Oil pump chain smashed thru alloy case and discussion on replacement oil pump conversion kit for BLB engine

[wjam]

You know I'm reading this with dismay. I have the same dealer problems in France.. Same sh1tty aftermarket"guarantee" which was worthless.. And I found an indie garage to do my work.

I saved money buying the parts (from OEM) and getting the indie to fit it.. about 800 saved over Audi and "guarantee" price.

Anyway, I just got to say that they are maybe the worst service I ever experienced. They also break the law. The local main dealer charged me for glow plugs they didn't fit (400 euros like) and I only found out cos i sought a 2nd opinion. Of course they then changed the glow plugs,

They left a case open against my aftermarket "guarantee" that effectively blocked all future work, despite the fact that I rejected their diagnosis in writing... The tactics are in fact simply criminal. I even got e-mails form them saying they considered me to be rude and offensive, Because I rejected their diagnosis.. which was adding parts that don't affect the problem I had reported . They insisted they MUST change everything diagnostics tells them...

I bought VCDS to ensure I was armed when i went in and this really ****** them off. Refusla to talk, but the case lay open.. so I was able to spend 3k there or do nothing.

a shower and no mistake. I wrote to the CEO with letters evidence etc.. Nothing. he doesn't give a ****

good luck all

WJAM

[TeZREX]

hello guys.

Why don't forget about expensive and shity main dealer repairs?
Talk to real vw/audi specialist not dealer trained but trained by life and love to the cars.

Let's come back to the 1.9 PD engines with simple oil pump. 2.0 tdi has very similar engine block to 1.9 pd tdi so basically it works like LEGO. Belive me or not but there is quite few BLB with above conversion driving perfectly. There is correct oil pressure from very reliable oil pump, less vibration due to removed balance shafts and more power without them.

engine with balance shafts and unreliable oil pump
http://www.fotosik.pl/pokaz_obrazek/...3c90bdd43.html

http://img341.imageshack.us/my.php?i...701280x768.jpg


same engine with old type il pump
http://www.fotosik.pl/pokaz_obrazek/...30694068c.html
http://img526.imageshack.us/my.php?i...801280x768.jpg

I'm currently doing above conversion in my a4 tdi with BLB engine which is a lot better and cheaper than your usual repairs. Hopefully back on road in 2 weeks time as i'm busy at work. Any one interested is more than welcome to come and have a look.

all this going to scrap http://s1666.chomikuj.pl/ChomikImage...&vid=617853439

BLB oil pump with balance shafts vs basic ARL oil pump http://s1666.chomikuj.pl/ChomikImage...&vid=617853440

my engine in work progress http://s1666.chomikuj.pl/ChomikImage...&vid=617853441
http://s1666.chomikuj.pl/ChomikImage...&vid=617881618


I know i know your mechanic / dealer said that it's not possible - come and check me.



chris

Did this conversion work and what effect does no balance shafts have on the engine??? Does anyone have any more conversion information??? My pump has'nt failed yet (SH*T friday 13th tomorrow!! :?/) but I don't fancy spending £900 on bits...
TeZ

[Mini Hog Dog]

Thankyou for all contributing so far to this very interesting and quite alarming thread, I also have an early BLB engine in my 2.0TDI Avant (Jan 05 on a 54 plate) the only good thing in my
case is no sign of anthying untoward so far and I bought new and have let the dealers sevice it so far, she has 80,000 miles up (just over 12000 miles per yr) and touch wood drives really well as it did when new. Having read the content of this thread so far what is not clear to me is the number of oil pump chain issues compared to the number of cars not yet affected, I would think many cars the same age as mine (6.5yrs) would have done more miles than mine, and a good numer at 120,000 - 150,000miles. I just dont know but would have to guess across Europe there would be tens of thousands of cars with engines code that have the chain type oil pump. If money was no object I would have it converted, then again If no object, I would have probably traded it in by now. Can the problem cause catastrophic failier in a single journey ? if so you may never get the chance to hear the problem start, yes you could be at high speed on the motorway where the wind and tyre noise would make it virtually impossible to detect. I must hope it never happens to me, and I will listen very carefully to my engine when it is cold and also when hot before I switch off.

[Mr-Rob]

To be honest mate, no one is able to give any definative answers.

Like you said there are thousands of cars running around with this design, like all forums a particular problem is magnified as it concerns just that type of car.

Stop worrying and just drive it, that's what I do.

[kjauto]

It does , I,ve had it running for 1 minute today - didn't drive yet. All front end needs to be put back together but engine started up and sounds ok - oil pressure ok. (let me remind - 1.9 ARL bottom end)




No balnce shafts in engine makes it quicker - less resistance to crank.

Balance shaft was designed to make a4/a6 engines smoother i mean less vibration as they are mounted in line to the body. Lets have a look on BKD golf engine (2.0 tdi) It's exactly same engine as BLB or BRE or any other with balance shafts. It works on the old oil pump exactly same as 1.9 tdi engines. You dont beleive check the part number. So if you have a look closer to 1.9 tdi and 2.0 tdi its basically same engine. Obviously BLB is twin cam head but engine block is same for 1.9 and 2.0 with slight modifications for 2.0 .

Balance shafts idea is absolute useless and causes troubles with oil pump drive. If anyone is iterested with my conversion i can provide some more info such as parts numbers and photos.

Don't let Audi dealers or specialists rip you off. Make it cheap and simple.

[TeZREX]

It does , I,ve had it running for 1 minute today - didn't drive yet. All front end needs to be put back together but engine started up and sounds ok - oil pressure ok. (let me remind - 1.9 ARL bottom end)




No balnce shafts in engine makes it quicker - less resistance to crank.

Balance shaft was designed to make a4/a6 engines smoother i mean less vibration as they are mounted in line to the body. Lets have a look on BKD golf engine (2.0 tdi) It's exactly same engine as BLB or BRE or any other with balance shafts. It works on the old oil pump exactly same as 1.9 tdi engines. You dont beleive check the part number. So if you have a look closer to 1.9 tdi and 2.0 tdi its basically same engine. Obviously BLB is twin cam head but engine block is same for 1.9 and 2.0 with slight modifications for 2.0 .

Balance shafts idea is absolute useless and causes troubles with oil pump drive. If anyone is iterested with my conversion i can provide some more info such as parts numbers and photos.

Don't let Audi dealers or specialists rip you off. Make it cheap and simple.

Kj thanks for the reply some more info would be really useful so I can decide what to do. Looking at the parts prices for the Oil pump and other kit it may be a lot cheaper and more reliable. Did you change the crank chain gear or swop the crank?? A parts list and some more detailed photos would be great...Im hand with the spanners so it doesnt phase me (bike engines are worst to work on...but generally more reliable)
Otherwise its a swift trade in if anyone will touch the car :?(

TeZ

[kjauto]

Hi, fortunately i'm dealing with car parts and had fire damaged ARL in stock. I ve used complete bottom end such as bearings, crank, oil pump. You can leave your old crank but there is quite difficult to remove sprocket off the crank and put new one on, make sure that you will not scratch the crank where the crank seal goes. Obviously you need a small one sprocket for old type oil pump. Another way is to use any crank 1.9 or 2.0 working on old type oil pump but there is a little problem with crank sensor ring set up ( speacial tool to set up correctly £300 for tool!!!) I've done mine without but wasn't easy.

Parts list as following:
Crank off: BKD, BMN, BMM, AZV, BSY or any 1.9 tdi PD
If use your crank front sprocket - 06A105209B £15
Oil pum chain 038115230A £ 18
chain tensioner 038115130 £6
Oil pump 03G115105 or 038115105B/D £75 ebay (£150 dealer)
Oil pipe (to feed pump) 06B115251 off AJM, AWX, AVf
Plastic cover between crank and sump 038103623 http://images37.fotosik.pl/278/30f938e6d009dc51m.jpg
Front oil seal 038103085E
rear oil seal 038103171S
Tube of good sealnt for sump (I always use wurth )


Then you will need to block oil feed for old pump/balance shafts, put everything together - job done

All scrap from my engine


Basic blb engine



Tool for rear crank seal


Crank off blb and ARL


Feed pipe for pump has got to be slightly customized


All done



Balance shaft surround


Oil feed to block up










I hope that will help

All done and tested (300 miles allready) Engine is smooth and quiet, gives a better response for acceleration.

[TeZREX]

Cheers for that, something to give serious considertion to...using the M?bike all the time at the moment.
Top work!!!

TeZ

[kjauto]

Fetch me your engine to wf9, will do it 4 you within 2 days

[alfie155]

brilleant! ive just bought a 2005 2.0 tdi 140 s-line avant! BLB engine! all my life ive wanted an audi and when my dream comes true i buy the wrong bloody one and read horror storys about!

oh im sh1tting myself now