Audi A2 3L: Hydraulic Pump Sound

[ecoangeluk]

Having trouble with hydraulics on A2 1.2 TDI. Revised Clutch actuator installed earlier this year along with gearbox rebuild.

 

Now there is a strange noise after the pump is pressurized the system (another whirring sound from the hydraulic motor area) 

 

See:   https://photos.app.goo.gl/gyUQgzwD2Stqy9Cd6

 

 

 

Edited June 1, 2019 by ecoangeluk

[ecoangeluk]

This is the video with change in sound: https://photos.app.goo.gl/GL6bWQvo4PfemKVg7

 

[Phoenix A2]

Moderator:

Moved to another sub-forum.

[DerWeißeA2]

I know the sound when a valve does not close properly due to contamination, foreign objects and so the pressure escapes through the pump.

[ecoangeluk]

Is there a way to stop pressure escaping? Flush out with new oil? New seals?

[ecoangeluk]

Refurbished Hydraulic Pump fitted. New Mineral Hydraulic fluid.  Basic setting and Clutch Creep point set as per http://wiki.ross-tech.com/wiki/index.php/5-Speed_Electronic_Manual_Transmission_(085)

 

3 changes before pump starts again even with a new Accumulator.

 

Put car back on it's wheels to test drive and engine stalled in 1st gear after engine start.

 

Refurbished clutch actuator was also fitted recently.

 

Any ideas?

 

 

 

[ecoangeluk]

Sehen Sie

 

https://youtu.be/WffSOuofw_Y

 

Und 

 

https://youtu.be/eDGUfC_ilKg

[ecoangeluk]

y251mrrvagcom.odt

[Mankmil]

Please reduce the KNZ (clutch actuator) voltage.
I'd suggest to set it to 1.76-1,78 V (or even lower if it is already on this level).

After your basic setting you should start the engine in N and check that the release shaft moves ~1-2mm forward/backward smoothly.

[DerWeißeA2]

It looks to me that during the gearbox installation, the release bearing has jumped out of the guides of the lever. Therefore, the clutch can not be fully operated.

 

When i put the gearbox back in the car, i fix the lever with a zip tie. This prevents it from moving, so the release bearing can't slip out of the bracket.

[ecoangeluk]

Vielen Dank. 

 

OK, adjusted back to 1.76v and clutch cable now moves 2-3mm in neutral. The pump runs for 4-5 seconds every 1:15 minutes

 

There is a noise with torque (clunk) but not sure if this is the clutch release bearing or suspension. 

 

All gears are working again although the engine stalls with air-conditioning on when at idle circa 850rpm. 

 

Otherwise it drives fine. 

 

To improve the number of changes before hydraulic pump activates would need what? New pipes? New gangsteller? 

 

MfG 

[DerWeißeA2]

Oh, you installed a clutch cylinder from Mankmil?

[Mankmil]

vor 24 Minuten schrieb DerWeißeA2:

Oh, you installed a clutch cylinder from Mankmil?

[Phoenix A2]

Related thread for further information:

 

[ecoangeluk]

That's a useful thread, I wish I had read a few months ago! Maybe I need to set KNZ lower than 1.76v to help stop the car stalling with aircon on? 

[DerWeißeA2]

Have a look at the measuring block in which the clutch value is output in percent. It should be between 0 - 5%.

[ecoangeluk]

Here is video of gear change vrs pump activation after fitting KNZ (1,76v) and reconditioned pump : 

 

[Phoenix A2]

On first sight, the 3L operates normal on the video above. Is there something you want to point to?

 

[ecoangeluk]

Hallo phoenix, yes the pump runs every two to three changes of gear lever. With new accumulator, mankmil KNZ and hydraulic pump, was hoping for 4 yo6 changes before pump runs again. Do I need to check wear on gangsteller?

[Phoenix A2]

From  my experience 2-3 gear changes before the pump runs again is the normal average. Sometimes i see 3L achieving 4 gears before pump starts again and i have never seen any that does more than 5 gear changes.

To note: That's with the engine turned off. With engine turned on it should be some more as the pressure hysteresis thresholds for the pump are higher. Maybe that's why someone can get confused about it.

 

Am 28.6.2019 um 10:19 schrieb ecoangeluk:

That's a useful thread, I wish I had read a few months ago! Maybe I need to set KNZ lower than 1.76v to help stop the car stalling with aircon on? 

Have you managed to solve the stalling issue when aircon is turned on?

 

[ecoangeluk]

Car still stalls with aircon on - especially when idling when "cold". The Clutch position % is 2.7% . Hope to travel to Germany later this week.