Touran shudders/vibrates (Solution)

Hello,
My Touran is shaking .

Year of manufacture: 2005.
MKB: BKD
km: 245000

The car has been experiencing increasing jerking in 6th gear, between 1300 and 2000 RPM, for approximately 30,000 kilometers. It's become so strong that I sometimes have to ease off the accelerator because I'm afraid the engine might get damaged.
It's noticeable even under partial load, and becomes increasingly pronounced under full load.
The shaking is not always the same intensity.

The exhaust gas recirculation (EGR) system has been malfunctioning since the beginning; the check light is on, but there is no noticeable loss of power.
Today, for the first time, it went into emergency mode in 4th gear at approximately 3000 RPM.
However, it turned out to be the usual error message: 'Exhaust gas recirculation rate too low.' He's always there.
After turning off the engine, everything went back to normal.


I've already searched a lot for that in the forum; and that's also why:
I have already replaced these usual suspects, but with no significant changes.
Throttle body, mass airflow sensor, wiring harness, all engine mounts, driveshaft joints.

What other causes could be responsible for this type of stuttering? According to what I've read, PD injectors tend to cause misfires across the entire RPM range, right?

Nothing vibrates above 2000 RPM! Based on what I've read, the EGR valve operates within this RPM range. Could it be the EGR valve, even though it's supposed to be sealed?

Could there be a leak in the intake manifold causing this problem?


Thank you.

Sure, please provide the text you would like me to translate from German to English. I will provide only the translation, without any explanations.
The timing belt has been replaced by VW.
Clutch replacement covered by warranty at 100,000 kilometers.
Transmission replaced at 150,000 km.


Could it be related to the coolant temperature sensor? I have the feeling that the jerking or shaking decreases as the coolant temperature decreases. Say: When the engine is cold, it barely stutters.

I've also considered ZMS, but the VW workshop says that if it was installed at 100,000 km, it's unlikely to have failed yet.


One more note about the AGR (Abgasrückführung): For a long time, it was deactivated by blocking the vacuum hose; in that case, there would be no error message.
How/where can I disable AGR in the dataset?

Quote:

I've also considered a ZMS; however, the workshop (VW) says that one installed at 100,000 km is unlikely to have failed yet.

Don't be mistaken . If it was replaced at 100,000 km, and now it has 145,000 km, it shouldn't be broken yet, right?! It's hard to argue with that .

Please check MWB 013, which relates to quantity deviations. Note the values displayed on the LL (likely a display or instrument). Then, briefly introduce a pulse of gas, allow the reading to return to the LL, and observe the values. If the values displayed for each cylinder are significantly different, or if the deviations increase noticeably over time, then the problem is likely with the ZMS (likely referring to a vibration damper or similar component).

The deviations are:
Cylinder: Value.
1: -1
2:0
3:0
4:1

And absolutely consistent. Does this mean that the ZMS (presumably a specific system or component) can be ruled out as a potential source of error?

'Sometimes, I'm also noticing an unstable idle speed.'

He reported that the engine exhaust temperature was 77 degrees, even though the display shows 90 degrees. Normal?


What else can I check?

engl wrote:

The magnitude of the deviations are: Cylinder: Value. 1: -1 2:0 3:0 4:1

What is this supposed to be?

The magnitude of the deviations are:
Cylinder: Value.
1: -1
2:0
3:0
4:1

What is this supposed to be?


The values that the Texa IDC4 Car Plus tester displays for 'deviation in injection volume' for each cylinder.


Or have I misunderstood something?
I'm going to the VW dealership tomorrow for business, so I could also have my car connected to the diagnostic tester there. I need to be able to tell the mechanic exactly what needs to be done.

The discrepancies in the quantities are:
Cylinder: Value.
1: -1
2:0
3:0
4:1

What is this supposed to be?


The values that the tester (which my friend has at the workshop) provides for 'deviation in injection volume' for each cylinder.



in mg/path

Although the decimal places are missing, as long as the number doesn't start with a 2, it probably won't be that tragic.

Can the PD elements be defective or leaking based on the error description?
A friend of mine bought a BKD engine with a crack in the cylinder head. I can exchange anything I want for a sample.



Today, I noticed that the engine was vibrating slightly at idle: specifically, there was a shaking motion on the driver's side, moving back and forth. After about 10 seconds, it returned to normal. But what about ZMS?



But: what should I do next?

Thank you!

I've decided to replace the seals on the PD elements, at least for now, after doing some more reading.

It might not hurt to do that.

Does it make sense to also replace the nozzle tips? Is there a meaningful way to verschandeln it, and is it necessary or worthwhile?


Regarding the screws used to secure the nozzles, I've read different things; sometimes it says 12 Nm + 180°, and other times it says 3 Nm + 90°+180° (but that's also for a different motor).

What now?


Thank you!

Today, I finally got around to replacing the nozzle seals.

3 hours later: Fortunately, it's now working as it should. There's no more stuttering, and the uneven idle has also disappeared.

Regarding the installation of the sealing rings: I believe it poses a risk of damage to simply slide the sealing rings onto the nozzle.
Since I didn't have the VW tool, I wrapped the nozzle with tape to protect the rings.
Use brake cleaner to degrease the nozzle; then apply Tesa tape, slide a ring over it, etc.



Thank you for the help you provided!
'The quick brown fox jumps over the lazy dog.'

Thank you for the feedback .

270,000 km, and still going strong!