2005 A4 Engine swap disaster. Advice needed please

[podge999]

HI Guys,
I'm having some serious problems and id appreciate any input from somebody who has a bit more experience than me with motors. Apologies if this is a bit long but its a tough one....

I have a 2005 A4. 2.0 TDI with the CVT box (Not sure if its B6 or B7). About 4 weeks ago i had the car dropped to indy garage because the engine wouldnt turn. I was told that the oil pump balancer shaft assy was shattered along with mountings, internal damage etc and that the engine was knackered. This is a BLB engine with the infamous balancer shaft issue.

The mechanic sourced a replacement engine that was also BLB engine code but it turned out that while it was a BLB engine, it was a later version that had the new gear assembly for the oil pump.

Tried to drop in the engine, found it wouldnt fit due to sub frame differences so he changed the sump and fitted the engine. His Audi contact advised that this was perfectly acceptable.

He used all my original electrics, injectors,sensors and wiring looms.

Car wouldnt start. Engine turned but wouldnt fire up. Dropped it out to Audi Main Dealer and after 4 days they identified the copper compressible washers that go under the injectors as the issue. These were replaced and still the engine wont start.

Audi have now given up saying that it is an electrical problem between my electrics and the new engine. A siemens - bosch mismatch that is probably unresolvable.

Car is back at indy and he wants to call it quits on this engine and try and source another engine but one that is an exact match for the one that came out.

Has anybody here any experience of this type of engine swap and the issues I am seeing? Is there any advice ye guys can give on how to proceed?

Any and all help much appreciated.

Regards
padraig

[danclyon]

If you can stomach being without it for a while, why not get your own engine remanufactured? Ivor Searle do a great job of this - won't be cheap - but will come back working.....

[Crasher]

The BLB was only made from 11/04 until 11/05 and they all use the same injector so that excuse is complete ********!

[kamil86]

as far as i know those injectors hasn't got a copper washer. but new stretch bolt need to be fit every time you replace injectors. they can cause problems. and also if they replace crank seal on gearbox side it need to be properly set up with timing. because is build in with reader ring for crank sensor.

[Crasher]

That is a bloody good point, they have not got a copper seal, me smells some bovine rectal emissions. Yes the crank sensor is a major problem on this engine.

[podge999]

Hi Lads,
Cheers for the feedback. In the end that engine was a load of ***** and i called it quits. Second engine had some ball bearings in the oil so that was a no go.... In the end i went and got a reconditioned engine/turbo fitted and picked her up last night. Sounds pretty damn sweet.

Apart from the non working headlight,empty aircon and greasy handprints in the cabin the only thing i'm worried about is the engine temp readings.
Previously it always sat at 90 degrees after a few mins of driving and ive confirmed running temp with two other lads with same car.
But now its sitting just below 60 (confirmed via OBD) after a good 20 mile spin. Indy says he noticed it was running cool but that everything was fine....

My bs detector is pinging....any ideas on why temp would be reading so low and whether or not im doing damage...

cheers

[pippip]

Stuck thermostat would be best bet.

Had mine running cold for about a year before I got it fixed. Used to go up if car had been running a while and if i left it parked and idle and turned off the aircon.

[podge999]

Stuck thermostat would be best bet.

Had mine running cold for about a year before I got it fixed. Used to go up if car had been running a while and if i left it parked and idle and turned off the aircon.

Yeah that seems to be most likely, and ill only be running for a week or so before i get it looked at. Ran VAGCOM on it there and got a shed load of instrument cluster errors so i reckon theres also some wiring probs somewhere along the line.

[fla]

it may seem inocuous but i would change the stat sooner rather than later as some cars run rich for longer if the stat is stuck open. Not too good to do for too long