2.5 TDI keine Leistung nach Kopfwechsel / Startverhalten | Posts 16+

I'm particularly concerned about the PD elements right now... They were treated with a wire brush, and that treatment was done while preparing them for the wedges.

Die Werte der Leerlaufruheregelung waren vor der Reparatur bei etwa 1,5 mg/H und weniger (also auch nicht unbedingt allzu hoch). Jetzt liegen die Werte teilweise bei 1 mg/H. Vor der Reparatur waren sie also schon nicht übermäßig hoch, obwohl ich eine Ölvermehrung von mehr als 1 Liter auf 100 km hatte. Vielleicht liegt es doch an den Elementen? OdeWhat about the wiring harness?

During my last longer trip, I noticed a noise: Around 1500 to 1900 RPM, there's a kind of knocking sound, similar to a faulty hydraulic lifter, but much deeper and more muffled.

During the initial test drive, I noticed a "hydroclack" sound, which then became less frequent and eventually disappeared completely. While I can't imagine that such a sound could have caused any damage with these consequences, what is your opinion on this?

I also tried giving it gas immediately after starting the engine, while it was idling. The engine doesn't respond to the accelerator pedal at all.

EDIT regarding the synchronization angle: In theory, a positive angle should lead to a slight increase in torque, but in reality, it has the opposite effect.

EDIT: Regarding the engine, the Hall sensor detects the camshaft position directly via a disc mounted on the timing gear. The fixed camshaft is then bolted to the camshaft sprocket. Therefore, it's also possible that the camshaft has a completely different position.
The camshaft hall sensor only measures the rotational angle of the camshaft sprocket, not the camshaft itself.

Andreas_M wrote:

I'm currently particularly concerned about the PD elements... They were treated with a wire brush, and that was done while preparing them for the wedges.

I also have serious concerns about that, based on my own and more expensive experience .

About 17 years ago, this was my first attempt to replace the injectors on my 1Z 1.9 TDI.
to clean. The engine was running normally before, but one injector had a slight leak to the cylinder head. I cleaned all four injectors with a wire brush .

Well, after the installation, it started very poorly, and when it did run, it made a lot of knocking noises under load, with no power; accelerating was almost impossible.
The outlet holes of the injector tip, when viewed with a good magnifying glass, appeared to be almost "forged shut." I then had to install new ones .

I suspect you're experiencing a similar problem. Before disassembling everything again, I would suggest testing other PD components first.

Regards,
Mpire

Unfortunately, I have to disassemble quite a few parts. I skipped having the injectors checked during installation because the local Bosch service wanted 80 euros plus tax per injector... and that was just for the inspection... So, almost 500 euros with the expectation that repairs would be necessary.

Now, just the cost of taking everything in and out to install the expansion bolts is already about 80 euros. In addition to that, there's the risk of damaging the threads on the clamping jaws at the head... it seems to happen fairly often with this type of motor .


Does anyone know of a cheaper alternative to the Bosch service?
It would probably be more sensible to replace all the nozzle inserts at the same time from the beginning.
Do you have any recommendations for products to buy?
Unfortunately, the injector sets that used to be available at the Diesel Schrauber Shop are no longer in stock. I ordered and installed them for my 1.9 engine back then, had them checked again, and ended up paying around 250 euros for everything.

[Translating...]

Hi,

Quote:

Wobei es wahrscheinlich sinnvoller wäre, gleich alle Düseneinsätze selbst im Vornherein zu tauschen. Hättet Ihr dafür Kaufempfehlungen? Die Düsensätze im Dieselschrauber Shop gibt es leider nicht mehr. Die hatte ich damals für meinen 1.9er bestellt und eingebaut, nochmals überprüfen lassen und am Ende komplett um die 250 Euro bezahlt.

erfahrungsgemäß benötigt man etwas Übung, es gibt dazu ein Video: https://community.dieselschrauber.org/en/viewtopic.php?t=17583

Wenn Du vor hast es nur ein einziges Mal zu machen (bei Deinem Auto) ist die Wahrscheinlichkeit nicht unerheblich, daß es in die Hose geht.
Und Nicht-Bosch Düsen habe ist auch schon rechten Schrott gesehen, im Tuningbereich (= gibt keine passende Bosch Düse) musste ich schon ab und zu eine Nagelneue entsorgen, da mieses Spritzbild. Von daher, wäre ich da erst recht vorsichtig, irgendeinen Kram zu verbauen.

Viele Grüsse, Rainer

I watched the video. And it's not the first time I've opened a nozzle (so far, only VEP nozzles, but it probably shouldn't be any different).

Of course, anything can go wrong.


I've already done some research online, but the prices vary quite a bit (for new injector nozzles with inspection, it ranges from about €140 to €250 per nozzle), and I can't really assess the quality of the work or the parts beforehand.

The local Bosch service wants to charge 177 euros gross for the parts, plus 80 euros net for the inspection. While it will certainly be of high quality, it's also the most expensive option.


Do you perhaps have any contacts for reliable repair technicians? As you mentioned, I don't want to just install anything.

Quote:

Do you perhaps have some contacts for reliable repair technicians? As you mentioned, I don't want to just install any random parts...

Sorry, I don't currently know of any reliable parts sources for PD components like nozzles or other individual parts (other than Bosch), simply because I haven't needed them yet. And when I did need individual parts, I didn't have the time for experimentation.

Andreas_M wrote:

Do you perhaps have some contacts for reliable repair technicians? As you mentioned, I don't want to just install any random parts...

If you live near Treffelstein in the Upper Palatinate region, I recommend trying BOSCH in Weiden. I've had really good experiences with that store.
The best thing to do is to go there in person and speak with the master craftsman; the people on the phone are not competent enough to discuss the internal workings .

Regards,
Mpire

The problem is that testing PD units requires a relatively expensive test setup... therefore, the number of alternatives is likely to be limited.

Update: Unfortunately, I couldn't find any more information online about the testing method used by the affordable Bosch service. Therefore, the injectors were taken to the local Bosch service center this morning.

Since I didn't really have much hope that the nozzles were still in good condition, he decided to repair them right away.
The entire process was supposed to cost me around €1200, as initially stated. However, on the way back, I received an updated price of €1400.

The bad news came after the lunch break: So far, 3 units have been tested. All 3 had electrical defects (allegedly due to wear and tear). It probably doesn't make sense to test the remaining 2 units either, as they are likely to be defective as well.

It seems the milling process for the pump nozzle wedges was ultimately a waste of time/effort.

It's strange that the engine was working perfectly fine before it was removed or modified, except for the issues with oil dilution and the resulting poor starting performance.

Hello Andreas,

I recently purchased a new PD element for my BRE motor, and since I don't want to publicly advertise it, I will send you a private message (PM).

Best regards, Rainer.