Touran TDI - nach Zylinderkopfwechsel - Vmax Tacho nur 180 | Posts 16+

Thank you for the input. The idea that aluminum can deform steel is quite interesting... and it would be new to me .

But the most important thing is that my car is finally working normally again.

According to the invoice, the diagnosis is: broken rocker arm on the cylinder head for cylinders two and four, and the PD (possibly referring to a pressure device or similar) unit is damaged/worn for cylinders two, three, and four.

I took a look at the replaced fuel injectors. On the part of the injectors that sits in the cylinder head, underneath the rubber seal, I noticed very slight scratches on the silver part. I examined two injectors, and they looked different from each other, but the scratches were minimal.

Reason for the almost-identical exchange: There would be immense pressure on it, and it needs to be 100% perfect; the scratches would compromise its integrity.

The CFO couldn't fully explain where they came from either, only that they were simply there.

Well... thankfully, the car is running normally again, and 2 years of warranty is not bad... next time, I'll come here earlier, I might save some money .

Thank you again.

Let me see those tipping levers sometime; I'd be interested to see what they look like. I doubt it's really like that, but I'd like to check.
The most extreme thing I've seen so far are sheared-off heads of the multi-tooth screws that attach the tilting levers to the head. I think I even saw a photo of this here, among the diesel locomotives.

"By 'tipping levers', do you mean the rocker arms that actuate the valves, or the pivot axis of the direct injection pump (PDE)? And were the scratches located on the outside of the nozzle tip shaft?"
And at first, did you just experience mild dehydration?

Either they messed something up while assembling the new head, or they got the valve timing wrong. And then the problems with the PDE injectors started. All for nothing.
And in the end, it turns out that the problem with the head wasn't actually necessary, because it was just the head gasket that was faulty (speculative).
However, what's remarkable are the stories used to sell these products. Unfortunately, I can't laugh because I don't understand the humor.

What was the total cost of everything, if you don't mind me asking?

Does 'Kipphebel' refer to the rocker arms that actuate the valves, or the pivot shaft of the PDE (pneumatic direct injection)?

Sure, that's right, it's a 16V. Sorry, I was thinking of an 8V.
shame on me

Things like that can easily be misunderstood, especially without pictures. That's why I'm asking.
The problem with the mechanism inside likely has to do with the pivot axis. That's probably why they also started experimenting with different nozzles, and they ended up with 3.0 mg of LLR on the clock.
The next question is: Why did it suddenly break? Well, it's probably because something went wrong when the head was being assembled. And then there's the issue of the valve timing.
Even if there are small scratches on the outside of the nozzle stem from being inserted into the head, this does not affect the tight fit of the element within the head.
Maybe I'm just misunderstanding something.

So, the scratches were located at the spot marked with the arrow.

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NicolaiKoeln wrote:

Maybe I'll become a diesel mechanic now .

For 3600EUR, you get a decent amount of tools to start with. That's true. Then you could get the head from KS or MSD, the rest from a wholesaler, and you could have converted it yourself in peace. } You won't get any dumber from it. }

Dear community,

In November, a new cylinder head with 4 new piezo injectors was installed. The cylinder head was replaced twice because the first one had a broken valve lifter.

The car was consuming more than 1 liter of oil per 1000 kilometers. Because of this, I took it to a different VW workshop for inspection at the beginning of July. They couldn't find anything wrong, but they still installed a new cylinder head.

We drove about 1000 kilometers on vacation, and on the way back, at a speed of 120 km/h, the engine suddenly lost power. We coasted to a stop, and the engine was full of oil. The oil had sprayed out of the dipstick opening.

Now the car is back at the VW dealership, and they say there's a crack in a piston, and the engine is broken.

Could it be that something happened to the pistons during the cylinder head replacement (which has been done 3 times), or are the pistons well protected during a cylinder head replacement?

The car has only 150,000 kilometers on it.

Thank you for a response.

NicolaiKoeln wrote:

Well... thankfully, the tourist's car is running normally again, and 2 years of warranty is not bad either... next time, I'll come here earlier, I might be able to save some money .

The never-ending story! A piston can fail even with 150,000 km on the clock. The likelihood certainly increases if someone inexperienced tinkers with the cylinder head and valve cover gaskets, which clearly happened here. Since you probably won't be able to fix it yourself: find a competent mechanic this time!
haithamina

Hi Nikolai, I've read about your problem and the various responses to it. I want to clarify things and advise you to immediately consult a lawyer to take action against the workshop.

And the problem arises as follows:
I am a test bench mechanic, and I have tested VW engines on the test bench, so I am familiar with all the weaknesses and flaws of the engine.

"Inside the cylinder head, there's a thin plastic fuel distribution pipe. This pipe needs to be replaced whenever the cylinder head is changed because it's not included in the new head. If handled improperly, this (very thin-walled) plastic pipe can break. The result: exactly the problem you're experiencing. The engine has significantly less power. Now, the workshop can't remove the broken pieces from the bore, and they'll tell you some nonsense about breaking in and seizing... complete rubbish. They want to cover up their mistake and make you pay for it."

Go to a different workshop and have them reinstall your old PD elements. If necessary, demand a refund, possibly with the help of legal protection insurance. I've had this issue on the test bench very often, and I've taken these engines apart and put them back together countless times. Your problem is definitely related to that.

Quote:

Hi Nikolai... I've read about your problem and the various responses to it. I want to clarify things and advise you to immediately hire a lawyer to take action against the workshop.

After more than a year, the matter is certainly resolved.

Strictly speaking, if only the ZKD (likely referring to a specific car part) had been replaced, the "delinquent" (likely referring to the person who owes money) would have been 3000 EUR better off.

emil954 wrote:

Hi Nikolai... I've read about your problem and the various responses to it. I want to clarify things and advise you to immediately hire a lawyer to take action against the workshop. And the problem arises as follows: I am a test bench mechanic, and I have tested VW engines on the test bench, so I am familiar with all the weaknesses and flaws of the engine. "Inside the cylinder head, there's a thin plastic fuel distribution pipe. This pipe needs to be replaced whenever the cylinder head is changed because it's not included in the new head. If handled improperly, this (very thin-walled) plastic pipe can break. The result: exactly the problem you're experiencing. The engine has significantly less power. Now, the workshop can't remove the broken pieces from the bore, and they'll tell you some nonsense about breaking in and seizing... complete rubbish. They want to cover up their mistake and make you pay for it." Go to a different workshop, and have them reinstall your old PD elements. Demand your money back if necessary, with the help of your legal protection. I have had this error very often on the test bench, and I have disassembled and reassembled the engines countless times. Your error is clearly

.

Hello emil954,

I'm interested in buying a Touran 1.9 TDI, manufactured in 2004, from my neighbor. I've read about the problem of cracks in the cylinder head of the 2.0 TDI engines in many forums. Based on your experience, can you confirm that this issue is less common in the 1.9 models?

1.9 TDI and 2.0 TDI engines are completely different engines. In particular, their cylinder heads have absolutely nothing in common.

Thank you for the quick response; I will talk to my neighbor about it.