jimjamjo

Just finished putting the A4 engine in. In case anyone's interested heres some particulars: The 1z engine came with the same injection pump, starter motor, flywheel, turbo, cylinder head The A4 items which were different: Clutch, Gearbox, manifolds, oil filter assembly, water pump pulley, engine front and rear plates, mountings, drive shaft mounting bracket, turbo to head oil feed pipe (on the A4 its turbo to oil filter housing), power steering bracket, coolant pipe on head Also, the 4 holes for the left engine mountings on the A4 are M8 - not M10. So these need oversizing and tapping. I'd never done this before but it was surprisingly easy. Using a 9mm drill bit, drill out the hole letting the drill do the work and then wind a 10mm tap into the hole. So with the tapping and different items, its quite a big changeover and added a day or so to the job. Main points: 1. change the oil filter housing over with the water pump assembly at the same time. You could leave the A4 filter housing if happy with using A4 filters :) . This would leave the turbo oil feed going to the oil filter housing instead of the head (the temperate gauge swaps over with the oil feed) 2. the A4 front plate covers 2 holes for the Galaxy left engine mounting so remove camshaft pulley, injector pulley, timing tensioner etc and remove the front plate. Retap the 2 holes to M10 as above before you put the new front plate on. 3. I used the A4 head with manifolds - the manifolds are a different size but everything else fits in with them ok as long as you swap over the turbo to head oil feed pipe. 4. remember to change the engine rear plate over when you swap gearboxes 5. the 3 holes for the Galaxy driveshaft mounting bracket were the right size but all rusted up on the A4 and also needed retapping M10. Nothing caused a major problem apart from removing hose clip from turbo vacuum pipe with a hangover on Sunday morning - ended up snapping the little f**ker off. By the way, the engine off eBay was showing moderate leakage from all four chamber on a leakdown (about 50%). It did smoke a fair bit for the 1st 5 miles but seems not too bad now - to be honest I've had enough of smelly old diesels so its going in Autotrader. Here's a pic of my new 2.3 petrol Gal :rolleyes:

hmm I had a broken hydraulic lifter in head (same 1.9tdi)- hard to start and copious white smoke when engine cold, minimal when warmed up. Youre due for a valve grind and new tensioner(if not yet changed) at 150k anyhow

Thanks for the advice Turk Bought an Audi A4 1z engine off eBay: http://cgi.ebay.co.uk/ws/eBayISAPI.dll?Vie...em=250121951237

Any one know where to get an 1z engine around Manchester? (Looks like rebuild would be around

Forget that - No 2 piston also worn :ph34r: Also topside of each bigend shell pitted

Hi I did a rebuild on my Galaxy about 18 months ago with 4 new standard pistons. It was fine for 12 months but suddenly conked out about six months ago - almost total loss of power and lots of smoke. Finally got round to leakdown testing it a couple of weeks ago - 2nd-4th chambers fine but no pressure on no 1. I've taken the head off and got the engine out again groan. no1 piston is chipped on top and looks like detonation 'melting' the crown between the inner hole and edge (pics to follow). Got the head checked over and that's fine. I could get a nearby mobile mechanic out to rebore 1 cylinder and pop an oversize piston in... or strip the block and get the full set(again!). Can anyone give me advice either way bearing in mind that I'd like to get another 4 years/ 60,000 miles out of it. I'd much rather go for the one cylinder option to save time and money but not if it ends up driving like a tractor. Also, there's 170k on the clock so far. 1998 1.9TDi

Hi I blinged the Gal with a MP3 CD player a couple of weeks ago. It was in Aldi for

Hi mate Must admit that's a good suspect - I'm on my third one! I've had a quick look at it - the front bolt is tight. I'll take it off and have a closer look

Just when I thought I'd got the old girl sorted, it's started juddering pulling away in 1st and reverse. I put a new B+B clutch in last October and it's done about 5,000 since. I took my time when I fitted it and double-checked all the bolts. Had a look at the mounting under the airbox and there's a bit of play - not sure what the tolerances are though? I've checked the forum and couldn't find any posts about it at all - which was a bit worrying. Help please?

Hi Ivor To clear up any confusion, here's a pic of the wife looking after our pet bunny:

Used the ignition and bar - loose in 2 secs :o

MM 2 posts with the same advice = a good recommendation :P I remember doing that a few years back on an old banger and it popped off nice and easy. The Haynes says 90Nm + 90 degrees which seems a piece of cake It feels like 200Nm trying to get it off at the moment. I might go with the wrench anyhow as the spend has been authorised by the wife. I managed to get her to agree to an engine crane a few weeks back :o

Cheers JB I was inclined to go that route after flying through the air when the wrench slipped off the hub nut a few weeks ago trying to get the 150Nm + 90 degrees Looking through the old posts (I've just realised that the default search is only past 30 days :o ), theres one about an electric impact wrench to undo the crank pulley. It seems a bit of a cop out but garages use air tools... prolly pick up this tomorrow am: http://www.machinemart.co.uk/product.asp?p...13&r=2047&g=107 :P

A bit tricky - busy time of year for me - I've got the mounting off so far. I've priced up the cog at

Yes mate

A piece of the grooved intermediate shaft pulley under the fuel filter pulley has snapped off as a result of something lodging behind it. Replacement sprocket =

Had another look under the timing cover, the belt looks fine, the tensioner appears ok but its hard to see the alignment marks on the tensioner without taking it all apart. I put some rough tippex marks on the cam and fuel cogs before doing the valve timing. I lined all the cogs up by the book e.g. bar in the end of the cam and rod through the pump cog and forgot about the Tippex . But looking at the tippex marks now, the fuel sprocket may be one cog out based on the Tippex. :unsure: Its run fine for 400 miles - I remember tightening the tensioner to 20Nm so can't see how it would slip?

How did your cambelt tensioner fail out of interest? Did the nut come loose in the middle I've just rebuilt my engine after 163k and reused the original tensioner...

Theres clouds of white smoke out of the back when its towed in gear and and a big patch of black soot on the floor by the exhaust when its stationary Unscrewing the fuel pipe on an injector gets spurts of fuel out of the pipe The only visible sign of a problem the morning after the breakdown was that main power relay 109 was half out of its socket. Retracing the journey, I'd driven over a speed bump about 400 yrds before. I've tried a new smaller grey replacement relay but no different.

Welcome Sword Does sound like the multigroove belt has snapped - possibly after one of the components attached to it has seized e.g. steering I'm not sure about the 2.8 but its all easy to see when you take off the air filter housing on the 1.9. Hopefully, a veteran 2.8r will offer an opinion Good luck with it

Hi Is there a engine warning light on the 1.9 anyone please? I've never seen one on start up. The only contender when you shine a torch on there is what looks like a 1 between two arrows. I made the mistake of leaving the owners manual under the drivers seat when the car had a leak a few years ago :unsure:

Hi Mate The nut went down the downpipe while the exhaust was disconnected from the turbo so won't expect it to come back up again. I've pretty much ruled out engine mechanical failure as the car died suddenly without misfire or noise.

no dice but thanks for the suggestion

:unsure: Oh that one. No it comes on for 4 secs when you put the key in and then goes off and stays off whether you crank it or not

No just battery light. Oil light goes out after a bit of cranking. I don't think I've got any door warning lights...