A4 TDI 2.0 PD injectors are not injecting fuel after ZK replacement.

Hello, my problem is:

I have installed new ZK with new valves etc., so it's completely new.
PD elements re-sealed and aligned, after everything was reassembled, the engine no longer starts. The battery was drained twice, but nothing changed. The spark plugs were removed and were all dry, so there was no injection. I have already changed PDs several times, but this symptom is unfamiliar to me.

Can anyone here help me? I'm at a loss

Hi,

After replacing the seals and, hopefully, the actuation rods that are inserted into the PD element, the PD element settings are actually "too tight".

Was was überhaupt durchgeführt wurde und ob dies korrekt war?
Don't forget the Cu-seals on the PD element. The BPW engine is a 2-valve engine and has .

Motor control unit error memory is empty? A faulty PD cable should be indicated...

Best regards, Rainer

The PDEs have been completely renewed, including the worm screws in the levers, which were replaced and then turned in completely to the end position and then back to 225 degrees, so everything was done according to the instructions. I haven't yet gotten to the reading/calibration stage, but I will do that later. It's strange that the glow plugs are dry, meaning that no diesel is being injected. I removed the nozzle again to see if any diesel was actually coming in, but the channels are full of diesel, so fuel is present everywhere.

ascendens wrote:

Everything on the PDEs has been renewed, including the worm screws in the levers, which were replaced and then turned in completely to the end position and then back out to 225 degrees, so everything was done according to the instructions.

Just to be sure: Was was the specific cylinder set to in terms of maximum stroke during setup?
Actually, it makes sense, but you never know.

To better assess you: Have you already completed this task before, or is this the first time?

Best regards, Rainer

I have frequently overhauled engines, performing tasks such as piston replacements and valve replacements and resurfacing, as well as other mechanical work. I have also occasionally replaced PDEs, but I am experiencing this symptom for the first time and am facing a puzzle. But what do you mean by the maximum start date for funding?

I wouldn't know what I could still adjust on the nozzles .

Sorry, I forgot to mention that I accidentally caused a short circuit when installing the starter. I hope it's not the cause.

ascendens wrote:

Excuse me, please. What I forgot to mention is that, while installing the starter, I accidentally caused a short circuit. I hope it's not the cause.

Perhaps already... first, perform an auto-scan and post the results.

PD-Element Settings:
/viewtopic.php?t=5408

Best regards, Rainer

Ok, I'll spend the night by the engine, let's see how far I can get. Many thanks

ascendens wrote:

Okay, I'll do that. I'll spend the night in the engine, and see how far I can get. Many thanks

Please don't copy the Space Junk Shooter, which shoots space junk into orbit.

What's the point of spending the night in the garage?

Remove cylinder cap, check PD settings (20min) and complete Autoscan (5min).



Best regards, Rainer

Hello, I have now finished reading everything and I have a very bad {FEELING/EXPERIENCE/RESULT}.
Feeling the experience as it unfolded. Okay, first, let's look at the car log:

I didn't think it would be this much , but maybe someone here can recognize something serious. I think the central control unit for the comfort system is the problem, but I don't know how it relates to the engine control unit.


Thursday, June 14, 2018, 23:26:34:42594
VCDS -- Windows-based VAG/VAS emulator runs on Windows 7 x86
VCDS Version: RKS 18.2.1.0
Data Status: 20180313 DS287.1
http://shop.dieselschrauber.org/en

Dealer/Workshop Name: 760116102XXXX

Vehicle Identification Number: WAUZZZ8E66A274448 Vehicle Registration Plate:
Odometer: 298080km Repair Order: Car Scan 1

Vehicle Type: 8E (8E - Audi A4/S4/RS4 B6/B7 (2001 > 2008))
Scan: 01 02 03 08 09 0F 11 15 16 17 18 25 36 37 45 46 55 56 57 65
67 69 75 76 77

Vehicle Identification Number: WAUZZZ8E66A274448 Kilometerstand: 298080km
---------------------------------------------------------------
Address 01: Engine Electronics Label file: DRV\03G-906-016-BPW.clb
Part Number SW: 03G 906 016 KM HW: 03G 906 016 KM
Part: R4 2.0L EDC G000SG 9749
Revision: --H02--- Serial Number:
Encoding: 0000172
Operating Number: WSC 66565 257 00032
VCID: 78F83A2D0B75298419-802C

1 Error found:
000568 - Extruder for Cylinder Pressure (G31)
P0238 - 000 - Signal too large - Sporadically
Environmental Conditions:
Error Status: 00100000
Error Priority: 1
Frequency of Errors: 2
Lost Count: 255
Mileage: 298088 km
Time: 0

Environmental Conditions:
Speed: 0 /min
Speed: 0.0 km/h
Last: 0.0 %
Voltage: 12.54 V
Binary Value: 00101100
Pressure: 183.6 mbar
Pressure: 2182.8 mbar

Readiness: 1 1 0 0 0
---------------------------------------
Address 03: Brake Electronics Label file: DRV\8E0-910-517.clb
Part Number SW: 8E0 910 517 J HW: 8E0 614 517 BH
Part: ESP8 quattro H06 0140
Revision: 00000000 Serial Number: 00000000000000
Encoding: 0004529
Operating Number: WSC 06325 000 00000
VCID: 2E54DC75B9B1273483-807A

1 Error found:
01826 - Gear for Steering Angle (G85); Power Supply KL30
000 - -
Environmental Conditions:
Error Status: 01100000
Error Priority: 3
Frequency of Errors: 19
Lost Count: 40
Time: 0

Environmental Conditions:
Hex Value: 0x0000
Hex Value: 0x0222
Hex Value: 0x0024
Hex Value: 0x0196
Hex Value: 0x0001
-------------------------------------------------
Address 08: Climate/Heating Control Label file: DRV\8E0-820-043.lbl
Part Number: 8E0 820 043 BQ
Component: A4 Air Conditioner 2833
Encoding: 00000
Operating Number: WSC 00000
VCID: 71EE07093B0F78CCDE-512E

4 Error codes found:
00716 - Blower Motor for Air Vents (V113)
41-00 - Blocked or No Power
00819 - High-Pressure Sensor (G65)
07-10 - Signal too weak - Intermittent
01330 - Central Control Unit for Comfort System (J393)
49-10 - No communication - Sporadic
01206 - Signal for ignition shutdown duration
27-00 - Unlikely Signal
---------------------------------------------------------------
Address 09: Central Electrical Label file: DRV\8E0-907-279-8EC.lbl
Part Number: 8E0 907 279 N
Part: int. Last Module NDL 0907
Encoding: 10012
Operating Number: WSC 06325
VCID: 3D76EB3937D7CCAC0A-4B0E

3 error codes found:
01496 - Headlight Auxiliary Lamp, Left (L22)
30-00 - Interruption / Short circuit after positive line
01500 - Headlight bulb, right (L23)
30-00 - Interruption / Short circuit after positive line
01330 - Central Control Unit for Comfort System (J393)
49-10 - No communication - Sporadic
---------------------------------------------------------------Address 15: Airbag Label file: DRV\8E0-959-655-94.lbl
Part Number SW: 8E0 959 655 G HW: 8E0 959 655 G
Part Number: Airbag 9.41 H12 3730
Revision: 91H12373 Serial Number: 0036M0G0CL4+
Encoding: 0033622
Operating Number: WSC 06325 000 00000
VCID: 3B72E5217AC3C29C34-806E

Subsystem 1 - Serial Number: 6332DRB40323CE98Y
Subsystem 2 - Serial Number: 6342DRB40324C9AC-
Subsystem 3 - Serial Number: 6352ARB4012D3358H
Subsystem 4 - Serial Number: 6362ARB4012D6BCB$
Subsystem 5 - Serial Number: 63729RB40122F18EQ
Subsystem 6 - Serial Number: 63829RB40122F1B6M

4 Error codes found:
01739 - Crash sensor for front airbag; driver's side (G284)
011 - Interruption - Sporadic
Environmental Conditions:
Error Status: 00101011
Error Priority: 2
Frequency of Errors: 1
Loss counter: 39
Time: 0

01738 - Crash sensor for front airbag; driver's side (G283)
011 - Interruption - Sporadic
Environmental Conditions:
Error Status: 00101011
Error Priority: 2
Frequency of Errors: 1
Loss counter: 39
Time: 0

01316 - Brake Control Unit
008 - Unlikely Signal - Sporadically
Environmental Conditions:
Error Status: 00101000
Error Priority: 2
Frequency of Errors: 5
Loss counter: 39
Time: 0

00532 - Supply Voltage
002 - Lower limit exceeded - Sporadically
Environmental Conditions:
Error Status: 00100010
Error Priority: 2
Error Frequency: 110
Loss counter: 39
Time: 0
---------------------------------------------------------------
Address 16: Steering Wheel Electronics Label file: DRV\8E0-953-549.lbl
Part Number: 8E0 953 549 Q
Part: Steering Column Module 0601
Encoding: 04042
Operating Number: WSC 06325
VCID: 418E97C94B2FA84C6E-4B0E

1 Error found:
01330 - Central Control Unit for Comfort System (J393)
49-10 - No communication - Sporadic
---------------------------------------------------------------
Address 17: Relay Module Installation Label file: DRV\8E0-920-9xx-8EC.lbl
Part Number SW: 8E0 920 931 P HW: 8E0 920 931 P
Component: KOMBI+WFS 4 H14 0110
Revision: 0110 Serial Number: 00000000000000
Encoding: 0007141
Operating Number: WSC 11111 111 11111
VCID: 3566F3195FE714ECC2-514A

1 Error found:
01330 - Central Control Unit for Comfort System (J393)
004 - No Signal/Communication - Sporadically
---------------------------------------------------------------
Address 25: Immobilizer Label file: DRV\8E0-920-9xx-8EC.lbl
Part Number SW: 8E0 920 931 P HW: 8E0 920 931 P
Component: KOMBI+WFS 4 H14 0110
Revision: 0110 Serial Number: 00000000000000
Encoding: 0007141
Operating Number: WSC 11111 111 11111
VCID: 3566F3195FE714ECC2-5168

1 Error found:
01330 - Central Control Unit for Comfort System (J393)
004 - No Signal/Communication - Sporadically
---------------------------------------------------------------
Address 37: Navigation Label file: DRV\8E0-035-192-RNSE.clb
Part Number SW: 8E0 035 192 D HW: 8E0 035 192 D
Part Number: RNS-E HIGH EU H72 0650
Revision: 04S Seriennummer: AUZBZ7F1141350
Encoding: 0301715
Operating Number: WSC 06325 000 00000
VCID: 25462359EF47646C72-51A4

2 error codes found:
00446 - Functional Limitation Due to Undervoltage
002 - Lower limit exceeded - Sporadically
Environmental Conditions:
Error Status: 00100010
Error Priority: 7
Frequency of Errors: 5
Lost Count: 24
Time: 0
Date: 2005.03.17
Time: 05:15:00

Environmental Conditions:
Voltage: 13.00 V
Kilometerstand: 655350 km
Number: 65535
Time: 255:255

02261 - Storage Media
014 - Defect
Environmental Conditions:
Error Status: 01111110
Error Priority: 5
Frequency of Errors: 21
Lost Count: 200
Time: 0
Date: 2018.01.08
Time: 12:42:05

Environmental Conditions:
Kilometerstand: 655350 km
Number: 901
Time: 05:55
---------------------------------------------------------------
Address 46: Comfort System Label file: DRV\8E0-959-433-MAX.clb
Part Number: 8E0 959 433 CE
Part Number: Comfort Gear T23 4035
Encoding: 07008
Operating Number: WSC 06325
VCID: 76E4341552615FF40B-4B28

Subsystem 1 - Part Number: 8E1959801H
Part Number: Tõrsteuer.FS BRM 0606

Subsystem 2 - Part Number: 8E1959802H
Part Number: Tõrsteuer.BF BRM 0606

Subsystem 3 - Part Number: 8E0959801E
Part Number: Tõrsteuer.HL BRM 0606

Subsystem 4 - Part Number: 8E0959802E
Part Number: Tõrsteuer.HR BRM 0606

4 Error codes found:
01331 - Driver's Side Door Actuator (J386)
49-10 - No communication - Sporadic
01332 - Driver's Side Door Actuator (J387)
49-10 - No communication - Sporadic
01333 - Rear Left Door Actuator (J388)
49-10 - No communication - Sporadic
01334 - Rear Right Door Actuator (J389)
49-10 - No communication - Sporadic
---------------------------------------------------------------
Address 56: Radio Label file: DRV\8E0-035-192-RNSE.clb
Part Number SW: 8E0 035 192 D HW: 8E0 035 192 D
Part Number: RNS-E HIGH EU H72 0650
Revision: 04S Seriennummer: AUZBZ7F1141350
Encoding: 0301715
Operating Number: WSC 06325 000 00000
VCID: 25462359EF47646C72-51A4

2 error codes found:
00446 - Functional Limitation Due to Undervoltage
002 - Lower limit exceeded - Sporadically
Environmental Conditions:
Error Status: 00100010
Error Priority: 7
Frequency of Errors: 5
Lost Count: 24
Time: 0
Date: 2005.03.17
Time: 05:15:00

Environmental Conditions:
Voltage: 13.00 V
Kilometerstand: 655350 km
Number: 65535
Time: 255:255

02261 - Storage Media
014 - Defect
Environmental Conditions:
Error Status: 01111110
Error Priority: 5
Frequency of Errors: 21
Lost Count: 200
Time: 0
Date: 2018.01.08
Time: 12:42:05

Environmental Conditions:
Kilometerstand: 655350 km
Number: 901
Time: 05:55
---------------------------------------------------------------
Address 76: Parking Assist Label file: DRV\8E0-919-283-8EC.lbl
Part Number SW: 8E0 919 283 D HW: 8E0 919 283 D
Part Number: Parking Assist 4-Channel H06 0010
Revision: 00H06000 Serial Number: 00067802020610
Encoding: 0000014
Operating Number: WSC 06325 000 00000
VCID: 316EC709AB8F38CC9E-514A

2 error codes found:
01546 - Sensor for Rear Parking Assist - Left, Center (G204)
009 - Interruption/Short Circuit to Ground
01330 - Central Control Unit for Comfort System (J393)
004 - No Signal/Communication - Sporadically
---------------------------------------------------------------
Address 77: Telephone Label file: DRV\8P0-862-335.lbl
Part Number SW: 8P0 862 335 M HW: 8P0 862 335 M
Part: FSE_255x BT H21 0200
Revision: 00000001 Serial Number: 00000000440856
Encoding: 0011811
Operating Number: WSC 06325 000 00000
VCID: 408892CD1025A14461-5168

No error codes found.

Ende----------------------------(Duration: 06:59)-----------------

Address 01: Engine Electronics Label file: DRV\03G-906-016-BPW.clb
Part Number: 03G 906 016 KM HW: 03G 906 016 KM
Part and/or Version: R4 2.0L EDC G000SG 9749
Encoding: 0000172
Operating Number: WSC 66565 257 00032
VCID: 78F83A2D0B75298419-802C
1 Error found:

000568 - Extruder for Cylinder Pressure (G31)
P0238 - 000 - Signal too large - Sporadically
Environmental Conditions:
Error Status: 00100000
Error Priority: 1
Frequency of Errors: 2
Lost Count: 255
Mileage: 298088 km
Time: 0

Environmental Conditions:
Speed: 0 /min
Speed: 0.0 km/h
Last: 0.0 %
Voltage: 12.54 V
Binary Value: 00101100
Pressure: 183.6 mbar
Pressure: 2182.8 mbar

Readiness: 0 1 0 0 0

To be on the safe side, I also took screenshots of the data blocks, which might be helpful. However, I have no idea how to get the JPGs into here. Below, under "File selection," the "Batten" function is not working for me.

Quote:

If you click on 'Select File+', you will see a box for selecting and uploading files from your computer. You can upload all types of files here, such as images, VCDS log files, or videos. Click 'Record with Camera+' to use your camera (webcam) for recording. If you click on 'Uploaded Files+', you will see a list of the files that have already been added, and you can then edit them as desired. If you want to replace a file ('Upload New Version'), you first need to select the file or recording and then click on 'Upload New Version' next to the uploaded files.

Hm? There's also a description above the button that explains how it works.

Screenshots related to Log File

The values are only present when the starter is engaged; it simply won't start, but I can detect a slight smell of diesel.

Hello,

The starting RPM of 189/min is so low that, depending on the engine control unit, the injection is not authorized...
For most PD-TDI fuel injectors, the minimum operating speed is 280/min.

Check the battery voltage and, if it's too low, charge it first.

You can also create "correct" log files with VCDS, see:
/viewtopic.php?t=12979

Best regards, Rainer Kaufmann