Okay...
Final Report:
The screw was loose, which caused the timing belt pulley to shift, and the valve timing was slightly misaligned (even with a new screw). The crankshaft stub was fine at the locking point. I used the appropriate tool to resurface the surface while it was still installed, and tightened the screw with the correct torque (I'll just say: too tight comes loose
). I also secured the screw with Loctite on the threads. The contact surfaces were assembled dry.
After readjusting the injection timing (purely mechanically), it ran perfectly again. I rechecked the injection start timing using VAG-Com. Everything was fine and didn't require any further adjustment of the pump.
I've already driven about 2000 km since then, and everything seems to be fine. I made a hole in the sound insulation so I can occasionally check the torque of the KW screw. After those 2000 km, everything was still the same.
I've now completely immersed myself in TDI technology, through self-study and repair manuals, and I've realized that it's just as straightforward a technology as that found in gasoline engines.
Yesterday, I cleaned the turnout mechanism. I'm just wondering where the metal shavings are coming from??? It definitely improved the elasticity, though.
Conclusion:
A TDI engine is simply too prone to problems (especially with very high mileage), and the replacement parts are too expensive. It's definitely cheaper to convert a naturally aspirated gasoline engine to LPG!
The only advantage of a diesel engine is that the lower RPMs reduce wear and tear on the engine block and head. However, all the peripheral components are simply too expensive and tend to break down more often! I just wanted to get that off my chest, no offense intended! The TDI is my first diesel, and I'm a little disappointed. If these repairs had to be done by workshops, this thing would be a money pit. Every colleague I've talked to about it, regardless of whether it's a new or old TDI, has already experienced very expensive problems!
P.S.: Since I was in Munich, the LLK is leaking!!!
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