Engine Vibration After Head Replacement

Hi,
I'm experiencing some issues with my 2003 Touran 1.9 TDI, which has an AVQ engine.
2. The timing belt needed to be replaced, and the original camshaft already showed signs of wear and tear, so I had it replaced as well. The bearing shells also looked worn. As a replacement, I had a camshaft from Campro installed, along with hydraulic lifters from INA (the black ones). New swingarm axles (original VW) were also installed.

After some time, the PD elements started causing problems, and eventually, the threads of the tension plates were stripped. The car then received a new (remanufactured) cylinder head (approximately 1000 km later, mileage of the Campro camshaft). This cylinder head already had a camshaft pre-installed (allegedly from Kolbenschmidt, the hydraulic lifters are silver and supposedly also from KS). Therefore, the Campro camshaft remained in the old cylinder head. The PD elements are functioning well (shift time deviation and quantity balance in the idle speed control are all good). However, I noticed that the new camshaft already shows signs of wear and imperfections after about 300 km. I still have the old cylinder head, and I previously removed the Campro camshaft from it. It looks good so far, but the bearing shells are heavily worn again.

"I specifically had both the old and the new cylinder heads checked to ensure that all the oil channels were clear and clean. The oil channels in the crankcase are also supposed to be in good condition, and I have never had any problems with oil pressure. Furthermore, an oil change was performed each time."
The workshop was an official VW service center.

My current problems are as follows:

"The vehicle now has a significant humming noise with vibrations, both at idle and at higher RPMs (regardless of gear, or whether the clutch is engaged or not). This was not present at all before the repairs (the dual-mass flywheel is brand new, along with the Sachs clutch)."
What can I do here?
Is it possible to measure the camshaft while it's still installed in the engine to determine if worn lobes are causing vibrations, or is that unlikely?

"The imperfections I'm seeing on the current camshaft give me concerns about its durability, especially since 300 km is not a significant run-in distance for a camshaft. Is there a way to determine if it's a Kolbenschmidt camshaft while it's still installed? Do Kolbenschmidt camshafts have that appearance on the sides of the lobes? Is the quality of Kolbenschmidt camshafts good?"

3. How is it possible that the bearing shells (which were originally VW parts) are so significantly worn on the Campro camshaft?



I really don't want to have to replace everything again and install a new camshaft with new lifters, etc.
The question is also which manufacturer, or should it be an original part? If I'm putting in this much effort, it should last.

Hi,

Have the PDUs been properly adjusted (mechanically) after installation?

Yes, exactly according to the regulations and a 180-degree turn.
Shouldn't that also have some kind of impact on the measurement readings?

Soundchef wrote:

Yes, exactly according to the regulations and 180 degrees back. Should that not also have some kind of impact on the measurements?

It happens, whether you do it correctly or incorrectly. Based on your measurements, it seems more likely to be the latter.

The camshaft and bearing shells are worn out - due to insufficient lubrication.
Wasn't there something about using shims in the PD swingarm pivot axis before?
If one is missing, there is a lack of oil pressure.
hg
Herbert.

I've now installed a new camshaft from VW, along with new bearing shells and new hydraulic lifters from INA. Everything has been re-adjusted, including the PD elements using a dial indicator. The knocking and vibrations have become somewhat more consistent, but they are still present. All the plugs in the swing arm axles are in place. These were also replaced during the cylinder head replacement.
Just to be on the safe side, I also checked the oil pressure, and everything is fine.

What else could it be?


Thank you for your feedback!!

Hello,

The values for the idle speed control in the MWB13 appear to be very good.
Perhaps you could briefly run the engine at idle with the cylinder head cover removed? Have an assistant in the vehicle who can immediately shut it off if necessary.
Caution: This might (hopefully) cause a malfunction. Consider covering the engine compartment. This way, you can relatively quickly see if the camshaft is receiving enough oil. Based on my observation, the camshaft and its bearings appear to be suffering from a lack of lubrication.

I unintentionally tested the operation of my BRE without the oil pump, and the timing chain rattles quite a bit in that configuration. After the repair, you can immediately hear inside the vehicle when the oil reaches the timing chain cover again.

Best regards, Rainer.

Thank you for the tips.

The oil supply to the cylinder head appears to be fine. A new VW camshaft was recently installed, along with new bearing shells and new hydraulic lifters. It has been running well for some time and shows no signs of problems (at least not visible with the valve cover removed). This was not the case with the Kolbenschmidt camshaft. The Kolbenschmidt camshaft is now being inspected by Kolbenschmidt.

Regardless, I still have a loud, booming engine noise that sounds rough. This is especially noticeable at engine speeds above 2000 RPM. Strangely, there's a slight hissing sound when accelerating at full throttle, starting around 3000 RPM (the turbo is a new unit from Garrett). So far, I haven't found any leaks on the charge air side (checked with compressed air) or any signs of soot on the usual suspects, such as the exhaust manifold gasket or the EGR valve.

The PD elements were replaced with new ones during the ZK exchange.
The values don't seem very impressive for the new PD elements. While they are still within the acceptable range, the switching time variations are quite high. There also seems to be a slight leak on cylinder 1.

What do you think about that?

Hello,

The variations in quantity are acceptable. Regarding the switching times: I don't have those values memorized, but they should be available in the forum.

Best regards, Rainer.