Blue smoke and erratic running after PDE repair.

Hello everyone,

I am new to the world of diesel engines (both physically and virtually ) and would appreciate your advice.

Recently, my 3-cylinder TDI engine was emitting a small amount of blue smoke and running unevenly when cold. It worked fine up to about 45 degrees Celsius, then everything was normal. Audi said that the PDE (pilot fuel) of the first cylinder was leaking. I immediately sent all of them to a Bosch service for inspection and repair. It was also confirmed that way.

Now everything has been reinstalled, and the result is much worse than at the beginning. I'm a bit worried. Can this be related to the revised PDEs and does it require some acclimatization time, or do I need to make changes in the MSG, or have I perhaps done something wrong?

Thank you in advance.

Hi,

We need an engine scan and the values for the idle speed control from the measured values in the engine control unit.

Best regards, Rainer

Hello Rainer,

Thank you for the response. I will take care of it. Once I have the data, I will get back to you.

Warm greetings

Hello everyone,

I'm back. The car scan has documented the following error:

Address 01: Engine Electronics Label file: DRV\045-906-019-ANY.clb
Part Number: 045 906 019 D
Part: VAG-Tuning G001DS .com
Encoding: 00005
Operating Number: WSC 02138
VCID: 162596A0729B663F06-4B1C
WAUZZZ8Zxxxxxxxxx AUZ7Z0A2001911

1 Error found:
18072 - Valve/Nozzle Control
P1664 - 35-10 - Electrical Fault in Circuit - Sporadic
Readiness: Not Available

I read the possible cause "Interruption or short circuit to ground in the motor cable harness" in another post, but I don't know how to fix the error. The PD cable harness has already been replaced. Do you have any ideas?

If you need help, please post the complete scan.

Monday, August 15, 2022, 13:50:18:07419
VCDS -- Windows-based VAG/VAS emulator runs on Windows 10 x64
VCDS Version: DRV 22.3.1.7
Data Status: 20220530 DS338.0
www.Ross-Tech.de


Vehicle Identification Number: WAUZZZ8Z12N018692 Vehicle Registration Number:
Odometer: 329980km Repair order:



--------------------------------------------------------------------------------
--------------------------------------------------------------------------------


Vehicle Type: 8Z (8Z - Audi A2 (2000 > 2005))
Scan: 01 02 03 08 15 16 17 18 37 45 46 56 57 75 76 77

Vehicle Identification Number: WAUZZZ8Z12N018692 Kilometer Stand: 329980km
-------------------------------------------------------------------------------
Address 01: Engine Electronics Label file: DRV\045-906-019-ANY.clb
Part Number: 045 906 019 D
Part: VAG-Tuning G001DS .com
Encoding: 00005
Operating Number: WSC 02138
VCID: 162596A0729B663F06-4B1C
WAUZZZ8Z12N018692 AUZ7Z0A2001911

1 Error found:
18072 - Valve Pump/Dose Control
P1664 - 35-10 - Electrical Fault in Circuit - Sporadic
Readiness: Not Available

-------------------------------------------------------------------------------
Address 02: Transmission Label file: DRV\6N0-927-735.lbl
Part Number: 6N0 927 735 D
Part: DS085 Gear 3081
Encoding: 00000
Operating Number: WSC 00000
VCID: 397F7D1C23456947CB-0960

No error codes found.

-------------------------------------------------------------------------------
Address 03: Brake Electronics Label file: DRV\8Z0-907-379-MK60.lbl
Part Number: 8Z0 907 379 C
Component: ESP FRONT MK60 0101
Encoding: 0019474
Operating Number: WSC 02154 785 00200
VCID: 489908D838AF00CF44-5140

1 Error found:
01314 - Engine Control Unit
013 - please read fault codes - Sporadisch

-------------------------------------------------------------------------------
Address 08: Climate/Heating Control Label file: DRV\8Z0-820-043.lbl
Part Number: 8Z0 820 043 E
Part: A2-FULLY AUTOMATIC CLIMATE 0510
VCID: 38797818184F704F34-2588

No error codes found.

-------------------------------------------------------------------------------
Address 15: Airbag Label file: DRV\8Z0-959-655.lbl
Part Number: 8Z0 959 655 E
Part: Front+Side Airbag 5005
Encoding: 00102
Operating Number: WSC 02154
VCID: 4E953EC08ACBDEFF0E-515E

No error codes found.

-------------------------------------------------------------------------------
Address 17: Switch Cabinet Installation Label file: DRV\8Z0-920-xxx-17.lbl
Part Number: 8Z0 920 930 Q
Component: KOMBI+WAYFARE. VDO D06
Encoding: 01135
Operating Number: WSC 05610
VCID: 4A9D32D076A3F2DF52-515E
WAUZZZ8Z12N018692 AUZ7Z0A2001911

1 Error found:
01304 - Radio
49-00 - No communication

-------------------------------------------------------------------------------
Address 46: Comfort System Label file: DRV\8Z0-959-433.lbl
Part Number: 8Z0 959 433 M
Part: Comfort Device T05 0615
Encoding: 06720
Operating Number: WSC 02138
VCID: 50A920B890FFC80F1C-4B1C

Subsystem 1 - Part Number: 8Z1959801
Part: Door Control. FS BRM 0001

Subsystem 2 - Part Number: 8Z1959802
Part: Door Control.BF BRM 0001

No error codes found.

-------------------------------------------------------------------------------
Address 56: Radio Label file: DRV\8E0-035-1xx-56.lbl
Part Number: 8Z0 035 152 A
Part: chorus II GRO 0007
Encoding: 00000
Operating Number: WSC 02138
VCID: 33634F340129931701-4B02

No error codes found.

Ende----------------------------(Duration: 03:49)-----------------------------

After the first scan, I deleted the errors and ran the engine again. The sputtering and jerking remains. After a second scan, the errors, except for the radio, are no longer listed in memory.

Monday, August 15, 2022, 18:52:42:07419
VCDS -- Windows-based VAG/VAS emulator runs on Windows 10 x64
VCDS Version: DRV 22.3.1.7
Data Status: 20220530 DS338.0
www.Ross-Tech.de


Vehicle Identification Number: WAUZZZ8Z12N018692 Vehicle Registration Number:
Odometer: 329980km Repair order:



--------------------------------------------------------------------------------
--------------------------------------------------------------------------------


Vehicle Type: 8Z (8Z - Audi A2 (2000 > 2005))
Scan: 01 02 03 08 15 16 17 18 37 45 46 56 57 75 76 77

Vehicle Identification Number: WAUZZZ8Z12N018692 Kilometer Stand: 329980km
-------------------------------------------------------------------------------
Address 01: Engine Electronics Label file: DRV\045-906-019-ANY.clb
Part Number: 045 906 019 D
Part: VAG-Tuning G001DS .com
Encoding: 00005
Operating Number: WSC 02138
VCID: 162596A0729B663F06-4AEA
WAUZZZ8Z12N018692 AUZ7Z0A2001911

No error codes found.
Readiness: Not Available

-------------------------------------------------------------------------------
Address 02: Transmission Label file: DRV\6N0-927-735.lbl
Part Number: 6N0 927 735 D
Part: DS085 Gear 3081
Encoding: 00000
Operating Number: WSC 00000
VCID: 397F7D1C23456947CB-0960

No error codes found.

-------------------------------------------------------------------------------
Address 03: Brake Electronics Label file: DRV\8Z0-907-379-MK60.lbl
Part Number: 8Z0 907 379 C
Component: ESP FRONT MK60 0101
Encoding: 0019474
Operating Number: WSC 02154 785 00200
VCID: 489908D838AF00CF44-5140

No error codes found.

-------------------------------------------------------------------------------
Address 08: Climate/Heating Control Label file: DRV\8Z0-820-043.lbl
Part Number: 8Z0 820 043 E
Part: A2-FULLY AUTOMATIC CLIMATE 0510
VCID: 38797818184F704F34-2580

No error codes found.

-------------------------------------------------------------------------------
Address 15: Airbag Label file: DRV\8Z0-959-655.lbl
Part Number: 8Z0 959 655 E
Part: Front+Side Airbag 5005
Encoding: 00102
Operating Number: WSC 02154
VCID: 4E953EC08ACBDEFF0E-515E

No error codes found.

-------------------------------------------------------------------------------
Address 17: Switch Cabinet Installation Label file: DRV\8Z0-920-xxx-17.lbl
Part Number: 8Z0 920 930 Q
Component: KOMBI+WAYFARE. VDO D06
Encoding: 01135
Operating Number: WSC 05610
VCID: 4A9D32D076A3F2DF52-515E
WAUZZZ8Z12N018692 AUZ7Z0A2001911

1 Error found:
01304 - Radio
49-00 - No communication

-------------------------------------------------------------------------------
Address 46: Comfort System Label file: DRV\8Z0-959-433.lbl
Part Number: 8Z0 959 433 M
Part: Comfort Device T05 0615
Encoding: 06720
Operating Number: WSC 02138
VCID: 50A920B890FFC80F1C-4B02

Subsystem 1 - Part Number: 8Z1959801
Part: Door Control. FS BRM 0001

Subsystem 2 - Part Number: 8Z1959802
Part: Door Control.BF BRM 0001

No error codes found.

-------------------------------------------------------------------------------
Address 56: Radio Label file: DRV\8E0-035-1xx-56.lbl
Part Number: 8Z0 035 152 A
Part: chorus II GRO 0007
Encoding: 00000
Operating Number: WSC 02138
VCID: 33634F340129931701-4B1C

No error codes found.

Ende----------------------------(Duration: 03:46)-----------------------------

Hello

Is the cable connector properly connected? Inspect the entire cable harness up to the engine control unit.

During your tuning, the blue smoke can also be caused by an incorrect injection timing. Just for information.

Were the PD elements correctly adjusted by you after installation?

Best regards, Rainer

Hello Rainer,

Thank you for your response. I'll just briefly explain how it happened. About two months ago, I took my car to Audi for the LongLife service. When I dropped it off in the morning, everything was fine; it ran without any problems. When I picked it up in the evening, it was making a slight jerk and seemed to be smoking a bit. I initially thought it was due to the new oil, but the next morning, with the engine cold, it was the same. When starting, it made a slight puffing sound and ran roughly. Once it reached operating temperature, everything was back to normal. Made:

- Oil change with filter
- Gear Ratio Adjustment
- Visual inspection
- Rescheduling of the service interval

Then I took it back to Audi. They confirmed my observation after a day of cooling down. Some blue smoke at start and uneven running, but everything was fine after about 45 degrees. Diagnosis - The PD unit of the first cylinder is leaking. They recommended replacing the PDE of the first cylinder and the PD cable harness.

I first started by replacing the cable bundle. However, this did not improve anything. Subsequently, I removed the PDEs and sent them to the Bosch service. There, I was informed that:

- The PDEs (paint delivery systems) are leaking at the nozzles and have a thick spray pattern.
- The mechanical opening pressure has reached the wear limit, 20-40 bar lower than the specified pressure.
- The injection quantities are no longer within the acceptable tolerances in all test steps and are pulsating strongly.

They were repaired, and I got them back. Subsequently, I reassembled everything according to the Audi repair manual. As a result, it now bleeds permanently and runs unevenly. Today, we will be performing the car scan, as shown above.

Maybe this will help to better understand the problem.

Warmest greetings and many thanks.

Now, the blue smoke doesn't necessarily have to come from the PD elements/fuel injectors.

Do the positive values of LLR remain for each cylinder, or do they move between different cylinders?

How did you set the PD elements? If it is assumed that the setup is okay, a compression test makes sense to rule out mechanical problems in the cylinders.

Best regards, Rainer

Compression test would also be my first choice.

Thank you for the responses. The LLR values remain the same. Multiple measurements. Immediately after starting, the first cylinder drops to -2.07 and remains at that level (flatline). Try to balance the second and third.

I will re-check the installation in the next few days. Maybe I made a mistake during the installation.

I also recorded a video of the engine starting and the first 20 seconds. Here, it can be clearly seen that immediately after starting, the first cylinder reduces and maintains the injection.

A brief update. Today, I first checked the existing installation. Everything was in order. Then I proceeded to swap the PDE (fuel injection quantity) for cylinder one and two, in order to see if the negative fuel injection quantity then appeared for cylinder two.

Good news first: it's not the case. However, during the expansion, I noticed that the upper sealing rings were very slightly damaged - almost impossible to feel with the finger. Probably, something got scraped during the installation or removal. Since I didn't have any new ones, I rotated them slightly in the seating area so that an undamaged area is in the position of the grooves. Subsequently, the ridge at the inlet grooves on the head was slightly broken again.

I'm pleased with the result. The error hasn't gone away. Cylinders one and two adjust the injection quantity. But now, Cylinder 3 has a constant "positive" value of 2.07.

So, the third PDE has also been upgraded and also had minimal damage to the O-ring. I slightly rotated the sealing ring and broke the edge on the intake grooves. I am also happy with the result. I feel like I am getting closer to the problem. All three cylinders are balancing the fuel injection amount. Not like before, where cylinder one or three had a constant value and remained at that. However, it is also high, but then it balances out again. It also ran smoothly for a while, but then it continued to smoke heavily. The error memory remains empty since the deletion.

I have already ordered an original Bosch gasket set and will be replacing all the upper rings. I am considering whether to try reinforced VITON gaskets. It seems to me that the grooves for the intake may be too deep, and that the standard rings are not sealing properly. Therefore, perhaps also the behavior after the service, which was characterized by a more active operation at a certain temperature.

Hello everyone,

After frustration due to a stripped screw, I have now reassembled everything. I have swapped elements one and three and also replaced the seals at the same time.

The problem hasn't gone away. The blue smoke and rough running have remained, and cylinder 3 still has the highest injection volume. This time, I rolled it out of the garage and just let it warm up. From around 45-50 degrees, the rough running became noticeably smoother, and the smoke decreased. And from around 60-70 degrees, it ran smoothly at idle, and there was no more smoke. Cylinder three also reaches the highest temperature.

So, a similar error pattern, except for the amount of smoke, as before the PDE revision. The error memory remains empty. My next step would be to replace the temperature sensor, unless you have another idea.

Rüdi wrote:

A compression test would also be my first choice