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VW Golf ARL PD 2002 - Intermittent severe engine noise #

Posted by Lindsay Flaxmer on August 22, 2010, 5:18 pm

Year of Manufacture *: 2002
Engine Size and Code *: ARL PD
( Optional ) Scanner Used: KTS
( Optional) Fault Codes: None

VOLKSWAGEN
GOLF GT TDI
VIN:WVWZZZ1JZ3W053796
ENGINE:ARL 150bhp PD
FIRST REG:26/07/2002
MILAGE:120,000

Hi
This Motor has this intermittent engine noise, when the noise is present it is so load it will turn heads!! The only way I could describe it is that it sounds like a motor with a big end gone or something on top of a piston; it also runs a bit light on a cylinder(only when knocking). when it knocks it does sound really sick, but It comes and goes with no rhyme or reason.

The first time I heard it was when the customer dropped it off, it was only very slight, the next day I drove 20 miles with no problems it drove perfect, left it for around an hour started it you would not believe the noise.

It stayed like this for some time (around half an hour in the workshop), no fault codes are stored or present, the one thing that I did notice on live data is that when it is making a noise injector smooth running compensation on number 2 cyl goes from 0.65 to 2.16 mg/S all the others stay the same.

It should be noted that at no time does the engine smoke, it starts first time on the button and when it is ok it is as sweet as a nut.

I have checked compressions when it is making the noise and when it isn’t, they are consistently good.

I have removed cam cover to inspect cam ect and all looks fine.

Could it be an injector? Anyone replaced these for being noisy? (Can they make that much noise?).

I just can’t understand why one moment its makes this horrendous noise and then it just goes smooth & quiet.

If it was making this noise all the time I would have no hesitation in pulling engine apart, but at this time I am a bit reluctant, because I am not sure that I may find anything!

So Guys,

Where do I go from here? Anyone had a similar experience?
Look forward to your comments and inputs, any help would be much appreciated.

Many thanks
Lindsay Flaxmer

Re: VW/Golf/ Intermittent Severe Engine Noise

Posted by Mark Mcgrath <iframe src='https://members.boardhost.com/ukautotalk8/info/user=UKAT2806' width='330' height='300' border=0 style='border:none;'> on August 22, 2010, 7:15 pm, in reply to "VW/Golf/ Intermittent Severe Engine Noise"
Mark McGrath

May not be relevant but we had a bmw a while back
that had horrendous diesel knock
if memory correct smooth running adjustment/correction at limit for 1 injector
we changed the offending injector problem solved
could it be diesel knock you are hearing HTH

Re: VW/Golf/ Intermittent Severe Engine Noise

Posted by Paul Howd <iframe src='https://members.boardhost.com/ukautotalk8/info/user=UKAT5151' width='330' height='300' border=0 style='border:none;'> on August 22, 2010, 9:27 pm, in reply to "VW/Golf/ Intermittent Severe Engine Noise"
Paul Howd

Would this happen to have a dual mass flywheel perchance??

Re: VW/Golf/ Intermittent Severe Engine Noise

Posted by Lindsay Flaxmer <iframe src='https://members.boardhost.com/ukautotalk8/info/user=UKAT5521' width='330' height='300' border=0 style='border:none;'> on August 23, 2010, 8:19 am, in reply to "Re: VW/Golf/ Intermittent Severe Engine Noise"
Lindsay Flaxmer

I think I am going to have to run motor in the workshop to monitor the injectors when its knocking, it’s not knocking this morning yet!
Sorry I didn’t mention (because I am a bit embarrassed) that we have fitted new dual mass & clutch,
When we had it apart I really thought we had found the problem it looked completely stuffed, but there you go its good this job!!

Cheers
Lindsay

Re: VW/Golf/ Intermittent Severe Engine Noise

Posted by Mark Murphy <iframe src='https://members.boardhost.com/ukautotalk8/info/user=UKAT1035' width='330' height='300' border=0 style='border:none;'> on August 23, 2010, 8:23 pm, in reply to "Re: VW/Golf/ Intermittent Severe Engine Noise"
Mark Murphy

Have a look at the camshaft.
see if any of the loubes look worn
Mark

Re: VW/Golf/ Intermittent Severe Engine Noise

Posted by Bryan Smith <iframe src='https://members.boardhost.com/ukautotalk8/info/user=UKAT5330' width='330' height='300' border=0 style='border:none;'> on August 23, 2010, 8:27 pm, in reply to "Re: VW/Golf/ Intermittent Severe Engine Noise"
Bryan Smith

No need to be embarrassed Lindsay. I recently watched a video on the autoinform site where Frank Massey changed one which turned out to be a fuel pump fault. Not exactly the same symptoms but maybe your approach was the correct one.
Might be worth a look anyway.
http://content.yudu.com/A1dxye/AI-2/resources/6.htm
Regards, Bryan.

Re: VW/Golf/ Intermittent Severe Engine Noise

Posted by Barry Saunders on August 24, 2010, 11:58 am, in reply to "Re: VW/Golf/ Intermittent Severe Engine Noise"
Message modified by board administrator August 26, 2010, 1:11 pm

Hi Lindsay as mark says have a good look at the camshaft lobes,does it make a booming noise in the air pipes
regards barry

FIXED (Tomorrow I hope)

Posted by Lindsay Flaxmer <iframe src='https://members.boardhost.com/ukautotalk8/info/user=UKAT5521' width='330' height='300' border=0 style='border:none;'> on August 24, 2010, 6:42 pm, in reply to "VW Golf ARL PD 2002 - Intermittent severe engine noise #"
Lindsay Flaxmer

Thanks for the replies lads; it looks like some of your guys have been there before.

It was knocking like a good one this morning so I rolled me sleeves up & removed the cam cover again, at first I thought it looked ok just a bit of slight graining on the very tip of the lobes, then removed the injector rocker levers & shafts I could then see to my delight that there was 3 badly worn tappet blocks one of which looked as though its ready to cave in.

Ordered new shaft & blocks for tomorrow I think we have cracked it.

Many Thanks
Lindsay

Re: FIXED (Tomorrow I hope) (Pictures)

Posted by Glyn Morgan on August 25, 2010, 6:29 pm, in reply to "FIXED (Tomorrow I hope)"
Message modified by board administrator August 26, 2010, 1:09 pm

Hi Lindsay,

A bit late but yours will probably look like these,

Regards Glyn

Re: FIXED (Tomorrow I hope)

Posted by Mark carter <iframe src='https://members.boardhost.com/ukautotalk8/info/user=UKAT1428' width='330' height='300' border=0 style='border:none;'> on August 25, 2010, 11:40 pm, in reply to "Re: FIXED (Tomorrow I hope)"
Mark Carter

Hi Glyn, That looks expensive !!!

Regards Mark

PS. Hows life?

Modern cars, Its all wizardry and witchcraft

Re: FIXED (Tomorrow I hope)

Posted by Paul Howd <iframe src='https://members.boardhost.com/ukautotalk8/info/user=UKAT5151' width='330' height='300' border=0 style='border:none;'> on August 26, 2010, 9:32 am, in reply to "Re: FIXED (Tomorrow I hope)"
Paul Howd

I never cease to be amazed when finding damage like this combined with only intermittant problems!

I also sometimes wonder what the long term viability of repairs are. After all, all that metel has gone somewhere. Has the oil filter really caught it all! What other damage might have taken place where you cannot see it?

Re: FIXED (Tomorrow I hope)

Posted by Paul Mccooke <iframe src='https://members.boardhost.com/ukautotalk8/info/user=UKAT5379' width='330' height='300' border=0 style='border:none;'> on August 27, 2010, 12:23 pm, in reply to "Re: FIXED (Tomorrow I hope)"
Paul McCooke

I had intermittent knock on TDCI early this year, chased my tail for a day looking for injector knock faults, turned out to be big end totally gone, it came and went all Day !
Lindsay, check the small plugs are present in the end of UPI rocker shafts, they fall out causing oil feed problems to valve train, sorry if im telling you how to suck eggs, but thought worth mentioning, regards, Paul

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