2009 Jetta 1.4TSI CAVD Low oil pressure

   #1  

naushad2982

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Has anyone else dealt with this error on the revised 1.4TSI Dual charged engines with low pressure issues?

i have 2 different ones with the same 2009 CAVD engines that have this problem.

the oil pressure gauge starts at 1.8Bar when cold then drops to 0.2Bar at full operating temperature. so i am sure it is an actual low pressure fault and
not a faulty sender.

On the first one i've replaced:

Oil pump (checked and cleaned the pickup first)
Main and conrod bearings. (clearances are within 0.05.mm)
Crankshaft!
Stripped and rebuilt the engine after flushing it with flushing oil and replacing the oil filter (4 times)
1 conrod was replaced earlier.
Using Gulf fully synthetic oil that is SAE 40 and on the VW approved list for the 502 00/ 505 00 list
Ive used SAE 50 oil which masked the fault but you'd hear the tappets rattling when hot.

anyone know if theres known issues on this engine?

the scan is below if anyone is interested.

Code:
 Monday,03,October,2016,16:19:32:58772VCDS -- Windows Based VAG/VAS Emulator Running on Windows 7 x64
VCDS Version: 16.8.1.1 (x64)
Data version: 20160902 DS256
www.Ross-Tech.com




VIN: WVWZZZ1KZ9U017684   License Plate: KCD 880C
Mileage: 84830km-52710mi   Repair Order: naushad






--------------------------------------------------------------------------------
--------------------------------------------------------------------------------




Chassis Type: 1K (1K0)
Scan: 01 02 03 08 09 15 16 17 19 25 42 44 46 52 56 62 72


VIN: WVWZZZ1KZ9U017684   Mileage: 84830km-52710miles


01-Engine -- Status: Malfunction 0010
02-Auto Trans -- Status: OK 0000
03-ABS Brakes -- Status: Malfunction 0010
04-Steering Angle -- Status: OK 0000
08-Auto HVAC -- Status: OK 0000
09-Cent. Elect. -- Status: Malfunction 0010
15-Airbags -- Status: OK 0000
16-Steering wheel -- Status: OK 0000
17-Instruments -- Status: OK 0000
19-CAN Gateway -- Status: OK 0000
25-Immobilizer -- Status: OK 0000
42-Door Elect, Driver -- Status: Malfunction 0010
44-Steering Assist -- Status: OK 0000
46-Central Conv. -- Status: OK 0000
52-Door Elect, Pass. -- Status: Malfunction 0010
56-Radio -- Status: OK 0000
62-Door, Rear Left -- Status: OK 0000
72-Door, Rear Right -- Status: OK 0000
 
-------------------------------------------------------------------------------
Address 01: Engine (CAV)       Labels: 03C-906-027-CAV.clb
   Part No SW: 03C 906 027 BA    HW: 03C 906 027 F
   Component: MED17.5.5       G   8913  
   Revision: L1H08---    Serial number: VWX7Z0H624K0D5
   Coding: 0000077
   Shop #: WSC 73340 981 67656
   VCID: 61CF4765B8AC3E4AC7-8034


7 Faults Found:
000010 - Camshaft Positioner (Bank 1 Intake) 
               P000A - 000 - Slow Response - Intermittent
             Freeze Frame:
                    Fault Status: 00100000
                    Fault Priority: 0
                    Fault Frequency: 114
                    Reset counter: 255
                    Mileage: 84593 km
                    Time Indication: 0
                    Date: 2000.00.00
                    Time: 14:41:32


             Freeze Frame:
                    RPM: 1133 /min
                    Load: 29.0 %
                    Speed: 10.0 km/h
                    Temperature: 87.0°C
                    Temperature: 38.0°C
                    Absolute Pres.: 820.0 mbar
                    Voltage: 13.589 V


000768 - Random/Multiple Cylinder Misfire Detected 
               P0300 - 000 -  - Intermittent
             Freeze Frame:
                    Fault Status: 00100000
                    Fault Priority: 0
                    Fault Frequency: 3
                    Reset counter: 255
                    Mileage: 84820 km
                    Time Indication: 0
                    Date: 2000.00.00
                    Time: 18:02:31


             Freeze Frame:
                    RPM: 893 /min
                    Load: 27.8 %
                    Speed: 0.0 km/h
                    Temperature: 62.0°C
                    Temperature: 33.0°C
                    Absolute Pres.: 820.0 mbar
                    Voltage: 13.716 V


000772 - Cylinder 4 
               P0304 - 000 - Misfire Detected - Intermittent
             Freeze Frame:
                    Fault Status: 00100000
                    Fault Priority: 0
                    Fault Frequency: 2
                    Reset counter: 255
                    Mileage: 84646 km
                    Time Indication: 0
                    Date: 2000.00.00
                    Time: 11:04:45


             Freeze Frame:
                    RPM: 887 /min
                    Load: 19.6 %
                    Speed: 0.0 km/h
                    Temperature: 49.0°C
                    Temperature: 29.0°C
                    Absolute Pres.: 830.0 mbar
                    Voltage: 13.970 V


000770 - Cylinder 2 
               P0302 - 000 - Misfire Detected - Intermittent
             Freeze Frame:
                    Fault Status: 00100000
                    Fault Priority: 0
                    Fault Frequency: 3
                    Reset counter: 255
                    Mileage: 84820 km
                    Time Indication: 0
                    Date: 2000.00.00
                    Time: 18:02:31


             Freeze Frame:
                    RPM: 893 /min
                    Load: 27.8 %
                    Speed: 0.0 km/h
                    Temperature: 62.0°C
                    Temperature: 33.0°C
                    Absolute Pres.: 820.0 mbar
                    Voltage: 13.716 V


001089 - EVAP Emission Control Sys 
               P0441 - 000 - Incorrect Flow
             Freeze Frame:
                    Fault Status: 01100000
                    Fault Priority: 0
                    Fault Frequency: 1
                    Reset counter: 255
                    Mileage: 84687 km
                    Time Indication: 0
                    Date: 2000.00.00
                    Time: 12:57:04


             Freeze Frame:
                    RPM: 1469 /min
                    Load: 18.4 %
                    Speed: 45.0 km/h
                    Temperature: 87.0°C
                    Temperature: 42.0°C
                    Absolute Pres.: 820.0 mbar
                    Voltage: 13.589 V


004256 - Control Circuit for Intake Air Regulating Flap 
               P10A0 - 000 - Electrical Malfunction - MIL ON
             Freeze Frame:
                    Fault Status: 11100000
                    Fault Priority: 0
                    Fault Frequency: 4
                    Reset counter: 255
                    Mileage: 84832 km
                    Time Indication: 0
                    Date: 2000.00.00
                    Time: 15:05:13


             Freeze Frame:
                    RPM: 913 /min
                    Load: 15.7 %
                    Speed: 0.0 km/h
                    Temperature: 84.0°C
                    Temperature: 54.0°C
                    Absolute Pres.: 820.0 mbar
                    Voltage: 12.700 V


004256 - Control Circuit for Intake Air Regulating Flap 
               P10A0 - 000 - Electrical Malfunction - Intermittent
             Freeze Frame:
                    Fault Status: 00100000
                    Fault Priority: 0
                    Fault Frequency: 1
                    Reset counter: 255
                    Mileage: 84826 km
                    Time Indication: 0
                    Date: 2000.00.00
                    Time: 09:27:00


             Freeze Frame:
                    RPM: 1420 /min
                    Load: 52.9 %
                    Speed: 33.0 km/h
                    Temperature: 84.0°C
                    Temperature: 32.0°C
                    Absolute Pres.: 830.0 mbar
                    Voltage: 13.589 V


Readiness: 0010 0101


-------------------------------------------------------------------------------
Address 02: Auto Trans        Labels: 0AM-927-769.clb
   Part No SW: 0AM 300 048 N    HW: 0AM 927 769 D
   Component: GSG DSG AG7     431 2668  
   Revision: 00043014    Serial number: CU501303067011
   Coding: 0000020
   Shop #: WSC 73340 981 98115
   VCID: 3B73D50D7A80349ABD-806E


No fault code found.


-------------------------------------------------------------------------------
Address 03: ABS Brakes (-----)       Labels: 1K0-907-379-60EC1F.clb
   Part No SW: 1K0 907 379 AE    HW: 1K0 907 379 AE
   Component: ESP MK60EC1   H35 0104  
   Revision: 00H35001    
   Coding: 133B600D21230001C81106EC841D0080B100
   Shop #: WSC 00046 412 00000
   VCID: 75E70335DC24A2EA8B-8020


1 Fault Found:
01169 - Door Contact Switch Driver Side (F2) 
            008 - Implausible Signal - Intermittent
             Freeze Frame:
                    Fault Status: 00101000
                    Fault Priority: 3
                    Fault Frequency: 1
                    Reset counter: 149
                    Mileage: 84597 km
                    Time Indication: 0


             Freeze Frame:
                    Count: 16384
                    Count: 32768
                    Count: 12800
                    Count: 147
                    Count: 48414
                    Count: 0
                    Count: 0
                    Count: 1091




-------------------------------------------------------------------------------
Address 08: Auto HVAC        Labels: 1K0-907-044.lbl
   Part No SW: 1K0 907 044 CT    HW: 1K0 907 044 CT
   Component: ClimatronicPQ35 130 1213  
   Revision: 00130023    Serial number: 00000000000000
   Shop #: WSC 00000 000 00000
   VCID: 7BF3150D3A00F49AFD-802E


No fault code found.


-------------------------------------------------------------------------------
Address 09: Cent. Elect.        Labels: 3C0-937-049-30-M.lbl
   Part No SW: 3C8 937 049 D    HW: 3C8 937 049 D
   Component: Bordnetz-SG     H54 2602  
   Revision: 00H54000    Serial number: 00000008808549
   Coding: E4850F2700041500470A00000F000000000959035C000100000000000000
   Shop #: WSC 00046 412 31414
   VCID: 326DF829ADCAF5D26E-8066


   Subsystem 1 - Part No: 1K2 955 119 E  Labels: 1KX-955-119.CLB
   Component: Wischer 131108 020  0501  
   Coding: 00049109
   Shop #: WSC 00046  


   Subsystem 2 - Part No: 1K0 955 559 AF  Labels: 1K0-955-559-AF.CLB
   Component: RLS     140808 046  0204  
   Coding: 00733221
   Shop #: WSC 00046  


1 Fault Found:
02389 - Release Signal Transmission; Position P/N 
            008 - Implausible Signal - Intermittent
             Freeze Frame:
                    Fault Status: 00101000
                    Fault Priority: 2
                    Fault Frequency: 3
                    Reset counter: 146
                    Mileage: 84583 km
                    Time Indication: 0


             Freeze Frame:
                        ON
                    Voltage: 13.05 V
                        ON
                        ON
                        OFF
                        OFF
                        ON




-------------------------------------------------------------------------------
Address 15: Airbags        Labels: 1K0-909-605.lbl
   Part No SW: 1K0 909 605 AB    HW: 1K0 909 605 AB
   Component: 56 AIRBAG VW8R  034 8000  
   Revision: 05034000    Serial number: 003B6D0BUU2K  
   Coding: 0013622
   Shop #: WSC 00046 412 31414
   VCID: 6CD126514F6E632264-8038


   Subsystem 1 - Serial number: 6332MSME3F612C67N


   Subsystem 2 - Serial number: 6342MSME3E320C77K


   Subsystem 3 - Serial number: 6351HSME1819212D4


   Subsystem 4 - Serial number: 6361HSME181832630


No fault code found.


-------------------------------------------------------------------------------
Address 16: Steering wheel        Labels: 1K0-953-549-MY8.lbl
   Part No SW: 1K0 953 549 BR    HW: 1K0 953 549 BR
   Component: J0527           752 0101  
   Coding: 0010041
   Shop #: WSC 00000 000 31414
   VCID: 03036DED42F08C5AB5-8056


No fault code found.


-------------------------------------------------------------------------------
Address 17: Instruments        Labels: 1K0-920-xxx-17.lbl
   Part No SW: 1K0 920 864 A    HW: 1K0 920 864 A
   Component: KOMBIINSTRUMENT 3HL 1212  
   Revision: V0002000    Serial number: VWX7Z0H624K0D5
   Coding: 0019503
   Shop #: WSC 73340 981 187765
   VCID: 2A5DE049851ABD12D6-807E


No fault code found.


-------------------------------------------------------------------------------
Address 19: CAN Gateway        Labels: 1K0-907-530-V3.clb
   Part No SW: 1K0 907 530 Q    HW: 1K0 907 951 
   Component: J533  Gateway   H07 5063  
   Revision:   H07 01    Serial number: 240808F2001293
   Coding: ED807F060002021003
   Shop #: WSC 00046 412 31414
   VCID: 3567C3355CA4E2EA4B-8060


No fault code found.


-------------------------------------------------------------------------------
Address 25: Immobilizer        Labels: 1K0-920-xxx-25.clb
   Part No SW: 1K0 920 864 A    HW: 1K0 920 864 A
   Component: IMMO            3HL 1212  
   Revision: V0002000    Serial number: VWX7Z0H624K0D5
   Shop #: WSC 00000 000 00000
   VCID: 2A5DE049851ABD12D6-807E


No fault code found.


-------------------------------------------------------------------------------
Address 42: Door Elect, Driver        Labels: 1K0-959-701-MAX3.lbl
   Part No SW: 1K0 959 701 AE    HW: 1K0 959 793 P
   Component: J386  TUER-SG FT    1520  
   Revision: 71009005    Serial number: 00000056988523
   Coding: 0004790
   Shop #: WSC 00046 412 31414
   VCID: 71EF3725684C8ECA57-8024


1 Fault Found:
00932 - Electric Window Motor; Drivers Side (V147) 
            005 - No or Incorrect Basic Setting / Adaptation - Intermittent
             Freeze Frame:
                    Fault Status: 00100101
                    Fault Priority: 6
                    Fault Frequency: 1
                    Reset counter: 153
                    Mileage: 0 km
                    Time Indication: 0




-------------------------------------------------------------------------------
Address 44: Steering Assist        Labels: 1Kx-909-14x-44.clb
   Part No: 1K0 909 144 C
   Component: EPS_ZFLS Kl. 69     2301  
   Revision: 00H15000    
   Shop #: WSC 00000 000 00000
   VCID: 2A5DE049851ABD12D6-807E


No fault code found.


-------------------------------------------------------------------------------
Address 46: Central Conv.        Labels: 1K0-959-433-MAX.clb
   Part No SW: 1K0 959 433 CA    HW: 1K0 959 433 CA
   Component:    KSG PQ35 G2  020 0204  
   Revision: 00020000    Serial number: 00000000000000
   Coding: 91900A0001060C7F2D04840560081F03E0FCA0
   Shop #: WSC 00046 412 31414
   VCID: 71EF3725684C8ECA57-8024


   Subsystem 1 - Component:   Sounder n.mounted     


   Subsystem 2 - Component:       NGS n.mounted     


   Subsystem 3 - Component:      IRUE n.mounted     


No fault code found.


-------------------------------------------------------------------------------
Address 52: Door Elect, Pass.        Labels: 1K0-959-702-MAX3.lbl
   Part No SW: 1K0 959 702 AE    HW: 1K0 959 792 P
   Component: J387  TUER-SG BT    1520  
   Revision: 71009005    Serial number: 00000514288502
   Coding: 0005046
   Shop #: WSC 00046 412 31414
   VCID: 72ED38296D4AB5D2AE-8026


3 Faults Found:
00933 - Electric Window Motor; Passenger Side (V148) 
            005 - No or Incorrect Basic Setting / Adaptation - Intermittent
             Freeze Frame:
                    Fault Status: 00100101
                    Fault Priority: 6
                    Fault Frequency: 1
                    Reset counter: 151
                    Mileage: 0 km
                    Time Indication: 0


00097 - Front Passengers Central Locking (Safe) Motor (V162) 
            012 - Electrical Fault in Circuit - Intermittent
             Freeze Frame:
                    Fault Status: 00101100
                    Fault Priority: 3
                    Fault Frequency: 251
                    Reset counter: 172
                    Mileage: 84587 km
                    Time Indication: 0


00929 - Locking Module for Central Locking; Front Passenger Side (F221) 
            008 - Implausible Signal - Intermittent
             Freeze Frame:
                    Fault Status: 00111000
                    Fault Priority: 3
                    Fault Frequency: 84
                    Reset counter: 172
                    Mileage: 84587 km
                    Time Indication: 0




-------------------------------------------------------------------------------
Address 56: Radio (J503)       Labels: 5M0-035-1xx-56.clb
   Part No SW: 1K0 035 183     HW: 1K0 035 183 
   Component: Radio RCD310  012 0029  
   Revision: 00000000    Serial number: VWZ1Z2H5715334
   Coding: 0500040004
   Shop #: WSC 00046 412 31414
   VCID: 60C9426173A63742C8-8034


No fault code found.


-------------------------------------------------------------------------------
Address 62: Door, Rear Left        Labels: 1K0-959-703-GEN3.lbl
   Part No SW: 1K0 959 703 P    HW: 1K0 959 795 G
   Component: J388   TUER-SG HL   1120  
   Revision: 11006001    Serial number: 00000003058300
   Coding: 0000144
   Shop #: WSC 00046 412 31414
   VCID: 3D77DB1564943AAA83-8068


No fault code found.


-------------------------------------------------------------------------------
Address 72: Door, Rear Right        Labels: 1K0-959-704-GEN3.lbl
   Part No SW: 1K0 959 704 P    HW: 1K0 959 794 G
   Component: J389   TUER-SG HR   1120  
   Revision: 11006001    Serial number: 00000003091886
   Coding: 0000144
   Shop #: WSC 00046 000 31414
   VCID: 3E75DC19699221B29A-806A


No fault code found.


End-------------------------(Elapsed Time: 02:14)--------------------------
 
Last edited:
   #3  

Uwe

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I don't know how you managing to run VCDS Version: 16.8.1.1 which is 7 versions out of date?
Because Kenya?

Naushad is cool, and his scan is legit.

-Uwe-
 
   #4  

naushad2982

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Because that's a scan taken in October 2016. Just added it for informations sake.

Any ideas?
 
   #5  

NZDubNurd

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There was a recent thread, about oil pressure on a 2.0 GTi engine - somewhat similar pressures.

Low when cold, REALLY low when hot.

As always, the pressure relief needs checking, but in this other thread (I can't find) the guy reported in the end, that a balancer shaft had lunched itself, and the oil was gushing into the sump from the bearings for it.

1.8 Bar cold is VERY low! Should be: oil over 80C, 2000 RPM = 2.0 bar minimum.

Ooooh... found it: http://forums.ross-tech.com/showthread.php?9261-Lost-oil-pressure/page2&highlight=oil+pressure+relief
 
   #6  

naushad2982

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Read it. Was thinking along the same lines of an internal leak as well. The dual charge doesn't have balance shafts though.....

shop air through the cylinder block to look for the leaks may be??
 
   #7  

Crasher

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Sorry to jump in here on such an old thread but did you find a solution to this problem as we are having the same problem?
 
   #8  

naushad2982

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So did you finally manage to figure it out? Belive it or not i now have another one..... Searching for information online brings me ti my own thread
 
   #9  

Crasher

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No I am still fighting it. I have been building VW engines for 40 years and nothing has ever puzzled me like this. It came in burning oil and it was the usual shattered piston, well two, but it did not rattle. It was obvious it had been worked on as there was silicone goo sticking out everywhere. This is the story in short (!) form as well as I can remember off the top of my head, if I remember more I will add it.

We have rebuilt it four times now and each time it sounds terrible and shows barely 2 Bar oil pressure.
The initial rebuild was
Original head professionally rebuilt by an engineering company with new exhaust guides and valves, checked to make sure not skimmed past minimum measurement
INA equalizer elements
INA cam levers
Used later CD revision cam carrier and cams as the original was damaged
INA fuel pump follower
Full FAI cam chain kit with VVT hub
Genuine VW VVT hub oil sleeve
Nüral revised design pistons (oil jets removed and bores honed with fine stones, good cross hatch, no wear or damage)
Block top surface flat steel block flatted down with 100 grit emery cloth
FAI oil pump
Genuine VW oil pickup
Genuine VW oil filter
Kolbenschmidt rod bearings
Elring gaskets throughout
Elring head bolts
Cam carrier oil strainer disc replaced with revised version
Cleaned out thoroughly with multiple tins of brake cleaner
Assembled with Red Line assembly lube
FAI VVT valve
Genuine VW water pump (not relevant)
G13 coolant
Millers completion running in oil
Turbo rebuilt by Midland turbo
Timing set using locking pin, dial gauge on number 1 piston and genuine VAG cam locking plate T10171A
Genuine VW injector seal rebuild kits fitted using T10133C kit
Oil system back filled, filter fitted and engine spun over until oil came out of the oil pressure switch hole which took about 15 seconds with the plugs out, good flow observed.
Engine started up and run for around 5 minutes but sounded terrible, no oil warning light.
Oil pressure gauge fitted and hot idle oil pressure barely 1 Bar.
We took the sump, timing chain cover, chain and cam carrier off and checked everything but could find nothing wrong but realised the used inlet cam was not correct so we fitted a new FAI inlet cam
We noticed the rod bearings seemed a bit baggy so we took the shells out and checked the crank, spot on spec at 57.778mm and Plastigauge checked the journals and all were perfect but we rebuilt with genuine VW rod bearings and bolts as aftermarket ones from Glyco never turned up, still sounded awful.
We took the sump off and fitted the original oil pump, rubbish oil pressure and still sounded awful
We did some system tests and decided the oil jets were opening too early so we fitted four new genuine jets and this is a sketch with the crank in and even worse with the rods on, still sounded awful and no change in pressure.
With the sump off we pressure fed the engine with oil via the switch fitting and oil oozed from the crank as you would expect and ran down from the head.
We took the three easy to remove main caps off and the bearings looked fine and the journals OK, not perfect but acceptable and assembled with new bolts
We put the FAI pump back on and the sump.
I designed and had made an aluminium plug that replaced the VVT valve and had a M10x1 thread in the top to take a pressure tester, this allows oil to the cam journals on both sides of the VVT top stop it unlocking, the port showed exactly the same 2 Bar as the switch position BUT the turbo feed showed nearly 4.5Bar. The factory spec is the usual 2Bar@2K@80°c blah blah but I and disappointed if I don’t get 5 Bar cold, 1.5 bar hot idle and at least 3.5 Bar at 2K so I was just not happy with the oil pressure
We tried Longlife 3 oil 5w/30 oil just in case (I had stopped worrying about ring glaze by this point), no different
Febi oil cooler, no different


Then the world imploded with Covid19 and we put our mechanic on furlough so it was then down to me to do the work.
I pulled the timing system down again (crank and rods left alone)
I realised the oil pump looked different to the original and I triple checked the application with FAI and they were happy it was correct. I opened up both pumps and found they were completely different designs, the original was a peculiar variable displacement design and I thought ahh hah, and ordered a new genuine pump (six times the price of FAI) only to find it also is the same revised design as FAI… dead end.
I took the plugs out and checked the pistons were the right way around and with my endoscope camera I could see what I thought were witness marks in the exhaust valve pockets so I went and checked the piston part number and they were correct.
I rebuilt it with a new full VVT FAI chain kit and new INA equaliser elements, still sounded terrible.
Then one of my friends noticed that the many of the last set of INA tappets were springy so we checked the two previous sets and about half were springy.
SO... I bought a brand new genuine VW head with lifters and pre-checked they were all solid and fitted it, with the head off the witness marks I thought I could see were not there and the valves showed no marks. Partly rebuilt hanging off the brace with no coolant and water pump just to check, still sound terrible with the same oil pressure but now the pressure at the turbo had collapsed to 2Bar… FFS!
We pulled the box, sump and chain cover and took out the crank and sent it to the engineers, they reported it as being to spec and just needing a polish… !!!
I thought this has to be the valves JUST touching the pistons (doesn’t explain the oil pressure though) so I ordered a genuine piston and yesterday we took the head off AGAIN (the mechanic is back off furlough now) and took a piston out. With it on the bench on an engineer’s block, using a dial gauge I measured the new, the original and the genuine piston and the new Nüral piston matches the genuine piston exactly and all three crowns are the same spec, the Nüral piston has the same revised ring land design as the new genuine piston.
So now I am left with a bare block hanging in the engine bay and no idea what to try next.
A used CAVD is not an option as they are all a decade old now and unless rebuilt are a grenade with the pin pulled waiting to go off, VAG don’t sell a bottom end to match the new head and a new engine is £5k and on back order.
 
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   #10  

Keithuk

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Because Kenya?

Naushad is cool, and his scan is legit.

-Uwe-
I wasn't saying he wasn't legit, I was just asking why he was using and old VCDS version?

A lot of thread its suggested they upgrade.
 
   #11  

Crasher

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The block is on the floor now. When I removed the rebuilt head I wa sure I could see coolant in the fresh oil but I dismissed it. With the head off the back of the block top deck looked odd, corroded or scorched but it was spotless when the head went on. When I fitted the new head I again made it spotless but today I noticed the same area is corroding already and the head gasket is stained... the problem is I never added any coolant; it is as if there is something wrong with the cast iron.
 
   #13  

Crasher

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Brand new genuine VAG aluminum head and it did it with the previous head... I am going to pressure test the (iron) block later.
 
   #14  

ai_Ingo

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When replacing the timing chain or camshaft adjuster, it is sometimes forgotten to reinstall the sleeve. This leads to a loss of oil pressure. It's just an example. Incidentally, the sleeve has the spare part number: 03C 103 825 A.
 
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Crasher

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Yes, there is a VAG TPI about it which I can't find at the moment, part number 03C 103 825 A £3.82 UK retail inc. VAT... replaced three times! I have the block on the bench bare and I cannot see anything wrong.
 
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naushad2982

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Im about to strip mine down and smoke test it for anything abnormal. will update on it soon
 
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One aspect I am looking into today was that on approximately 06-06-2010 the oil filter changed design slightly and from part number 03C 115 561 B (now J) to 03C 115 561 D (now H) where the car was built 07-09-2009. The change date on ETKA is shown with an asterisk (*) which means that VAG are unsure of the actual change point and it is shown as a date rather than VIN or engine number. The confusing point is, as far as I can see, NOTHING else relevant changed (except the DSG flywheel!!).

I have tried to identify the timing chain cover but the number cast into it, 03C 109 211 BF BG does not come up on ETKA so it must be a VAG use internal casting number and the engine data sticker is missing... I have seen people break these covers during removal so what if the chain cover is from a different car? The number history for this cover is 03C 109 210 BG up until 01-12-10 and when it changed to 03C 109 210 CE and on 01-09-2013 it change to 03C 109 210 CQ so inferring that all are interchangeable. If you take the number cast into the cover and change the last numerical digit to 0 and then put that into EKTA, it comes up as the cover for a CAXA engine.

When we took it apart the first time we found the cam carrier and both cams were damaged and so the carrier and inlet cam are used and the exhaust cam is a new FAI part. Looking at the cars original oil pump 03C 115 105 Q I can see this changed to 03C 115 105 AG on 01-04-2012 and this isn’t mentioned at all on ETKA unless you check the old part number off of the component but the date change makes it irrelevant. On the 01-03-2013 the cam carrier changed part number but that would also be irrelevant to the oil filter change point. It is very depressing to think the original oil filter is long gone and would have been interesting to look at now. We have saved every other part except the oil filter...



 
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naushad2982

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I don't think we are dealing with an oil filter issue. My current engine is the generation 1 dual charged with the paper filter and the oil pressure relief valves in the timing cover.

However the rust on the block and the residue on the under side of the hesd gasket is the same
 
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The rust threw me as I am not in the habit of taking off heads I have just fitted. Did you note the cold oil pressure on the one you are dealing with?
 
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naushad2982

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Yes, mine starts at 2bar when cold. Then drops to a hair above zero at full operating temperature. Revving it to 2000rpm takes it to about 1.3bar
 
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