Performance loss in BKC... Error undetectable

Hi,

I have a Touran BKC in the workshop that has been experiencing a lack of power since the head gasket was replaced at an incompetent garage (a place specializing in exhaust and brake repairs ).
Cold start proceeds without any issues.

So far, I have checked:

- MWB 003, LM 925 mg/H
- MWB 004, rotation angle -1°.
- MWB 001, max. Amount: 47 mg/h.
- MWB 011, max. LD 2050 mbar
- Pressure tandem pump:
LL: 2.4 bar
Maximum operating pressure: 7.25 bar.

- MWB 013, all substances below 1mg.
- MWB 018, 0
- MWB 023, all values between +5 and -35.
- MWB 007, okay.
- MWB 008, okay.

Knocked on the cat (presumably a car part), okay, the muffler doesn't rattle.
VTG is functioning correctly, fuel supply from the tank is okay.
Air filter clean.

Does anyone have any other ideas about what might be causing this?

Greetings.
John.

Question: Approximately how much power is lacking? Is the correct gasket installed?

Approximately 51 kW / 70 horsepower... you have to downshift even on slight inclines.

Poetry: There's a two-hole fitting inside, so the maximum deviation can be 0.1mm, which shouldn't cost 26kW .

Okay, I've now removed the valve cover and checked the basic settings of the common rail pressure sensor (PDE). So far, it seems to be okay. Now I'm going to pull some fuel out of the system to see what the injector nozzles look like...

He doesn't smoke, or rather, he smokes very little... in a simulated exhaust test, you wouldn't see anything coming out of the exhaust pipe.

Does this part have a DPF?

Tax deadlines?

BKC has a maximum of one retrofitted open DPF, which contradicts the good MAF sensor readings. Has the engine control module (ECU) been logged with diagnostic tool 8?

Falscher ZK mit falschen PD-Elementen drauf, z.B. der/die vom BLS?

Best regards, Rainer.

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Steuerzeiten?

According to MWB 004, the offset is exactly -1°, so it's okay.

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Incorrect ZK with incorrect PD elements on it, e.g., those from BLS?

The part number on the cylinder head is 038 103 373 R, and the production date (I unfortunately forgot to write down the TN) indicates it was manufactured in late 2005. The vehicle's year of manufacture is 2006. Was the BLS engine already used in the Touran at that time?

According to Uncle Edgar, the fuel injector should be a 038 103 265 KX if it comes with all valves, connectors, and the high-pressure pump (PDE), or a 03G 103 351 C if it's just the injector itself.


Okay, I'm going to make a rather basic adjustment by slightly increasing the fuel delivery values (FD) and see what happens. The idle air mass of 3.8-4 mg with a warm engine suggests that the BLS particulate filter diesel (PDE) might not be the issue...

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MWB 8 schon geloggt?

Yes, but unfortunately, nothing noticeable .

Okay, I gave it a little more power now, let some customers take it for a test drive, and the customer is happy.

So it seems that Rainer's theory is correct... however, that doesn't satisfy my perfectionism; I would have much preferred to find *the* error .

vwSchrauber wrote:

Okay, I gave it a little more power now, let the customers take it for a test drive, and the customer is satisfied.

Is chip tuning being offered as compensation for (suspected) poor work by other companies?

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So, it seems Rainer's theory is correct... but that doesn't satisfy my perfectionism; I would have much preferred to have found _the_ error.

Did you tell the customer that he may have had incorrect engine parts installed during the timing belt replacement? If so, what was his reaction?

dieselschrauber wrote:

BKC has at most one retrofitted open DPF, and a good MAF (Mass Air Flow) maximum value actually speaks against that... Has the engine control module (ECU) been logged with software version 8 yet? Falscher ZK mit falschen PD-Elementen drauf, z.B. der/die vom BLS? Best regards, Rainer

Are the timing chain components different, or is it the camshaft, or both?

Both .

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Chiptuning als Kompensation für (vermutlichen) Pfusch anderer Betriebe?

no ulf, OBD tuning .

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Did you tell the customer that he might have had incorrect engine parts installed during the timing belt replacement? If so, what was his reaction?

Basically, the action was only intended as a test, but the customer insisted that I install the testing software on it. My initial thought was that even with longer operating times, a lack of fuel (insufficient fuel supply) wouldn't necessarily result in significantly more power output, or rather, it should cause noticeable jerking.

In short: the customer didn't care, as long as his car ran like it used to .

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Sind die PD-Element anders oder die Nockenwelle, oder beides ?

You can identify DPF camshafts either by examining the injection cams (requiring a close look) or by looking for the two notches (instead of one) on the front face of the camshaft, near the tandem pump.

*thread revival*
or
*bumping the thread*

The customer is now standing there again, and the car is consuming 9 liters per 100 km .

The fuel injectors installed have the part number 038 130 073 AG.
Are they now part of the BKC, or are they from the BLS?

Greetings.
John.

It should be BKC. Are the PD elements properly adjusted? Is the tilt lever shaft secure?

What actually comes out of the exhaust pipe – is it just a normal smell, black smoke, or something super clean?

Best regards, Rainer.

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Müsste BKC sein.

I was afraid of that. The camshaft is definitely for PD engines without a DPF (Diesel Particulate Filter).

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Einstellung der PD-Elemente ok?

Checked, okay.

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Kipphebelwelle fest?

Last autumn, I replaced one of them – a plug in the oil channel was missing.

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What actually comes out the back of the exhaust pipe, normally just a foul smell

.

It runs relatively cleanly, but my impression is that it's not getting enough fuel. I increased the amount to a maximum of 50.5mg and extended the injection duration, but the engine hardly runs any better than a standard SDI.

Removed the exhaust from the double muffler - no change. Removed the catalytic converter and blew it clean - it's clear.



The next action will be a motor disassembly. Let's see what comes to light .

And if another plug comes loose?

Due to the oil loss, there is a drop in oil pressure in the cylinder head, which means that the valves only open partially. However, I believe that this should then trigger an error code related to the mass airflow sensor (MAF).

Roger wrote:

Due to the oil loss, there is a drop in oil pressure in the cylinder head, which means that the valves only open partially.

Is this because the hydraulic lifters are not completely filled?
I'm not so sure about that, because, in my opinion, they are essentially self-priming. In the worst case scenario, this would mean they fill up a bit slower after the engine starts.