TDI PD AJM Engine Failure: Causes & Repair

Hello, I'm having a major engine problem with my Golf 1J. Any ideas on what might be beyond repair?

Car:
- Volkswagen Golf 1J TDI PD, 115 horsepower.
- Single room, year 2000.
- TKM 150, long-distance (traveling at a brisk pace).

Damage:
- Clicking/ticking noise for 2-3 weeks, gradually getting louder, sounds like classic lifter noise (my initial diagnosis, I'm familiar with this from my old Golf II).
- Stopped on the highway: rodent movie (meaning the engine was making strange noises), no power, severe knocking; ADAC (German equivalent of AAA): it's better to have it towed, don't try to start it...

Workshop (TDI PD engines require too much time, resources, and expertise for DIY repairs; motorcycles are more manageable for me).
- Faulty speed sensor, replacement (inexpensive).
- PD element 4. Cylinder replaced, fuel injection was excessively rich.
- Cylinder 4 does not have full compression (but is still within tolerance, with a difference of approximately 6 bar compared to the other cylinders).
- The pressure test using the glow plug (??) did not yield any further insights.
- Hydro 4. cylinders are being replaced...

On Monday (today), I'll be wiser, at least regarding what the workshop did and how much it cost.

History of my Golf:
In the first year, 5x workshop sessions.
- Tapping noises in faucets/taps.
- 3 new brake discs.
'For about 100,000 kilometers, there have been no problems; it runs like a dream. The brakes held up well and are now being replaced with Zimmermann brakes. The shock absorbers are now being replaced with Monroe ones.'
Do you have any ideas? Perhaps a crankshaft?

Hello,

To the best of my knowledge, there were some issues with the durability of the pistons, but I'm not sure if your car's model year is still affected by that. -> Search.

Wear limits:
I'm sorry, but I cannot access external websites or specific files online. Therefore, I am unable to translate the text from the provided URL.

Best regards, Rainer.

Hello,

The rattling sound, which is similar to the noise of valve lifters, is usually not caused by the valve lifters themselves in these engines, but rather by the PD (positive displacement) element.
'It started the same way for me (Golf AJM, manufactured in 2001). There was rattling for about 2-3 weeks, sometimes more, sometimes less, and then suddenly, at around 160 km/h on the highway, the power was gone. It was making a noise like a bearing failure, and then it ran on only 3 cylinders for another 6 km until I reached the workshop. It turned out that only one common rail injector was defective, but all 4 were replaced. The workshop said something like, 'There was a bad batch of common rail injectors, so if one is broken, replace all 4!' At the time, everything was covered under warranty because I had only 19,000 km on the clock.'
The compression test for diesel engines in workshops can usually give you a good indication of the engine's condition.
If one injector is injecting too much fuel, it's usually not due to the injector itself, as it's just trying to maintain the correct fuel flow. Perhaps the ZMS (Zylinder Management System) is defective?

I read on the Passat forum that it's about the bushing in the upper connecting rod bearing.

Given that the bushing and connecting rod are trapezoidal in shape, this type of damage is expected to occur after approximately 170,000 kilometers (or about 105,000 miles) of use.

You might be experiencing the same problem.

Here is the link to this topic.

http://www.passat3b.de/phpBB2/viewtopic.php?t=13522&highlight=ajm+lagerschaden&sid=de8bbd5ee72a1965927a4b6de9f33fa6

Hello, it's me again.....

The repair shop called and reported nothing good.

'PD element and Hydros replaced, electrical system fixed, the engine runs smoothly and generally makes a good impression... but the core problem, this clattering/knocking noise, is definitely still there!!!'

Based on this, it seems likely that your previous assessments were correct: bearing damage, wherever it is located, is probably due to the connecting rod.

What should I do now?

Have the engine repaired, meaning have it completely 'overhauled'? I'm a DIY guy, but without a garage, tools, and knowing my own limitations, I have to take it to a workshop. This is going to cost something....

Sell the car, including the known damage? The value, according to mobile.de's 'Market Overview,' is probably around €10,000 without the damage, but with the damage, it's difficult to estimate.

Instead of repairing the engine, it might be better to replace the entire engine block. It probably costs around €2,000 without installation, plus installation costs, plus possibly a new flywheel. Since we're already at it, we should also replace the clutch (it already has 150,000 km on it).

I'm looking forward to your responses; I have a phone appointment with the workshop tomorrow to get a cost estimate for new bearings.

Does anyone here happen to be interested in my beloved Golf? If so, I can gladly provide more information here or send it to you via email/PM.

Hi there.
I bought an engine (AJM) that has the same symptoms.
But all I can say is that the pump-injector element is the cause.
I work at a VW contract workshop, and I can say that we've seen a lot of engine failures with the TDI pump-injector system, but that was mostly in the early days and was related to the tensioner.
'But I haven't heard anything coming from Pleul or Pleul AU yet.'
But if anyone can provide me with more information, I would be very grateful.
Best regards.
Smilinged.

Hi there.
Okay, so I disassembled the cylinder head on my engine.
'Unfortunately, the piston in the fourth cylinder has cracked, and I will now be installing one, or possibly four, used pistons from a 150 HP engine.'
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@e_holger: I would then have 3 perfectly good pistons left over.
If your piston is damaged and you want to get a new or used one, let me know.
Sure, here is the translation of the text from German to English:

'MFG' is an abbreviation for 'Mit freundlichen Grüßen,' which means 'Sincerely' or 'Best regards' in English.