Audi 80 tdi juddering bucking jerking

[Obsidian]

yo! Midskev, you say u got the turbo off complete with the exhaust manifold? before the inlet manifold came off? Can u access all the screws/nuts easily in that state? i've struggled so far, ended up having to remove all the piping and the air filter to get at and still couldn't see a way of getting the thing off. Also, did you need any gasket kits, so the exhaust and inlet manifolds? i'm assuming you did but you never know, there seems surprisingly few around the turbo area.

[midskev]

hi

yeah i took airbox out and all pipework egr exhaust inlet pies ect

then undid the 8 bolts on the exhaust manifold they need a good crack to shift them and a brused knuckle or two

gaskets where fine both inlet and exhaust

[Obsidian]

thnx m8, gonna give it ago in a few days, weather permitting, and time of course, it'll be the third time i've taken it apart to clean the inlet manifold.

did someone mention replacing the rubber signal hoses? the little braided felxes to all the sensors? wondered wher u get such things from, think igot afew suspect ones i wanna be sure of again.

did any1 find out where the 109 relay is?

[allan_audi]

thnx m8, gonna give it ago in a few days, weather permitting, and time of course, it'll be the third time i've taken it apart to clean the inlet manifold.

did someone mention replacing the rubber signal hoses? the little braided felxes to all the sensors? wondered wher u get such things from, think igot afew suspect ones i wanna be sure of again.

did any1 find out where the 109 relay is?

Why do you need to remove the exhaust/turbo etc to remove the inlet manifold? I removed my inlet manifold for cleaning, took couple of hours. Its little bit fiddly, but you can get the allen keys around the turbo/exhaust.

[Obsidian]

thnx there allan! You must have alot more patience then I, or bendy alen keys! I tried to do what u just suggested but always failed to get onto the screw heads, how many hold on the inlet manifold? coz i can;t seem to get two in the central area, because of the turbo unit.

just as an update, i cleaned out the turbo inter-cooler and re-fitted it, but found the little signal pipe tapped intoo the output duct was a bit brittle. I've since replaced this and cleaned out the nozzle, and it seems like the juddering is less common and far less severe. I dunno wether this is just me or maybe others have found this. All i did was replace the last couple of inches of the pipe, there's a flexible rubber-type sleeve on the end of the rigid plastic pipe, where it fits to the inter-cooler nozzle.

Since doing all this work i think i've generally improved the running of my car, it feels more responsive now, so thnx you guys, it's been a help. Only wish i could definitively get rid of the juddering.

[allan_audi]

thnx there allan! You must have alot more patience then I, or bendy alen keys! I tried to do what u just suggested but always failed to get onto the screw heads, how many hold on the inlet manifold? coz i can;t seem to get two in the central area, because of the turbo unit.

just as an update, i cleaned out the turbo inter-cooler and re-fitted it, but found the little signal pipe tapped intoo the output duct was a bit brittle. I've since replaced this and cleaned out the nozzle, and it seems like the juddering is less common and far less severe. I dunno wether this is just me or maybe others have found this. All i did was replace the last couple of inches of the pipe, there's a flexible rubber-type sleeve on the end of the rigid plastic pipe, where it fits to the inter-cooler nozzle.

Since doing all this work i think i've generally improved the running of my car, it feels more responsive now, so thnx you guys, it's been a help. Only wish i could definitively get rid of the juddering.

Yeah it is more awkward than difficult, there are six bolts. You need to remove the air cleaner and the turbo pipes out the way, but it is possible. You need to acces from underneath the turbo, using 1/4" socket and allen key bits with various size extensions. You can see the bolt holes in the diagram below (item 25), you may need to register for the website but its free.

http://www.vagcat.com/epc/cat/au/A80...50/49/1603042/

I've not looked at the intercooler yet, I'll try changing the rubber hose, it has to be perished by now.

I definately have the car running much better.

[stevegrass777]

I think i have read somewhere that the map sensor is a common faulty component.
It is in the ECU .I think it can be replaced along with small pipe....
Could this overboost the turbo and cause the Big pressure pipe to burst.

[allan_audi]

I think i have read somewhere that the map sensor is a common faulty component.
It is in the ECU .I think it can be replaced along with small pipe....
Could this overboost the turbo and cause the Big pressure pipe to burst.

If the map sensor were faulty I dont think you would get boost. Most of the pipes on these cars are old now, I think age is getting the better of them. The large rubber pipe on the inlet moves around because its fixed at one end and moves with the engine on the other, so probably splits with age and wear.

[Obsidian]

thnx for that allan, it's sligthly different to my engine but it seems to tally up in the crucial area, of the inlet manifold, i still think i'm gonna struggle getting those bolts off. i'm not a give at the first hurdle kinda guy and have several attempts at getting it off, it's just too cramped to get any of my tools onto the bolts at all.

Anyway, back to the MAP pipe, i suspect that the rigid plastic pipe could also be partially blocked with debris, and may merit a good blow out, though getting the whole thing off maybe a bit of a task. Certainly seems to be less of a judder now, and i've found that the flexible woven hose to the waste gate valve is also a bit perished and brittle, along with the EGR hose too! Maybea cumulative effect going on there, the cars are all 'of an age'.

Hmm, i'm also scratchy my head a bit about the front brakes, uneven wear in pads has been high-lighted on arecent MOT and on closer inspection i think on of my calipers maybe binding a tad. Might be something to look at.

[allan_audi]

thnx for that allan, it's sligthly different to my engine but it seems to tally up in the crucial area, of the inlet manifold, i still think i'm gonna struggle getting those bolts off. i'm not a give at the first hurdle kinda guy and have several attempts at getting it off, it's just too cramped to get any of my tools onto the bolts at all.

Anyway, back to the MAP pipe, i suspect that the rigid plastic pipe could also be partially blocked with debris, and may merit a good blow out, though getting the whole thing off maybe a bit of a task. Certainly seems to be less of a judder now, and i've found that the flexible woven hose to the waste gate valve is also a bit perished and brittle, along with the EGR hose too! Maybea cumulative effect going on there, the cars are all 'of an age'.

Hmm, i'm also scratchy my head a bit about the front brakes, uneven wear in pads has been high-lighted on arecent MOT and on closer inspection i think on of my calipers maybe binding a tad. Might be something to look at.

If you want to clean the rigid plastic pipe, why not try using an airline, take the end off the ECU first otherwise you will damage the pressure sensor, then blow the line out from the intercooler end.

As for uneven brake pad wear, its usually calipers sticking seized, check the glide pins too (Single pot with sliding caliper), I refurbished calipers with new seal kits but I'm wondering whether its just easier to replace the calipers, especially the rears.

I wish there were somewhere to compile a list of technical details, cause we're discussing all kinds of things on this one thread!!