BLS Engine Problems: Integrated PD Components

Hello everyone,

I am asking for your help because I don't know what to do anymore.
Here's the translation:

"It's about a BLS engine with a DPF from a 2007 Škoda."
The said the NW was defective. So, the NW was replaced along with the hydraulic components and the swing arm axle (which was also really worn out), but there was no change.

I made a video today showing the oil pressure.

Quote:

The problem starts around 20 seconds into the video. You can either search for "Irgendwolink" or simply enter the problem with the BLS motor into a search engine.

Okay, the engine starts perfectly well, both when cold and when warm. It runs smoothly at idle. However, around 2200 RPM, it begins to make a rattling/knocking/clattering noise.

I've been searching for about 50 hours now and I don't know what else to do.

2 PD elements are new. The connecting rod bearings have already been checked and are okay.
The compression pressure for the 4 cylinders is between 26 and 28 bar.
Valve timing has been checked multiple times and is okay.
The oil pressure is constant at 2 bar at idle speed, and approximately 5 bar at around 2500 RPM, as also shown in the video.
Okay, there are no error codes in the memory. I've also attached a log from when it was running.

I would appreciate your help and I am grateful for any advice you can offer.

Best regards, Tom.


Edit Autoservice: Removed log fragments.

It sounds like something a carpenter would do.

Unfortunately, it's difficult to determine whether the sound is a grinding/scraping noise or possibly a hissing sound, perhaps coming from the turbocharger or the intercooler system. It's also unclear when and how the noise starts, develops, and disappears as the engine speed decreases.
Turbocharger OK? Intercooler piping sealed?

A few more details about the symptoms or repair attempts would be helpful.

Please post the log files as a CSV file, saved in the same format as VCDS uses. No one can make sense of that other data.

Hello,

Okay, so I checked the turbocharger insofar as the shaft spins freely and there's no axial play. The intercooler piping is airtight!

Well, the knocking/clattering sound appeared suddenly, and then the suggested replacing the camshaft (which was also damaged).
It's definitely a knocking or banging sound starting at 2200 RPM; no hissing can be heard.
I also checked the camshaft again because there are versions with and without a DPF (Diesel Particulate Filter).
Ah yes, when it starts sputtering and the RPM drops, the engine needs about a minute to recover.

Best regards, Tom.

According to your description, it could be the hydraulic lifters. This would also suggest that the camshaft is worn.
Possibly an oil channel is partially blocked, causing the amount of oil supplied to the hydraulic lifters to be insufficient at higher engine speeds.

Hi Tom,

Okay, hier ist der Text:

"Die Sonne ging unter und färbte den Himmel in leuchtenden Farben. Ein leichter Wind wehte durch die Bäume und raschelte im Laub. Ich stand am Fenster und betrachtete die Szene, überwältigt von ihrer Schönheit. Es war ein Moment purer Glückseligkeit."

Quote:

Replacing the camshaft (which was also damaged).

"I think to myself, well, it broke into a thousand pieces, and one of them is probably somewhere in the oil system, rattling around."

Sure, that's not how it will be, but what kind of damage did all those replaced parts have?

Was happens if a component was not replaced, old seals were reused, or similar cost-saving measures were implemented?

If the engine is allowed to idle after the high-revving session shown in the video, will the rattling noise eventually disappear?

Can you create more audio files like this one?

Okay, please provide the German text you would like me to translate into English. I will only provide the translation.

Hi,

"Excuse me, so the camshaft was misaligned on the 4th cylinder, and it was more off on the exhaust valve than on the intake valve."
The hydraulic lifters were also worn there, but only showing signs of wear from grinding, with nothing broken.
I also thought about contamination in the oil passage, but I have mixed feelings about using system cleaners.

And yes, the engine stabilizes itself after a while (about a minute or so) when idling.

Best regards, Tom.

Hi.

The description and the sound seem to fit well with a "hydraulic lifter."

If it is pressed frequently and quickly, i.e., at speeds above idle, it will stall, and the relevant valve will rattle.
When it's rarely and gently squeezed (idling), it has more time to fill and retain the oil.

Okay, please provide the German text you would like me to translate into English. I will only provide the translation.

Thank you for your reply. So, you mean that one of the new hydraulic units is defective or that there's an oil leak somewhere?
"I immediately removed the valve cover after parking, and all the hydraulic lifters were hard, so I filled them with oil."
What other testing methods are available for the valve lifters, so I can get an idea of where to start looking for problems?

Best regards, Tom.

That doesn't make any sense. Your information is just complete garbage.

If help is to be offered here, it requires proper communication that allows one to draw meaningful conclusions. I'm not interested in having to extract every piece of information bit by bit.

1. Vehicle (with or without a balance shaft module)? Edit: Sorry, it's a 1.9 2V engine, so definitely without.
2. KM Standing.
3. When did the noise start? Before or after the replacement of the Northwest (NW) component?
4. Has the cause of the northwest damage been identified, and is there any lubrication present in the head?
etc.

What noise sources can be definitively ruled out at this point?

Hi,

For now, thank you for the quick responses.

1. Vehicle (with or without a balance shaft module)?
No balancing wave module, standard oil pump - I believe that's only found on the 2.0 16V TDI engines, right?
2. KM Standing.
140,000
3. When did the noise start? Before or after the replacement of the Northwest (NW) component?
The noise was what made us look into it, and that's when we saw the problem with the camshaft.
4. Has the cause of the northwest damage been identified, and is there any lubrication present in the head?
Okay, I think so because every time I stop the engine, the hydraulic lifters are full, and the bearing shells on the crankshaft also looked very good, which suggests that the lubrication is working properly.

What noise sources can be definitively ruled out at this point?
So, we checked the connecting rod bearings, turbocharger, and compression (to rule out a piston fracture...).
We didn't include optional extras like the Lima unit, etc., because I've already experienced my fair share of surprises with those kinds of things.
Valve timing checked X times.
"Two PD elements were replaced because the noise was coming from what sounded like a 2+3 cylinder engine (assumption). I will install two more today, as it also sounds like they are misfiring."

Have you ever experienced a crack in the diesel line leading to the common rail injector, where fuel might be leaking into it?

If the other two power supplies don't work, I'll take one apart to see what's inside; maybe there really is something defective on the circuit board, and I can also see how the holes look.


Best regards, Tom.

Hey Smudo!

smudoo wrote:

...I've now spent about 50 hours searching and I don't know what to do anymore.

It looks like a lot of time and money, but all the more lack of planning .

Please make another verschandeln audio recording of the sound and upload it here as well. (In your first post, click "edit" in the upper right corner, then click "select file" at the bottom, etc.)

You can also take logs of modules 13, 18, and 23, preferably while they are idle if the problem is present.

From what I've gathered from your previous posts, the troubleshooting and problem isolation process so far has been conducted through completely random part swapping.
Are the PD elements so cheap and do they automatically pop in and out with the gasket, that you would start using them?

Sure, here's the translation:

"Again:"
First, create a proper audio file with precise time stamps indicating when the noise you're complaining about occurs.
After that, upload the LOG files 13/18/23 while the engine is idling and showing an error; make sure they are not corrupted! It needs to be clear which cylinder the problem originates from.
...and stop introducing more errors by replacing parts unnecessarily.

Best regards from Munich!

Hello,

Okay, I replaced the fuel injectors because I had disconnected them, and after doing so, the noise on cylinders 2 and 3 disappeared. When I disconnected them individually, it might have been a coincidence, or perhaps other injectors are also faulty.
I will try to get a better recording tomorrow.
Here's the log; the last 50 lines show it running idle.

Thank you in advance.

Best regards, Tom.

Quote:

So, I swapped the PDs because I disconnected them, and then the noise wasn't audible on cylinders 2 and 3 anymore. When I disconnected them individually, it might have been a coincidence, or perhaps other ones are also defective.

I don't understand anything. If you don't mind me asking, where are you from?

Okay, bitte gib mir den deutschen Text, den du übersetzt haben möchtest. Ich werde ihn dann nur ins Englische übersetzen.

Hi,

Okay, so I disconnected each PD element individually (simply unplugging the connector for the solenoid valve), and on the 2-cylinder setup, the noise disappeared (I thought it was a faulty injector). Then, when I replaced that one, the problem moved to the 3rd cylinder. The engine would then only run on 3 cylinders, and the knocking/clattering sound would go away, but it was obviously just coincidental.
I'm from Austria!

Best regards, Tom.

Hey Smudo!

smudoo wrote:

... I'm from Austria! ...

Okay, then that's also clarified; it just leaves the question of where the country is located?

The 13/18/23-LOG shows no abnormalities, and the values are actually very good.
Therefore, I would advise against using PDEs (partial differential equations) for now, as there will be plenty of opportunities to use them later!
It appears that the problem either affects all cylinders or none of them, because otherwise, one cylinder would stand out in the data logs.

Please create an audio file and upload it here.

Best regards from Munich!

Quote:

The 13/18/23-LOG shows no abnormalities, and the values are actually very good.

Im Log Zeile 143, MWB18 ---> "n128 = Keine Schließzeitidentifikation (Begin of Injection Period = BIP) möglich (Motor AUS ODER elektr. F(ehler)

I only experience this when the engine is in idle mode and then fires all 4 cylinders simultaneously, but it could also be due to data recording occurring every 2 cycles.

Starting from line 145, the idle speed control for cylinders 3 and 4 deviates from the normal operation.