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AFN Jerking: ESP, Timing Belt Issues?

 
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Post09-08-2007, 2:22    Subject: AFN Jerking: ESP, Timing Belt Issues? Quote

Start a new thread because I was extremely annoyed the day before yesterday.
A lot has already been written about the "AFN idle jerk" issue, and some people have replaced everything from the flywheel to various other components, but nothing has improved the situation.

Okay, let's start from the beginning.

I bought my Porsche (mileage now approximately 225,000 km) when it had 216,000 km on the odometer.
Also, partly because the previous owner replaced everything except the ES nozzles (or had to replace them due to defects).
Turbo, ZR, WaPu, ESP front axle – all were only about 15,000 km old.
Regarding the "Z" component, it was newly installed at 209,000 kilometers.

At 217000, I naturally had to go to Rainer immediately to get the 150 horsepower realized with T5 injectors. icon_lol.gif
So far, the car has been running great.

At 223,000 kilometers, the car started to misfire while stationary after a long highway drive (500 km).
I assumed this was due to the poor road conditions in Poland, and that something had been damaged (e.g., an engine mount).
However, after review, they were found to be acceptable.
Since I was already aware of the stuttering issue with the AFN, and no one had yet identified the real cause, I didn't dwell on it any further.

Recently, I drove about 350 kilometers on the highway without stopping and then turned off the engine to refuel.
After refueling, it wouldn't start anymore.
The summoned repair service identified a faulty ESP (Electronic Stability Program).
However, since these were replaced two years ago at 168,000 kilometers, I ruled out a defect.
So, we disassembled the overvoltage protection device on site, and a horrifying sight was revealed.

The timing chain was misaligned and rubbing against the cover and other components.
In the process, he got scratched, and the entire timing belt drive was full of torn pieces of the timing belt.
However, he wasn't clever, which was surprising considering his appearance.
The roadside assistance technician immediately concluded that the timing belt had likely jumped a tooth and suspected engine damage.

The next day, we could see the valves through the valve cover.
"However, all of them were fine. There were no signs of any defects."

So, I called Rainer and asked him for some advice.

After reading the control unit data, the error message "ESP: No plausible signal" appeared.
That suggests that the ESP is probably broken.
All the connectors and other connections are fine.

After installing a new timing belt and tensioner pulleys, the engine, of course, wouldn't start.
So, we installed a new ESP, and it worked just like it always did.
Therefore, the timing was correct, so it didn't slip.

Unfortunately, the ESP unit was replaced exactly 25 months ago, which means the Bosch warranty (24 months) has expired.

Now I'm wondering how an ESP can fail after just two years and 57,000 kilometers. I've submitted a goodwill request to Bosch, but it will probably be rejected.

Now, let's get to the main point.
After warming up, the engine started misfiring again just like before, and the ZR (presumably a component or fluid) immediately started leaking outwards.
If we had left it like that, he would have gotten upset again.

So, we swapped out the ESP console.
After checking with several Audi mechanics (including Rainer, who confirmed this immediately by phone), it appears that some AFN engines may have this problem.

The new console is installed now. The ZR is running where it should be.
And the stuttering is gone.

Now we can speculate whether the pump was damaged because of the tilted bracket. I need to take a closer look at it.

The fact is, if the pump hadn't failed, I wouldn't have noticed the wear on the timing belt, and it would have eventually broken.
Therefore, my advice to everyone who is experiencing this stuttering.
Check your ZR.

It was an expensive experience.
But I hope the tractor will now run properly without anything breaking.

Drive safely.


Translated on 30-10-2026, 0:31.
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