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? Ode"Is there a problem with the wiring harness?"

During my last longer trip, I noticed a sound: At approximately 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. I can't imagine that such a sound could have caused any damage with these consequences, but what is your opinion on that?

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

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

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 is also possible that the camshaft is in 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 .

Okay, after the installation, the engine started very poorly, and when it was running, it made a lot of knocking noise under load, and there was no power; it was almost impossible to get it moving.
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 you disassemble everything again, I would suggest testing other PD components.

Regards,
Mpire

Unfortunately, I have to disassemble some parts again. I skipped having the injectors checked during the 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 the entire process, including installing and removing the expansion bolts, is already around 80 euros. In addition to that, there's the risk of damaging the threads of the clamping jaws at the head... it seems to happen quite often with that engine .


Does anyone know of a more affordable 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 the whole thing.

Hi,

Quote:

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 nozzle sets in the Dieselschrauber Shop are no longer available. I ordered and installed them for my 1.9 engine back then, had them checked again, and ultimately paid around 250 euros for the whole thing.

According to experience, it takes some practice, and there is a video available for that: https://community.dieselschrauber.org/en/viewtopic.php?t=17583

If you plan to do it only once (with your car), there's a significant chance that it will go wrong.
"And I've also seen a lot of low-quality injectors that weren't Bosch, especially in the tuning scene (where there often isn't a suitable Bosch injector available). I've had to discard brand new ones from time to time because of their poor spray pattern. Therefore, I would be very cautious about installing any random parts."

Best regards, Rainer.

I watched the video. And it's not the first time I've opened a nozzle (so far, I've only opened 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, including inspection, they range from about €140 to €250 per nozzle), and it's difficult to assess the quality of the work or the parts beforehand.

The local Bosch service wants to charge €177 gross for the parts plus €80 net for the inspection. While the quality is certainly guaranteed to be excellent, it's also the most expensive option.


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

Quote:

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

Sorry, I don't currently know of any reliable parts sources for PD components, specifically for 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 in Treffelstein, Upper Palatinate, 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 to 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 testing facility... therefore, the number of alternatives is likely to be limited.

Update: Since I couldn't find any more information online about the testing method used by the Bosch service, I took the injectors 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 euros, as initially stated. However, on the way back, I received an updated price of 1400 euros.

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 have failed as well.

It seems the milling process for the pump nozzle wedges was a complete waste of time.

It's strange that the engine, before being removed or modified, was working perfectly fine, except for the issues with oil dilution and the resulting poor starting behavior, and it wasn't lacking any power.

Hello Andreas,

I recently purchased a PD element for my BRE motor a few months ago. Since I don't want to publicly advertise it, I'll send you a private message.

Best regards, Rainer.