VS Golf 2.0TDI BKD - stalls at start + white smoke

Hello everyone,

I have a Golf V - manufactured in 2006, and for some time now, I've been experiencing the issue that the engine occasionally makes a rattling sound during starting, and white smoke is also coming out of the exhaust.

The funny thing about this is:
This doesn't happen every day. I deliberately left the car parked for 3-4 days --> The car started up perfectly the first time without any problems. The next day, the car started up like in the video. However, the problem disappears again after 1-2 times of giving gas.
During the drive, nothing out of the ordinary is noticeable.

There is no consistent error pattern. Sometimes the phenomenon occurs after 10 minutes of inactivity, but sometimes it takes up to 1 week.

I measured the car and found the following error in the memory:

Address 01: Engine Electronics Label file: DRV\03G-906-016-BKD.clb
Part Number SW: 03G 906 016 HJ HW: 028 101 225 3
Part: R4 2.0L EDC G000AG 7001
Revision: 12345678 Serial Number: VWZBZ0E0228177
Encoding: 0000078
Operating Number: WSC 01392 785 00200
VCID: 72A83CF66D42D006C5-8026
VINID: 9E69EAAAA05BA869C1006248102EE3E9AE

1 Error found:
16686 - Cylinder 2
P0302 - 000 - Combustion misfire detected - Intermittent
Environmental Conditions:
Speed: 819 /min
Torque: 78.0 Nm
Speed: 0.0 km/h
Last: 0.0 %
Voltage: 14.14 V
Injection Rate: 2.96 mg/h
Temperature: 57.6°C
(no unit): 0.0

Readiness: 0 0 0 0 0

What could it be?

Thank you in advance.

Hello,
so, the white smoke is coming from burned coolant, and since you're also having starting problems (occasionally), I would recommend first Step 1: Inspect the AGR cooler.

It occasionally happens that certain components expand at a specific temperature, causing the cooling fins to become leaky, which can then allow coolant to enter the combustion chamber. The water accumulation in the cylinder must first be purged during the starting process, and this also creates the smoke.

If you need to access the underside of your vehicle (e.g., using a lift, a pit, etc.). Ä.) Then, I would advise you to temporarily close the 2 coolant hoses on the AGR cooler (it would be best to connect them with a piece of tubing) and then to observe the behavior regarding white smoke and starting problems again.

Specifically, if you leave the vehicle for 3-4 days and it starts after, I would suspect a mechanical issue, possibly involving the cooling system. "While a head gasket might be possible, it would likely be a recurring issue, requiring frequent coolant refills (or the appearance of oil in the overflow tank)."

PS: Also, schau mal auch mal den Turbowelle-Motor an oder prüfe, ob du dort übermäßige Ölverluste in den Ladeluftschläuchen feststellst. Vom Geräusch her könnte er auch in naher Zukunft defekt werden. (Dieses Heulen/Pfeifen, die du am Ende des Videos hörst).

Hi,
Does the "white" smoke smell acrid or sweet? In the first case, it would be unburned DK.
You definitely have a problem with the fuel injector for cylinder 2. It could be either the injector, the PD drive, or the wiring harness.
Please provide the injection data for each cylinder.
Technical articles, e.g., https://community.dieselschrauber.org/en/viewtopic.php?t=9888
hg
Herbert.