Golf IV 1.9 TDI AXR - Stutters under load (Solution)

Hello everyone,
When I drive my Golf IV, I experience strong shaking/vibration/jerking of the engine whenever I press the accelerator.
Especially under load (at high altitude), the engine vibrates/shudders very strongly.
The more he is under load, the more violent the shaking.
However, when idling, everything is fine, it's just that it might be a bit louder.

First, some information about the vehicle: VW Golf IV 1J1, 1.9tdi AXR, manufactured in 2002, 155,000 km, previous owner had an MTM chip installed, increasing power to 130 PS

Error codes that could be read:
19557 - P3101 Engine for Intake Valve (V157) Interruption/Short to Ground, 35-10, intermittent
18080 - P1672 Radiator Fan Control 1 Open/Short to Ground, 35-10, intermittent

I have deleted the two errors, but the upper error has now reappeared.

The following measures have been taken so far:
- Air mass sensor replaced > Didn't help
- Suction tube pressure sensor replaced > No effect
- Checked and cleaned the battery terminals > Did not help
- Suction tube pressure sensor replaced > No improvement
- AGR pressure sensor replaced > No improvement
- Intake manifold valve and AGR valve removed and cleaned > No improvement
- New poetry at the AGR valve towards the fresh air pipe with a smaller passage > Nothing helped
- The VTG linkage can be moved, at least a few centimeters, which I don't have much knowledge about. The car mechanic said that this is okay.

Also also also also also also also also also also also also also also also also also also also also also also also also also also also also also also also also
From the starting position in 3rd. From idle speed to 4500 RPM, approximately 120 Km/h, then engage the clutch and coast to 70 Km/h.
See Appendix

From another forum, there was also a reference to the PD cable harness, but nothing about it is recorded in the fault memory.

What I had forgotten: When accelerating, there is a lot of black smoke coming from the exhaust, so it seems like there is a lack of air!?

Thank you for all the tips!!!

Quote:

- Throttle body and AGR valve removed and cleaned > No improvement

Take it apart - I'm pretty sure it needs to be replaced.

Hello, to the diesel mechanic and thank you for the tip!

Then you might be saying that the AGR valve is not closing properly, and because of the high exhaust gas rate, the engine is not getting enough fresh air.

The AGR valve actually looks quite good, the diaphragm seems to be sealed, I tested it with a vacuum syringe.

What about the suction valve?
Is it also responsible for regulating the AGR rate, in addition to the function of soft parking, in the AXR?



Thank you!

"Check the "valve control" mechanism...

Quote:

In my Golf IV, I'm experiencing problems with a strong shaking/vibration/jerking of the engine whenever I press the accelerator. Especially under load (high altitude), the engine shakes/vibrates very strongly.

Shake or vibrate?

If the errors have been fixed and it still vibrates, the internal bearings of the drive shafts may be affected. In reverse gear, the vehicle would then accelerate smoothly.

The fuel filter is fine... that's the first thing that comes to mind.

Because the valve actuator for the intake manifold is made of plastic?

So, I also believe that the suction valve is faulty.
I'm just wondering if she's also responsible for the issue.

I recently ordered a new item on eBay, and Wessels + Müller actually charged me €243.50 for it, with a discount, of course

Hm, I can't really tell the difference between shaking and vibrating, it's so strong that the entire dashboard vibrates when I press the gas pedal harder. So, the frequency will also increase.

The fuel filter is usually not the problem; it was replaced 10,000 km ago.

The gearbox often suffers from tooth wear.
I wouldn't be surprised if you're still having problems with that item from the colorful department store

You could have disassembled it before buying a new one

@klahaui: The parts offered in the free market differ, at least in my case with my Audi, only in price.

I would also need to remove a few screws first, and the inspection/replacement should take about 15 minutes.

So, the one in the colorful department store is, of course, also an original Pierburg part... you wouldn't want to put any junk in there...

The three screws are not a problem, I already removed them, but the cover for the engine is designed in such a way that it doesn't just come loose directly.

Once the new one arrives, I'll take the old one apart after installation, as I have the right to return it.

You can check the fuel filter with VCDS: look at parameter MWB 023. If the values become significantly negative with increasing load, then he will not receive fuel.
Context: The valve needles/valve plates of the PDE move significantly faster in air/vacuum/humidified conditions than the expected time-to-actuation characteristic indicates. MWB 023 shows the deviation (positive/negative) from the expected time.

That's very interesting, thank you for the information!

I once made a log.
...back to third gear from neutral to 4500 RPM,
The values are already becoming negative, but I cannot assess it.

I'm attaching the log now!
Thank you all!

And here's also a video from today's afternoon drive (not from the log), maybe you can hear/see the vibrations:

Okay, I have today removed the old suction valve, the teeth, and the entire interior – everything looks good, with no signs of wear.

As a test, I then mounted the new suction valve, but the shaking is still present.
The acceleration feels a bit better to me, maybe it's just the placebo effect

And what about the error log entry, will it reappear after deleting it?

So, the error memory currently shows nothing, I had cleared it before installing the intake valve.

But last time, it also took some time for the error to appear.
I think I should check the mass points on the cable towards the ECU.
Somewhere, there must be a mistake.

Can we at least rule out something in my two logs? Wastegate housing? Fuel filter?

Thank you and best regards,
flexbeat

The values in MWB 023 are, for the most part, correct.

Great, thanks for looking
Then he should at least get enough fuel.

I will then probably try my luck with the next step, which is to replace the PD cable.
Or is there a way to exclude this through a log?
MWB 18?