[1.2 TDI] - ANY - Engine rebuild

titusm

A2OC Donor
@titusm The link was to the marketplace, so I assume that you don't have access. The post referred to an engine on ebay, here's a direct link: https://www.ebay.co.uk/itm/264940350003?hash=item3dafacea33:g:rlgAAOSwVVlcozZn
thanks.
I so hate engines that are sprayed with paint to cover imperfections:))
Mine is ANY engine this is AYZ - not sure of the differences between them - apparently only maps.
A 100k km engine...should look quite clean...no need to spray it.
 

titusm

A2OC Donor
From what I can gather, main caps are pre loaded with press when assembled.
This is the reason you cannot remove crankshaft. Normal engine will be just bolted down so it will be easy to take it off.

So, rebuilding your engine without changing main bearing will be waste of time. As your engine has already done 200,000km.

May be you need to de-carbon your engine first to see if this will improve.
Piston rings should improve compression.
Rod bearings...i guess those would make no difference.

I expect injectors rebuild to make a big difference.
 

titusm

A2OC Donor
The head is held on with nuts, the studs pass through the head, so head removal is easy. To replace the piston rings (and the rod shells) undo the bolts at the crank and push the pistons out of the top.

RAB
This is what i did not get from the drawing.
I am just a little bit worried that undoing the bolts for the cylinder head would release the bolds for the block.

I was thinking the same thing...take out the oil pump and then release the pistons up top.

Thank you very much for the tip.
 

RAB

Technical Specialist 1.2 TDI
The cylinder head is designed to be removed! The only difference between an ANY and AYZ I could discover is that the former's EGR is vacuum controlled whereas the latter's is electrically controlled. That's why they have different ECUs; no other reason.

RAB
 

titusm

A2OC Donor
As usual...:))
When you plan something...things can get an ugly turn.

My wife filled my little bug with petrol:((((( and drove until the engine stopped...and then...tried to start it again a few times....
I am waiting for the new fuel filter. Hopefully the tandem pump and injectors did not suffer. Otherwise I will start with a new tandem pump and rebuild injectors.

BUT...as usual we start a new rebuild with "the important" stuff:)))...A new light switch...from ebay...(unfortunately the ones with head fog light is not available - but the front fog lights work this way too only together with rear). Do not ask me...how much I paid for it:)))
And also I installed the komfort blinker.
The car does not work but at least it looks better:))))

new_light_switch.jpeg
 

Proghound

Admin Team
United-Kingdom
Hope there's no damage to the pump & injectors. My other half did that to her car once, we had the tank drained and a new filter and all has been fine ever since. If nothing else it will have cleaned your fuel system through :)
 

titusm

A2OC Donor
Hope there's no damage to the pump & injectors. My other half did that to her car once, we had the tank drained and a new filter and all has been fine ever since. If nothing else it will have cleaned your fuel system through :)
I hope so too...
The issue now is that I can not air out the system.
I changed the filter...and drained all the petrol from the system...
Now I am trying to prime the pump - I use a small external pump too absorb fuel back in the lines but something is wrong. Maybe I broke some
o-rings when I replaced the fuel filter.

It's not an easy job... I really hate the way they mounted the fuel filter on this one...(mine has the metal filter...a real pain to change)
 

titusm

A2OC Donor
@RAB any idea what compression is good for 1.2 tdi? 300 psi / 20bar or more?
I think I might only do the injectors, tandem pump and turbo if the compression is good although I suspect it might be a bit low.
 

RAB

Technical Specialist 1.2 TDI
New: 25 to 31 bar, wear limit 19 bar. No more than 5 bar difference between all cylinders.

Any component in a diesel fuel system will rely on the lubricant properties of the fuel. Petrol has no such properties; as such, I would be most concerned about the tandem pump and injectors.

RAB
 

titusm

A2OC Donor
The new dip stick arrived.
Thanks to the guys from ebay, Poland and Lithuania. For some reason there are lots of unexpected parts for this cars in this countries.
Later today I will attempt to restart the car. I had to rebuild part of the fuel intake.
oil dip stick.jpeg
 

titusm

A2OC Donor

Back after installing the new valve: 057127247A -- the one that is installed on the filter. -- pictures in the post above

Now priming is very easy... (it took like 5 or 6 manual pumps to have fuel without air)
The engine runs better and by the looks of it the consumption is much lower.
After longer idle there is no more white smoke(and the idle is not so rough).
The injector correction ...is better(before I had correction of 0.5 when warm)...So that valve is a big pain if it goes bad...
Some pictures from when I had issues too with priming (after having to bleed the petrol out :)) ).

This is the picture of the valve in discussion(some picture from the internet). Replace it from time to time.
fuel valve.jpg
 
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titusm

A2OC Donor
I took the liberty of a small drive to get some more data with vagcom.
In the link below there is a graph on how the engine works now.
I taught that the injection deviation was slightly fixed but it seems that not so much. Injectors rebuild is still on the list.
By the looks of if - in the graph there is something wrong with cylinder 3 BUT now after the valve(057127247A ) replacement there is not such a big difference between the injectors deviation as before (in the second link/graph).

I love this site - you can upload your logs and you can see them event after a long time.
If you press the legend you can take out from the graph different readings.
Also scroll works as a zoom.
print screen:
1646253522836.png

1646738432568.png


This is another log I took almost 1 year ago. (the fuel filter valve was not changed in the next log) You can see that cylinder 3 injection deviation was much higher over all.
 
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titusm

A2OC Donor
@RAB sorry for asking you all the questions:))...
So it seems that I installed the wrong valve for the filter -> 057127247A instead of 057127247E (it fits in the filter)

From you knowledge what would be the main difference between the two (A vs E).
With my old one I tried to blow air trough it and it was extremely restrictive (the E original one). I don't know if this is normal or mine was completely broken.
With the A code (the new one) the flow is not so restricted. The air flows trough it much easier.
Apart from the opening temperature does this valve also influence return fuel flow?
And going forward...why would they install a restrictive valve on the return fuel flow(if this is the case)?
 
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RAB

Technical Specialist 1.2 TDI
They would perform the same function. They divert fuel, depending on the temperature. They should be interchangeable.

RAB
 

RAB

Technical Specialist 1.2 TDI
Just to complicate things, there seems to be possibly four versions of the valve! According to 7zap:

Audi A2​
Lupo​
AMF
057 127 247 E​
1J0 127 247 A​
ANY/AYZ
057 127 247 E​
1J0 127 247 H​

The Lupo used the early A2 fuel filter throughout its production run (and it's very easy to change, unlike the A2's).

RAB
 
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titusm

A2OC Donor
Found an engine somewhere near me.


he wants 500 euro with all included - injectors and turbo. Unfortunately the gearbox is gone:(
 

audifan

A2OC Donor
The 057 127 247 E does not appear to be available anywhere although if you swap the first three numbers to 1J0 127 247E they are available.
 

titusm

A2OC Donor
Just to complicate things, there seems to be possibly four versions of the valve! According to 7zap:

Audi A2​
Lupo​
AMF
057 127 247 E​
1J0 127 247 A​
ANY/AYZ
057 127 247 E​
1J0 127 247 H​

The Lupo used the early A2 fuel filter throughout its production run (and it's very easy to change unlike the A2's).

RAB
This means that the 1J0 might be...somehow usable?
Maybe lupo does not have this 60 degree limit for temperature?....And I believe this because the same valve seems usable in lots of other cars.
 

RAB

Technical Specialist 1.2 TDI
This means that the 1J0 might be...somehow usable?
Maybe lupo does not have this 60 degree limit for temperature?....And I believe this because the same valve seems usable in lots of other cars.
So the SSP is wrong?

The SSP doesn't make a distinction between A2 and Lupo, so why are the part numbers different between models that use the same engine?

RAB
 
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