2001 Allroad 2.5tdi AKE timing belt tensioner failure

**Crasher** · 11-10-2014,06:32 PM

Which tensioner had the bolt sheared off on?

**skyegtb** · 11-10-2014,07:44 PM

Hello again! Well, got stuck back in to it again this afternoon and by 6.30pm I had the camshafts removed. Unfortunately I found extensive damage - pretty much all 24 rocker fingers were shattered (many of them have presumably ended in the sump as lots were missing), one of the camshafts was sheared in 2 and some of the camshaft bearing caps were shattered. On the same head as the broken cam one of the bearing cap studs had been pulled out from the head and left a broken hole where it used to live... I didn't get a chance to start pushing the valves as it began raining very heavily along with getting dark. I pulled the injectors out too thinking that I might be able to do a pressure test in to the bores with my air compressor to check the valves, but at this point in time I would be very surprised if any of the valves were still straight... Anyway, one of the heads is definitely needing welding at minimum so I'm already thinking about either scrapping the car or possibly getting a recon eninge if the price was right. I see a lot of used engines on eBay - maybe that will be the way to go.
Out of interest, the camshafts in this car seemed to be in great condition with almost no sign of wear. I also noted that they were solid cast cams but for some reason I thought AKE engines had the hollow cams. The cams also had no Audi markings or anything like that. Do you think these were replaced before I bought the car 3 years ago?
Anyway, tomorrow I will test the valves as best as I can and will report back. I might even take the heads off as I really want to see the condition of the pistons. I can still hardly believe the amount of damage I found.... I can't believe a cam would snap as the result of the tensioner bolt shearing, but it certainly looks like it did..
Here are all of the pics I took that should show things in more detail. Comments are welcome!

**bluezie** · 11-10-2014,08:06 PM

Oh dear, that's about as bad as it can get!

**Crasher** · 11-10-2014,10:45 PM

That head with the broken cam cap base is dead. I would find a pair of the later roller cam heads, rebuild them and fit. I have done this conversion in the past using the genuine exchange heads but at £2k per side this is becoming unjustifiably expensive now.

**bluezie** · 12-10-2014,10:02 AM

I would try to find some second hand heads with worn cams (or a complete engine), which should be relatively cheap, then rebuild them with the full kit.
A freind of mine has a 2001 A6 Avant Q tiptronic AKE, and it is popping through the inlet manifold on one cylinder. It does start and run, so I imagine it has a worn cam (165K) and a follower has either dislodged and is holding an inlet valve slightly open, or an inlet valve has got slightly bent as a follower jumped out. He has lost interest in it and hasn't has the cam covers off, so don't know for certain what's happened. As far as I know, the car is for sale complete as it stands, of may be pursuaded to break. If interested, I can find out more, and have the covers off.

**skyegtb** · 12-10-2014,10:45 AM

Originally Posted by bluezie

I would try to find some second hand heads with worn cams (or a complete engine), which should be relatively cheap, then rebuild them with the full kit.
A freind of mine has a 2001 A6 Avant Q tiptronic AKE, and it is popping through the inlet manifold on one cylinder. It does start and run, so I imagine it has a worn cam (165K) and a follower has either dislodged and is holding an inlet valve slightly open, or an inlet valve has got slightly bent as a follower jumped out. He has lost interest in it and hasn't has the cam covers off, so don't know for certain what's happened. As far as I know, the car is for sale complete as it stands, of may be pursuaded to break. If interested, I can find out more, and have the covers off.

Thanks for the offer. I am going to try to get the heads off the car today and inspect the pistons. If the bottom end looks OK I might consider replacing the heads/cams etc, but am thinking it might be a better option to get a whole replacement engine.

**Crasher** · 12-10-2014,01:03 PM

The trouble is, a second hand engine is going to be at least 11 years old so what are the chances of finding a good one? The AKE bottom end is strong so if it does look OK (check the piston protrusion if any have hit) then I would rebuild the heads.

**skyegtb** · 12-10-2014,06:36 PM

Originally Posted by Crasher

The trouble is, a second hand engine is going to be at least 11 years old so what are the chances of finding a good one? The AKE bottom end is strong so if it does look OK (check the piston protrusion if any have hit) then I would rebuild the heads.

Hi Crasher. Agreed. I got the passenger side head off today and found the valves to be straight and the pistons completely unmarked and undamaged - this surprised me as I was at least expecting to see some impact marks from the valves, but there was no sign at all.... I will get the drivers side head off tomorrow (just got to remove one water pipe) and hope to find the same. Both heads need to be replaced as there has been internal damage to both as a result of the shattered rocker fingers damaging some of the castings and valve spring keepers etc so assuming the drivers side bottom end is the same I will repair the car with 2 replacement heads, new camshaft kit etc. I may still buy a complete used AKE engine if the price is right and rebuild the heads on it, keeping the rest for spares.
I will update tomorrow with some pictures. Cheers,

**skyegtb** · 12-10-2014,06:39 PM

Originally Posted by bluezie

I would try to find some second hand heads with worn cams (or a complete engine), which should be relatively cheap, then rebuild them with the full kit.
A freind of mine has a 2001 A6 Avant Q tiptronic AKE, and it is popping through the inlet manifold on one cylinder. It does start and run, so I imagine it has a worn cam (165K) and a follower has either dislodged and is holding an inlet valve slightly open, or an inlet valve has got slightly bent as a follower jumped out. He has lost interest in it and hasn't has the cam covers off, so don't know for certain what's happened. As far as I know, the car is for sale complete as it stands, of may be pursuaded to break. If interested, I can find out more, and have the covers off.

Hi Bluezie, I might be interested in the heads but only if they were checked for damage beforehand. I want heads that will require no more than a new cam kit fitted preferably from a known good running engine. Cheers, Angus

**bluezie** · 12-10-2014,07:46 PM

Originally Posted by skyegtb

Hi Bluezie, I might be interested in the heads but only if they were checked for damage beforehand. I want heads that will require no more than a new cam kit fitted preferably from a known good running engine. Cheers, Angus

I've sent my freind an email, so see what he says. Ps the car is in Bucks, so about 500 miles away!