Misfires on 2.0 TDI engine, rough running (Solution)

A 2.0 PD-TDI 16V (engine code BRE) has an uneven idle and only runs on 3 cylinders (error code P0304 - misfire cylinder 4, similar errors: P0301, P0302, P0303, P0305, P0306). When looking into the engine compartment, the engine exhibits significant shaking in the engine mounts, both in and against the direction of rotation.

As the speed and load increase, the uneven running almost disappears, and only slight vibrations can be felt. During deceleration or when coasting (fuel injection amount 0 mg/H), the engine noise and vibrations are normal.

Reading the error memory with the HEX-V2 and VCDS yields the following:

Quote:

Wednesday, August 16, 2017, 2:55:42:17557 VCDS, a Windows-based VAG/VAS emulator, runs on Windows 8.1 x64. VCDS Version: RKS 17.8.0.1 HEX-V2 CB: 0.4401.4 Data as of: 20170809 DS276.3 Vehicle Identification Number: WAUZZZ4F88N0***** License plate: "Die Sonne scheint hell, und die Vögel zwitschern fröhlich. Es ist ein wunderschöner Tag, um spazieren zu gehen oder ein Picknick im Park zu machen. Viele Menschen genießen das gute Wetter und verbringen Zeit im Freien." "Die Sonne scheint hell, und die Vögel zwitschern fröhlich. Es ist ein wunderschöner Tag, um spazieren zu gehen oder ein Picknick im Park zu machen. Viele Menschen genießen das gute Wetter und verbringen Zeit im Freien." Address 01: Engine Control Module Label file: DRV\03G-906-016-BRE.clb Control unit part number: 03G 906 016 ME Hardware: 03G 906 016 ME Part and/or version: R4 2.0L EDC G000SG 0945. Encoding: 0000072 Operating number: WSC 66565 257 00032 VCID: 72BED0A158AB68C75DE-8026 Sure, here is the translation of the text from German to English: "1 error found:" 000772 - Cylinder 4 P0304 - 000 - Misfire detected

.
Environmental conditions:
Error status: 01110000
Error priority: 3.
Error frequency: 1
Lost Counter: 255
Mileage: 287,129 km
Time: 0
Date: 2017.08.15
Time: 13:47:27

Environmental conditions:
Speed: 882 RPM
Speed: 0.0 km/h
Last: 0.0%
Voltage: 13.38 V
Injection volume: 2.96 mg/hour.
Temperature: 79.2°C
(no unit): 0.0http://shop.dieselschrauber.de

Unfortunately, there are no electrical faults or interruptions detected in the PD elements within the memory, which is concerning because simple failures in the PD cable harness are almost impossible to rule out.
Since the engine no longer misfires when revving or under no load, the dual-mass flywheel can be ruled out. Are the compression problems caused by issues such as damage to the valve timing mechanism, a crack in the piston, or something similar, or are they due to a defect in the specific positive displacement element?

Removing the cylinder head cover, the first thing that's noticeable is the reduced distance between the top of the pump-nozzle element number 4 and the corresponding rocker arm.

The connecting element between the adjustment screw on the tilting lever and the pressure distribution (PD) element has broken. As a result, the PD element moves to the "not activated" position with each lift, causing the PD element (VAG part number: 03G 130 073 G / 03G130073G) to disintegrate.

Hi,
Does the engine control unit (ECU) detect the combustion misfire based on the current flow of the valve (keyword: BIP - Burn Identification Pulse)? After the somewhat outdated SSP, there is an error message regarding the BIP Control Limit.
hg
Herbert.

Herbert wrote:

Hi, Does the engine control unit (ECU) detect the combustion misfire based on the current flow of the valve (keyword: BIP - Burn Identification Pulse)? After the somewhat outdated SSP, there is an error message regarding the BIP Control Limit. hg Herbert

Hello Herbert,

Theoretically, it's definitely possible, but I have no idea if my engine control unit (ECU) does that. The engine, however, is running so severely unevenly at idle that simply measuring the rotational speed would be sufficient...

Best regards, Rainer.

And increasing the idle correction amount has no effect, perhaps the control unit also notices this. These things are supposed to be smart .
hg
Herbert.

After installing a reconditioned (like-new) PD element from Bosch and new PD connection elements, the PD elements were adjusted. We decided not to disassemble or repair the old PD element, as a deposit is refunded upon its return.

The engine is running again.