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Audi A2 1.6 FSi BAD 2003 - Engine struggling to run & manifold glowing red #

Posted by Steve Pearman on January 21, 2012, 3:30 pm

Year of Manufacture *: 2003
Engine Size and Code *: 1.6 FSI, BAD

First listened to this car running badly at the garage while i was there doing another job, garage decided it was a problem with the head and valves,had it removed and sent away to be sorted. Now its back on the car the running is just as bad, very lumpy and it also sounds like its spitting back through the inlet.
First look at it shows no fault codes,i had it trying to idle when the light was going and with in a couple of minutes the exhaust manifold and cat where cherry red?. Garage have checked and re-checked the timing and say its correct. I measured the inlet manifold at idle and its around 3hg, dropped the exhaust and checked to see that the manifold flaps are not seized.
Any help appreciated.

Re: Audi/ A2. Engine struggling to run&manifold glowing red

Posted by Dean Gammon <iframe src='https://members5.boardhost.com/ukautotalk4/info/user=ukat3365' width='330' height='300' border=0 style='border:none;'> on January 21, 2012, 6:47 pm, in reply to "Audi/ A2. Engine struggling to run&manifold glowing red"

Is the cat blocked?

Re: Audi/ A2. Engine struggling to run&manifold glowing red

Posted by Steve Pearman <iframe src='https://members5.boardhost.com/ukautotalk4/info/user=UKAT2852' width='330' height='300' border=0 style='border:none;'> on January 21, 2012, 8:13 pm, in reply to "Re: Audi/ A2. Engine struggling to run&manifold glowing red"
Steve Pearman

Hi Dean, No it is not they have disconnected the cat where it joins the manifold which made no difference. Could a jammed open egr give this symptom, also do you know if the FSI has any thing in the manifold apart from the swirl flaps that would restrict the air flow.

Regards
Steve.

Re: Audi/ A2. Engine struggling to run&manifold glowing red

Posted by Steve Kefford <iframe src='https://members5.boardhost.com/ukautotalk4/info/user=UKAT1094' width='330' height='300' border=0 style='border:none;'> on January 21, 2012, 9:09 pm, in reply to "Re: Audi/ A2. Engine struggling to run&manifold glowing red"
Stephen Kefford

Sounds to be running very lean, there is a breather assembly down the back of the block which suffers leaks, smoke test?

Also need to confirm high pressure pump is doing it's thing.

Cheers
Steve

Re: Audi/ A2. Engine struggling to run&manifold glowing red

Posted by Glyn Morgan <iframe src='https://members5.boardhost.com/ukautotalk4/info/user=UKAT2543' width='330' height='300' border=0 style='border:none;'> on January 21, 2012, 11:51 pm, in reply to "Re: Audi/ A2. Engine struggling to run&manifold glowing red"
Glyn Morgan

Hi Steve,

Can you see the misfire counters in serial data,
is there a misfire on one or more cylinders ?

Glyn

Re: Audi/ A2. Engine struggling to run&manifold glowing red

Posted by Steve Pearman <iframe src='https://members5.boardhost.com/ukautotalk4/info/user=UKAT2852' width='330' height='300' border=0 style='border:none;'> on January 22, 2012, 11:39 am, in reply to "Re: Audi/ A2. Engine struggling to run&manifold glowing red"
Steve Pearman

Hi Glyn, no i haven't gone through and looked at all the data yet and i didn't have the label file for this model, i will do a smoke test next to see if that shows up any manifold leaks with the vacuum only showing 3Hg?.

Regards
Steve.

Re: Audi/ A2. Engine struggling to run&manifold glowing red

Posted by Kevin Apps <iframe src='https://members5.boardhost.com/ukautotalk4/info/user=UKAT2589' width='330' height='300' border=0 style='border:none;'> on January 22, 2012, 3:37 pm, in reply to "Audi/ A2. Engine struggling to run&manifold glowing red"

Steve.

Can you post exactly what work was carried out to the head. If the valve seat were cut was any work carried out to shorten the valve length

Kev.

Re: Audi/ A2. Engine struggling to run&manifold glowing red

Posted by Steve Pearman <iframe src='https://members5.boardhost.com/ukautotalk4/info/user=UKAT2852' width='330' height='300' border=0 style='border:none;'> on January 22, 2012, 5:30 pm, in reply to "Re: Audi/ A2. Engine struggling to run&manifold glowing red"
Steve Pearman

Hi Kev, I wouldnt be suprized they found much wrong with it,because its running exactley the same as before they removed it but i will ask tomorrow what was done to it.

Regards
Steve.

Re: Audi/ A2. Engine struggling to run&manifold glowing red

Posted by Darren Jones <iframe src='https://members5.boardhost.com/ukautotalk4/info/user=UKAT5495' width='330' height='300' border=0 style='border:none;'> on January 26, 2012, 9:09 pm, in reply to "Re: Audi/ A2. Engine struggling to run&manifold glowing red"
Darren Jones

Hi Steve , is the car running in stratified mode when it should not be as 3 hg vacuum could suggest this, as throttle body is activated to give no vacuumm in statified mode. Could the timming still be incorrect ie crank pulley woodruff key broken.Massive air leak but i dont think this is the case with cylinder head being removed & refitted and this would of probably would of being discoverd when this was done.Just some thoughts Darren

Re: Audi/ A2. Engine struggling to run&manifold glowing red

Posted by John Kennard <iframe src='https://members5.boardhost.com/ukautotalk4/info/user=UKAT5582' width='330' height='300' border=0 style='border:none;'> on February 1, 2012, 1:55 pm, in reply to "Re: Audi/ A2. Engine struggling to run&manifold glowing red"
John Kennard

Hi Steve, I have had a number of vehicles that have had symptoms just like this in the past, some struggle to run others run fine, it only seems to take moments for the exhaust manifold to become cherry red. In all cases it was down to a misfire situation and excess fuel entering into the exhaust and overheating the system, a set of ign coils has cured every one.

I have never forgotten a Renault scenic; I drove 1.5 miles to the dealer to pick up a set of coils and on the way back I wondered what all the smoke and hot smell was coming from the car, it was dark and as I drove into the yard one of my mechanics wondered what the strange red glow was under the vehicle. The whole exhaust from manifold to tail pipe was about to melt and the rubber mounts were smoking and just about to catch fire, we never got the burning smell out of that car. I have even had them where the misfire has been virtually undetectable and the exhaust heats up excessively with no misfire codes recorded but coils have cured the problem. I would guess the excess fuel flashes off the CAT if it is an efficient catalyst and raises the temp of the exhaust. Hope this helps.
John Kennard.

Re: Audi/ A2. Engine struggling to run&manifold glowing red

Posted by Joe McGeoghan <iframe src='https://members5.boardhost.com/ukautotalk4/info/user=UKAT5290' width='330' height='300' border=0 style='border:none;'> on February 2, 2012, 10:37 pm, in reply to "Re: Audi/ A2. Engine struggling to run&manifold glowing red"

Cam has spun on pulley boss.

Re: Audi/ A2. Engine struggling to run&manifold glowing red

Posted by Steve Pearman <iframe src='https://members5.boardhost.com/ukautotalk4/info/user=UKAT2852' width='330' height='300' border=0 style='border:none;'> on February 8, 2012, 11:02 pm, in reply to "Re: Audi/ A2. Engine struggling to run&manifold glowing red"
Steve Pearman

I've still got to get back and sort this out guys, so keep your ideas coming, much appreciated. I will let you know how it goes asap.

Last time there i did a smoke test which didn't show up any major leak and also asked about the cylinder head repairs. The only problem they found where worn guides(no burnt valves).

Regards
Steve.

Re: Audi/ A2. Engine struggling to run&manifold glowing red

Posted by Kevin Apps <iframe src='https://members5.boardhost.com/ukautotalk4/info/user=UKAT2589' width='330' height='300' border=0 style='border:none;'> on February 8, 2012, 11:51 pm, in reply to "Re: Audi/ A2. Engine struggling to run&manifold glowing red"
Kevin Apps

Steve
"The only problem they found where worn guides"

So the seats would (should) have been re-cut ?

Kev.

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