High emmissions on 1.4tdi

Little Dog said:
I believe I have one of those in the attic, it didn't fit my A2 though Fibi Pats Finder said it would. I had to buy the expensive new cover option as advised by @Robin_Cox . At the time the earlier gasket was NLA from Audi so I don't know where you will get one now other than used on eBay.

You probably need a good mechanic, if I'm right and you have the wrong gasket, it will have been blindingly obviously wrong and he should not have fit it. Where are you in North Yorkshire? Send a PM, I may be able to help.
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@Little Dog I'm a bit confused now. I spoke with Audi, the part number 045103483C, this is the same number as the febi one I bought. Audi said they had no notes down to say any design change. So if the same code, have I bought the right one? The mechanic seems really experienced but as said don't think overly familiar with A2's, it seems like the overall design of the a2, everything seems difficult to put right :)..
 
Sunflower said:
@Little Dog I'm a bit confused now. I spoke with Audi, the part number 045103483C, this is the same number as the febi one I bought. Audi said they had no notes down to say any design change. So if the same code, have I bought the right one? The mechanic seems really experienced but as said don't think overly familiar with A2's, it seems like the overall design of the a2, everything seems difficult to put right :)..
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It's an old car so many parts are NLA, makes them challenging to maintain. I'll get you some pictures to illustrate this problem.
 
This is a factory cover with factory seal, this is what I think you had on your car:

IMG_1177.JPG


There are 4 internal locating slots with a tag on the gasket. on the outside there is a corresponding recess that is sealed with a raised tag on the gasket:

IMG_1186.JPG


The Febi gasket and later Audi gaskets have neither tags and are much lower so freely pass oil through the 4 slots and their corresponding recess:

IMG_1182.JPG


There is also a locating tag on the Febi gasket that stops it seating at the top of the bearing cap.

As a result a new gasket with an original cover floods oil down the back of the engine.

You need to check your cover; if it is factory original it will not seal with a new gasket.
 
@Little Dog
Thank you , I appreciate you taking the time to post all this information. I see what you mean now. I presume mine is the original. All these things I'll check, thanks again. I'll keep you updated.
 
Sunflower said:
@Howey
No I couldn't see any smoke myself, but I wasn't revving it up like the mot garage.i could smell burning at times though. you sound like you know what you are doing re the petrol, not sure if I'm brave enough at the moment. What does adding the mineral two stroke oil do to the diesel?
I will try get a one off test before putting in for retest if I can, if not just hope I ho
I can get the engine clean of the oil mess and hope for the best!
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Adding mineral 2 stroke oil is said to help lubricate the fuel system and ease starting, might be all nonsense but it sure doesn't hurt anything!

The diesel emissions test is in my opinion a total and utter farce with no defined limits for how hard/fast to rev an engine and the instructions given are totally contradictory. Most modern vehicle don't rev beyond 2500 rpm whilst stationary so that's a good bench mark
 
Little Dog said:
This is a factory cover with factory seal, this is what I think you had on your car:

View attachment 127039

There are 4 internal locating slots with a tag on the gasket. on the outside there is a corresponding recess that is sealed with a raised tag on the gasket:

View attachment 127040

The Febi gasket and later Audi gaskets have neither tags and are much lower so freely pass oil through the 4 slots and their corresponding recess:

View attachment 127041

There is also a locating tag on the Febi gasket that stops it seating at the top of the bearing cap.

As a result a new gasket with an original cover floods oil down the back of the engine.

You need to check your cover; if it is factory original it will not seal with a new gasket.
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Is the same true for the 4 cylinder 1.9 engine as my friend has just had exactly same leak on his mk4 golf
 
there is a very similar drawing and instruction for the sequence of bolting / unbolting of the rocker cover for the 1.9tdi as for the 1.4. I wouldn't be surprised at all if it is similarly sensitive to the design - and possibly generation of cover / seal compatibility (given how many of those engines were built probably went through the same evolution process?).
 
Howey said:
Is the same true for the 4 cylinder 1.9 engine as my friend has just had exactly same leak on his mk4 golf
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I don't know but I would have thought the 4 cylinder PD covers from the factory would be extended 3 cylinder covers. They would have had the same issues as the 3 cylinder so would probably also have had the same upgrades.. The best thing your friend could do is to retrieve the old gasket.

@Sunflower the cover I have in the attic is a 045 103 475 B, it came off a 2002 AMF engine. The new cover currently available from Skoda and posted earlier is a 045 103 469 G. Checking on Autodoc the cover changed 08/2003 and became 045 103 475 C. However 045 103 475 C is listed as compatible with 045 103 469 G E J and others too. All very confusing but it appears pre 08 2003 cars had cover 045 103 475 B and this became obsolete and NLA when 045 103 475 C was introduced with a new gasket design. If you car is earlier than 08 2003 then you likely have the wrong gasket fitted. If it is post 08 2003 the you need to take a closer look at the components you have fitted before you buy more parts.
 
Little Dog said:
I don't know but I would have thought the 4 cylinder PD covers from the factory would be extended 3 cylinder covers. They would have had the same issues as the 3 cylinder so would probably also have had the same upgrades.. The best thing your friend could do is to retrieve the old gasket.

@Sunflower the cover I have in the attic is a 045 103 475 B, it came off a 2002 AMF engine. The new cover currently available from Skoda and posted earlier is a 045 103 469 G. Checking on Autodoc the cover changed 08/2003 and became 045 103 475 C. However 045 103 475 C is listed as compatible with 045 103 469 G E J and others too. All very confusing but it appears pre 08 2003 cars had cover 045 103 475 B and this became obsolete and NLA when 045 103 475 C was introduced with a new gasket design. If you car is earlier than 08 2003 then you likely have the wrong gasket fitted. If it is post 08 2003 the you need to take a closer look at the components you have fitted before you buy more parts.
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His brother fitted 2 new Gaskets (old ones long gone sadly) then he took it to his garage where it was fixed but the mechanic only stated that he fitted a "better gasket". It's sorted now but not sure how
 
Hi, sorry for the delay in updating my progress. It passed mot
😀




I spent a lot of time trying to source rocker cover to suit and had so much to catch up with. It was challenging, v stressful as short on time. In the end I purchased 2 covers, Skoda G model and a supposedly D cover!.(that's what I was told). I wanted to make sure I had received one by the time taking my car to the garage. The cover on my car was the D model.

.i ended up using the skoda G one, which was better. Thanks @Robin_Cox. The other one looked different to my original one, you couldn't see a letter after the numbers
😟




This seems OK, no oil leaking, so far.

I then put in the forte Fuel emmissions, used the v power, tried to give it a good run before taking it in. I can't find the print out details to post, but the emmissions had halved to 1.50. I had also used a diesel purge can before this, so maybe this helped also. The mot guy was a bit surprised
😄
. So, it was a huge relief I could drive it home.



Thanks again to everyone forr all your input, knowledge and help, what an amazing group this is
🙏
.. I wished I had checked to start with though.
If anyone needs a rocker cover, let me know!. I've hot a lot to learn..





@Robin_Cox @Little Dog @Howey @bix

@dj_efk
 
Sunflower said:
Hi, sorry for the delay in updating my progress. It passed mot
😀




I spent a lot of time ...

.i ended up using the skoda G one, which was better. Thanks @Robin_Cox. The other one looked different to my original one, you couldn't see a letter after the numbers
😟
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very glad to hear it! Although obviously sympathetic to the hassle you went through, the resulting discussion and end result nicely describe the entire issue, so this will be a useful thread for other folk encountering the same issue in the future.
 
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