Author Topic: MK4 150 bhp problem. (Read 4301 times)

Torchd · « **on:** February 19, 2009, 03:13:01 am »

Hey guys!

My friend has an MK4 TDIPD and it makes this terrible sound and the turbo is not making any boost.

I live in Pakistan and theres no one here to diagnose problems in such cars let alone fixing them.

Heres rge link to the video.
http://www.youtube.com/watch?v=1HWwovyjAJE

jtanguay · « **Reply #1 on:** February 19, 2009, 07:59:36 am »

yep..... sounds like he needs a new camshaft.

some good info on the repair can be had here at tdiclub.

Torchd · « **Reply #2 on:** February 19, 2009, 09:22:27 am »

the cam has marks on it....

So you mean the fueling/air has no issues?

Its more of a hardware problem?

zukgod1 · « **Reply #3 on:** February 19, 2009, 09:50:39 am »

Ya as in the lobes on the cam are gone...

"some good info on the repair can be had here at tdiclub."
http://forums.tdiclub.com/showthread.php?t=225918&highlight=PD+failure

Hey · « **Reply #4 on:** February 19, 2009, 08:54:59 pm »

ouch.. I hope it can be repaired without spending to much money! Camshaft are not always cheap!

jtanguay · « **Reply #5 on:** February 19, 2009, 09:34:32 pm »

Quote from: "Hey"

ouch.. I hope it can be repaired without spending to much money! Camshaft are not always cheap!

expect the camshaft to be around $700USD or more...

and that isn't labour, and extra parts needed. (if the car has enough km's on it, it might even be economical to just go ahead and do the timing belt while in there)

where was your friend getting his oil changed? and what oil change interval was he using? you can't cheap out with a PD motor. even when using the proper oil the camshaft wear is still an issue... its because the lobe is used to fire the injector (lots of pounding and abuse there)

Smokey Eddy · « **Reply #6 on:** February 19, 2009, 09:36:35 pm »

$700 USD?!?!

thats going to write off those engines in a couple years for sssuuurreeeee

what a design flaw. Holy CRAP! I'm not really contributing to this thread and i apologize.

I thought i read on here you could get them for less than that? more around $300 US

Torchd · « **Reply #7 on:** February 19, 2009, 09:58:29 pm »

Thanks guys for the replies.

Jtanguay..

He was using some cheap oil before and that too probably fake. He has recently moved to Pakistan from UK and hes not aware of the way things are done here!

Now hes using mobil 1 fully synthetic. But i guess its too late.

jtanguay · « **Reply #8 on:** February 19, 2009, 10:00:38 pm »

well prothe has a camshaft that apparently will fit year wise, but is made for an ALH

http://www.dieselvw.com/038109101ECamshaft.htm

i don't think it will be too long before he finds a supplier for PD cams...

but the cam is only one of many parts that can be damaged... your best option would be to find a used head somewhere, honestly. $1000 for a used head would be a good deal... then just swap it.

the link below has quite a bit of shocking information regarding these types of failures...

http://forums.tdiclub.com/showthread.php?t=237678

i suggest anyone thinking of owning a PD motor read through the whole thread. owning one CAN be done properly, but with strict adherence to using ??w40 oils, and driving the motor gently until warmed up. another big problem is the EGR system dumping soot into the oil. lots of abrasive wear from the soot will wear down components under lots of stress, and the cam is under a considerable amount of stress from firing the injectors. (an oil additive with moly might not be a bad idea in this situation)

Torchd · « **Reply #9 on:** February 20, 2009, 08:09:26 pm »

I dont think getting a used head is an option for me. As it will be a pain to bring it over.

What do you think in worst scenario case what parts should I be replacing?

Thanks.

jtanguay · « **Reply #10 on:** February 25, 2009, 01:07:42 pm »

Quote from: "Torchd"

I dont think getting a used head is an option for me. As it will be a pain to bring it over.

What do you think in worst scenario case what parts should I be replacing?

Thanks.

lets see... camshaft and lifters at least in a worst case scenario... theres probably a lot more, but i'm not sure. it would be best for you to pull the valve cover and make a visual inspection, as well as take pics and post them here. you should be okay to re-use the valve cover gasket to put it back on when done. thats the only way to know for sure what kind of damage is present.

DieselMonkey · « **Reply #11 on:** February 25, 2009, 02:27:46 pm »

My 2002 VW Golf Mk4 Anniversary done the same thing. It is a standard 150bhp model, no remap or anything and it was always serviced with the PD oil. The only conclusion that I can come to with this (and I run a precision engineering / CNC machine shop and recondition engines and rebuild VW engines all the time) is that there are inconsistencies with the hardening of the cams or the hydraulic tappets which has just continued for years. The first instances seemed to occur from 02 models on but even 06 and 07 PD engines are doing it. Its absolutely incredible that this is going on. VW wont even stand over the repair if the car is outside warrenty. Mine done it at 58,000 miles !!! The new cam cost £375 + VAT from the VW dealer..... However I can help you if you are in need.... I have just stripped a 150 PD engine which I replaced for a customer. The car in question broke the 3 bolts that hold the engine mount to the block. He replaced the timing belt himself and didnt have the bolts tight enough..... the car had 70,000 miles on it and the cam is LIKE NEW....therefore I am going on the notion that if that cam with 70K on it is like new, if it where a design issue, it would show SOME wear. Basically, this is just a good cam (one of the lucky ones). I dont think its anything to do with driving styles or even lubrication, including the oil used.

If you need the cam and the matching hydraulic tappets, PM me. Its the only economic solution if you cant physically find a 150 head in Pakistan, postage of a whole head isnt realistic and it isnt necessary anyway.

- Matt