BKD Seats for PD Elements

I've been experiencing intermittent jerking and cold start problems with my A3 BKD engine.

In the MWB 13, cylinder 1 is set to +2.99mg/stroke.

Today I removed the PD elements and the seat of the 1st. Zyl doesn't look good.

Furthermore, on the wave of the rocker arm, the plug of the oil channel on the side of cylinder 1 is no longer properly seated.

Is there a way to repair the seat, or is it just a head replacement? Or could it be that the oil plug is preventing the valves from opening properly, which I don't really believe.

The right is the one from the 1st. Zylinder, the one from the 2nd cylinder.

And a picture of the 2-cylinder engine's location. I'll get back to you on that first.

chli1976 wrote:

or could it be coming from the oil plug, which prevents the valves from opening properly? I don't really believe that.

But it is a well-known problem:

/viewtopic.php?t=21918&highlight=stopfen

I'm familiar with the 2-valve design, but with my 4-valve setup, the valve hasn't fallen out yet.
I will send out more pictures tonight.

I occasionally have a fault entry in the error log: 16685 Combustion Nozzle. Zylo.

Here is the image of the pivot axis and the image of the 1st cylinder's seat.

New head installed, and the shaking and starting problems are gone.

Hello,

Thank you for the feedback! How many kilometers did the engine have on it?

Hi, Rainer

[Translating...]

ca. 150.000km

What does this kind of repair cost? (new/used/refurbished?) Is VAG expected to offer a discount/warranty? Or, as before: Customer, are you watching?

Here in Austria, the complete cylinder head with valves and camshaft costs 1140 euros original. Everything you need is included, except for the cylinder head gasket (O-rings, screws, etc.).

In our case, we only had a cylinder head without camshafts as a replacement, but that would have been more expensive than the original with the camshafts.

sorry for the question but could you please mark the part of the stuffing that often falls out?

LG Chris

I saw it for the first time when I was stuffing. I have removed it and stuck it in.

Quote:

The new engine has been installed and the shaking and starting problems are gone

Have you also renewed the PDs? These should actually show similar traces to the ZK.

I had another Audi A4 BLB of a good acquaintance here today, with the same problem.
I had these already sealed about 1.5 years ago at 170,000 km, with the recommendation that the ZK and all PDS should actually be replaced. Today, I replaced the PDS rings for cylinder 2 (for the last time). The fit of Pd and ZK appears to be only an oval-shaped fit.

Back then, I already had the feeling that the PDS (mounted) were no longer standing upright in my head. It appears that the PDS values for cylinders 2, 3, and 4 (perpendicular to the mounting holes) tend to point towards the tilting lever shaft.

The question I'm asking myself is whether and how it might be possible to carry out a repair that is cost-effective.

If such vehicles were 2 years older than they are now, they would be worth approximately 3450 EUR (parts + labor) after a proper repair (Zk + Pds).

economically TOTAL DAMAGE.

Considering the fact that these vehicles already suffer from significant quality issues, such as: ZMS (Zentralmotoraufhängung), Ausgleichswellenmodul (Ausgleichswellenmodul), etc. Cylinder damage or front axle, etc.
I personally find it very difficult to recommend this repair to others.

Therefore, I am looking for a "socially acceptable" repair method to keep these faulty constructions running.

I have reused the old PDs, but they weren't as thoroughly processed as in your image.

The BLS has the PD that have been attached once and have a copper disc, and it also does not have an equalization wave module.

In this game, the fuel side can't really be sealed anymore.

Oops, it's a BLB, not a Bls. I have corrected it.

Hi

Are there perhaps also differences between PPD and the normal PD elements?

Maybe ask a laser welder if it's possible to 'economically' weld it (in the head) and then rework it... The shape of the seat in the head doesn't seem that complicated...

Quote:

Are there perhaps also differences between PPD and the normal PD elements?

The PPDs appear to be, in fact, more precisely manufactured (see: Photo).
They also appear much smoother overall, and the guides seem to be designed to be more generous. Four weeks ago, I replaced two of them on a Passat 3C BKP. (Unfortunately, they don't really do much electrically). But I was already wondering why they hadn't been used up.

Quote:

Maybe ask a welder to see if they can "cheaply" weld it (in their head) and then rework it... The shape of the seat in the head doesn't seem that complicated...

I think it's really not feasible.

I am looking for an affordable solution that is also feasible and durable.

What I have in mind roughly is the following:

Re-drilling of the hole in the ZK (both diameters) using a reamer or similar tool to a dimension X and Y until the hole is round again.

PDs disassemble and generously remove damaged guides (Image Point 1) and replace them with custom-made (pressed or molded) rings. Then, machine to our size X and smooth. This would restore the upper guide. The aluminum guide part must be newly manufactured to the corresponding oversized dimensions X and Y. This could still be optimized regarding the engine compartment without narrowing the fuel channels.
Then you just need to find O-rings with an excess.

Whether all of this is feasible and the level of effort required is currently unknown to me. I'm struggling with the question of whether and how to restore the perfectly smooth surface of the ZK borehole.
A machine builder or engine repair technician should actually be able to say something about that.

What do you think?