft movement at all. After I fitted the turbo it runs ok and the noise in subject is gone. Also no more oil pressure light. Just has a bit rough idle which feels like misfiring. No errors on scan though. After reading some threads, it seems no one knows what causes it on these engines. Will try egr blanking plate and see if it helps at all. If it does, I will have it deleted.

 

[Pav]

Well done. I have issue with turbo atm. Favourite p0299 comes on. Actuator faulty. Not sure if I can replace just actuator on bv43 turbocharger. Best thing is that I had that turbo out few weeks ago to get refurbished for this reason and they said to me that is been refurbished and all been checked. Look's like it they missed something.

 

[slepy]

Well done. I have issue with turbo atm. Favourite p0299 comes on. Actuator faulty. Not sure if I can replace just actuator on bv43 turbocharger. Best thing is that I had that turbo out few weeks ago to get refurbished for this reason and they said to me that is been refurbished and all been checked. Look's like it they missed something.

Who did the rebuild?

 

[Pav]

Company in Nottingham, they said that they will replace the actuator FOC however it would not be a new one as you can not buy an actuator for this unit
03g145702h
Part no.: 5303-970-0109

Found some chinese stuff on google but not sure if that going to work