VW Passat TDI: Black Sludge - PD Engine Fix

Greetings from Austria.

No power, low boost pressure, black sludge in the fuel system.

Fuel filter replaced (the filter housing was very dirty), fuel level sensor with fuel pump removed (there was even more dirt there, it looked like black sludge). Clean the fuel level sensor and fuel tank. Of course, several test drives were carried out in the meantime, but with no significant results. The last step was to remove the valve cover, check the hydraulic lifters, and inspect the rocker arm shaft for the common rail injectors (side plugs are present). The common rail injectors were removed (they were quite tightly integrated into the cylinder head, which I found to be a bit too loose). I can't say whether the problem was caused by the contamination of the fuel supply to the common rail injectors or by an inadequate seal between the common rail injectors and the cylinder head. In any case, after replacing the common rail injectors with four used ones, including a new gasket set, the problem was solved.

Sincerely,

Walti 130.

Black sludge reminds me of the "Dieselgate" scandal; in this case, it's likely that problems will arise again.
If the filter clogs again after a short time, you should check out Grotamar and examine the (yard/farm?) fuel station and fueling habits.

Thanks for the tip, I already added an antibacterial additive to the diesel, I think it's from Pro Tec.

In Austria, we have a biodiesel content of up to 7 percent in diesel fuel, which is why fungi and bacteria can thrive in the fuel tank.
And let's not even talk about the resulting engine wear (the regeneration process of the particulate filter leads to oil dilution).

walti130 wrote:

In Austria, we have a biodiesel content of up to 7 percent in diesel...

... which is the case throughout the entire EU according to EN 590 (standard for diesel fuel), and even in all non-EU countries that adhere to the EN 590 standard...

https://de.wikipedia.org/wiki/Dieselkraftstoff

http://www.shell.de/autofahrer/shell-kraftstoffe/technische-informationen/b7-diesel-mit-bis-zu-7-biodiesel.html

Then everyone in the EU faces the same problems.