Vibrating PSA CR DI (Suzuki) at 1500 RPM

I have the following problem.

The motor vibrates at exactly 1500 RPM.
Furthermore, it barely produced 1/min of power until the year 1800.
The air mass sensor is new.
AGR is clean and regulates.
Boost pressure is within normal limits.
All injectors are within a range of +/- 0.5mg per dose.

when the trunk is full (400kg) and the trailer (850kg) is attached.
then the vibration is almost gone, and the acceleration between...
900 and 2200 RPM is noticeably better.

Regarding the vehicle:
Suzuki Grand Vitara XL7 2.0 TD

Regarding the engine:
Peugeot COMMON RAIL, 2.0 L, 80 kW at 4000 rpm.
Engine code: RHW.

Michael 111 wrote:

I have the following problem. The motor vibrates at exactly 1500 RPM. Furthermore, it barely produced 1/min of power until the year 1800. The air mass sensor is new. AGR is clean and regulates. Boost pressure is within normal limits. All injectors are within a range of +/- 0.5mg per dose. when the trunk is full (400kg) and the trailer (850kg) is attached. then the vibration is almost gone, and the acceleration between... 900 and 2200 is better. Regarding the vehicle: Suzuki Grand Vitara XL7 2.0 TD Regarding the engine: Peugeot COMMON RAIL, 2.0 L, 80 kW at 4000 rpm. Engine code RHW

.

Ahoy!

I didn't realize that Suzuki also uses PSA diesel engines. According to the engine code, it's the DW10ATED4, which is a 2.0 HDi 16v. This makes troubleshooting easier because these engines are common in vehicles from several manufacturers.

The quantity correction is excellent; the correction values can deviate up to 7 mg/H.

Two things immediately come to mind.
-ZMS failure.
- Fluctuations in rail pressure.

To check the rail pressure, quickly connect a multimeter to measure it and see if it's fluctuating within the expected range. A diagnostic tool can also detect deviations during a parameter measurement run; it's not very responsive, but you can see if the value jumps significantly. Ideally, use an oscilloscope; this will show you if one of the three pump elements is no longer working.

It's possible that an injector is leaking internally, which is a common problem with Bosch systems. To check this, remove the leak lines, connect four measuring cylinders via hoses, and ensure that the cylinders fill evenly.

In which load range is the vibration most severe: full load or partial load?

Thank you for the quick response.

ZMS?

The vibration is always at 1500 RPM, whether under partial or full load.
even if he's just rolling.
It's worst under full load.

Going uphill and going downhill are the same.
It's only better when the vehicle is loaded.
But most of the time, I drive alone, and the trunk is empty.

Michael 111 wrote:

THANK you for the quick response. The vibration is always at 1500 RPM, whether under partial or full load. even if he's just rolling. Going uphill and going downhill are the same. It's only better when the vehicle is loaded. but most of the time I drive alone, and the trunk is empty

.

Okay, so even if you're not giving it any throttle (in boost mode)? Does the engine then make any noises like knocking or anything like that? I can't say anything about the transmission, since PSA hasn't made 4x4 vehicles for years, so it's either from another manufacturer or from Susi. Perhaps, under these circumstances, the jerking could also be caused by the all-wheel drive? I'm not very familiar with that. Whether a dual-mass flywheel (DMF) is installed that's compatible with the transmission... *shrugs*. But if it does have one, and you can rule out the transmission, I would definitely take a closer look at the DMF.

ZMS?

All-wheel drive can be engaged or disengaged, and it makes no difference whether it's on or off.
The transmission is from Suzuki.

Michael 111 wrote:

ZMS?

Dual-mass flywheel!

Michael 111 wrote:

ZMS? All-wheel drive can be engaged or disengaged, and it makes no difference whether it's on or off. The transmission is from Suzuki

.

Two-mass flywheel, try using the search function; you'll find enough reading material there to keep you busy for about 2 days.

I'm going to check the rail pressure.
BUT I've been searching for a while now with little success.
Sometimes I feel like the weather might be a factor.
There are very rare days when he actually performs well.

Michael 111 wrote:

I'll check the rail pressure. BUT I've been searching for a while now with little success. Sometimes I feel like the weather might be a factor. There are very rare days when he actually does it

.

Okay, so if you're braking with the engine, the rail pressure doesn't matter because it won't inject anything (fuel cutoff). Therefore, listen carefully to see if it's knocking, and possibly check if an injector is dripping during the fuel cutoff.
It's best to turn off the engine while rolling, as after 2 seconds, it can no longer inject fuel because the fuel rail pump will have stopped working. Be careful not to remove the key, as this will activate the steering wheel lock!
If the engine is still misfiring, you can almost rule out the motor itself. Even if one cylinder isn't firing, you would likely barely notice it at that RPM. If necessary, you can perform a "cylinder balance test" – see the search function for instructions.

According to my Suzuki documentation.
Is the thrust cutoff only active above 2000 RPM?

Michael 111 wrote:

according to my records from Suzuki. Is the thrust cutoff only active above 2000 RPM?

No, anything above 1100 rpm causes it to leak, as you can see on the BC. Try adjusting the ignition to rule out the fuel injection system.

You wrote that it vibrates at 1500 RPM. Does it vibrate in all gears?
Sorry for the silly question, but you're not talking about "vibrating," are you? It's possible that the engine is vibrating at 1500 RPM, and that vibration is causing it to come into contact with the muffler or something else on the body. Try giving it some gas while it's idling at 1500 RPM and listen to see what happens.

I mean vibrating!
and when the engine is off, the vibration disappears.
(during the journey/ride)

SOOOOO

I once measured the rail pressure at exactly 1500 1/min.
http://img444.

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Notably, this occurs when the duty cycle and rotational speed are constant.
the rail pressure is so uneven.

Then I measured the return flow volume of the injectors.
http://img144.

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It looks pretty good.

After that, I removed the fuel filter, and lo and behold...
http://img122.

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many small chips.

As the last step, I removed the fuel pressure regulator.
http://img256.

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It looks like a new pump is needed.

I hope that's the cause.
Luckily, I still have a warranty.
Now, he is in the workshop .

Oh dear, that's the problem with the dissolving cam lobes in the fuel injection pump.
I am familiar with these issues from Renault (Delphi and Bosch) and from Ford (Delphi).

Apparently, the following items need to be exchanged:

Fuel injectors.
Pump.
Pipes.
The tank needs to be cleaned.

The problem is that the diesel is constantly being circulated, which causes the wood chips to distribute evenly throughout the system.

Have you ever driven the car completely empty, so that the engine turned off, and then let it idle for as long as it took for it to start again?
Apparently, there's no official cause of failure for these pumps (some say it's a weak point in the pump, others say it's bad fuel). I just think it's a bit of everything. If you get a bad pump, you might also put in some bad fuel, and then you might also experience fuel starvation (which leads to a lack of lubrication in the pump), and then it's in trouble.

Because of the warranty, I hope you've always had all the inspections done properly, otherwise they might reject the warranty claim .

'So, I always get my gas at Aral or Shell.'
And I never drove it with an empty tank.
but the previous engines in the Grand Vitara had the following code: RHZ.
They all had the same concerns.
However, they didn't vibrate.
In most cases, only the pressure regulator was replaced.
'But those didn't have as many wood chips in the filter housing.'

With the warranty, it should be fine. The last inspection was...
Just a week ago.
However, it still needs to be approved by ZUCKI ZUCKI.
and into parts.
Let's see what SUZUKI says!

I wish you good luck and low costs.

Have a nice weekend.