I want to repair an AJM engine in a Golf 4 and need tips.

Hello tinkerers,

I'm thrilled to be working with this community!

I've been given a Golf 4 with an Ajm engine to repair. I could just put it back together, but there's a problem:
According to VW:
The customer had been on the train when the car broke down at 240 km/h and died. He then restarted it and drove to the nearest VW workshop, but it then experienced misfires! VW diagnosed the following:
1. 17958 P1550 011 Turbocharger pressure regulation difference
2. 16685 P0301 035 Cylinder 1 misfire

After that, the head was removed and the diagnosis of engine damage was made.

According to me:
The customer brought the car to me because VW was too expensive and unbelievable.
I then inspected everything and I couldn't find any damage to the block, crankshaft, head, turbo, or other parts. Unfortunately, I couldn't get a picture of the head gasket, which had already been replaced by VW! Because I have little experience with these engines, I need your advice and a repair manual.
I believe there can't be anything seriously wrong, but I just lack the experience with these engines.

[quote='JA´s Car Service']

The customer was driving when the car suddenly broke down at 240 km/h and stopped.
[/quote]
Of course, with 115 horsepower! It probably just over-revved going downhill. Can it be easily over-revved?

When the boost pressure regulation difference occurs, the boost pressure is simply reduced. I can't really understand what 'engine failure' means.

What reason does VW give for the engine damage?

Regards,
Manuel

The "Crystal Ball" problem. What should we say? If there was an error during combustion in cylinder number one, I would start looking there. There are a lot of information available here regarding differences in the boost pressure.

Misfires at 240, I'll leave that unmentioned

I have 240 from the customer, and he's been running it since he installed the *** chip!

It's not a problem if it's not running perfectly; he should still be able to use it, but it should be smooth.

I haven't received any information from VW; the mechanic wasn't available!

Hi,

aha... a chip, so!

Maybe you should first write down EVERYTHING you know about the car. The mileage would also be helpful, as would the alleged performance of this chip.

Have you ever calculated how fast the machine would spin at a speedometer of 240 with this gearbox? Maybe there's something already there...

Best regards,

Jan

Hey Leute,

AJM --> 240 ???
Naja, mein Golf dreht bei 210 laut Tacho irgendwas um die 4000 U/min. Aber bitte.

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Maybe he has one of these new super-diesel types in the tank. According to the advertisement, they promise around 300% more power with 100% less fuel consumption
[Scherzmod=OFF]

Greetings

Okay, here's the translation, keeping the HTML tags, BBCode tags, and URLs intact:

Naja, bei 4.500 Umdrehungen und ner kleinen Tachoabweichung kann das schon sein.

Fehlercodes für Verbrennungsaussetzer im Fehlerspeicher allein, oder war da noch etwas vom Zylinder 1?

Gruß WarLord

Hi,

we can ignore the speedometer discrepancy... the 240 will be what the speedometer shows. The relationship between RPM and what the speedometer reads depends only on the gearing and should therefore be the same for all identical cars, because the speedometers have to display too much and this is calculated from the wheel rotations.

4000 @ 210 would mean 4571 RPM at a reading of 240, which shouldn't be a problem - my ASV was already revving higher on the highway (naturally downhill).

Best regards,

Jan

Are you sure that the turbo is okay? Does it spin easily, with little play, and no visible wear marks on the compressor or housing? And did the car smoke a lot after the failure?

Best regards!

[quote="JA´s Car Service"]VW has diagnosed the following issues:
1. 17958 P1550 011 Turbocharger boost pressure regulation difference
2. 16685 P0301 035 Cylinder 1 misfire[/quote]
The "loading pressure" story could be related to tuning.

The engine cutting out could indicate a faulty PDE.

Hey, unfortunately, I can only tell you what the customer has provided, and if the thing only runs at 200, that's a problem.

I just need a repair manual for the device and some good advice!

WarLoard also mentions something about spark plugs on page 1. Do you have any suggestions?

What do 'PDes' mean?

[quote="JA´s Car Service"]
Stupid question, what do PDes mean??[/quote]

[b]P[/b]ump [b]D[/b]yser [b]E[/b]lements

Hey, let's be honest, do you really know what you're doing with that engine? You should definitely have some experience working on newer VAG diesel engines. Especially the fuel injection system, you need to know it inside and out, as that's where the problem lies. If you remove the cylinder head, you'll find not only valves and spark plugs, but also fuel injectors. When you remove the valve cover, you'll be able to see them from above and then essentially look at the pump. Unfortunately, it's difficult to see if they're defective. Therefore, it would be a good idea to connect the assembled engine to a workshop-compatible diagnostic computer (there are also ones available here in the online shop, at least the necessary adapter with software) and search for the error. Otherwise, you're left with the option of randomly replacing parts. However, your customer probably isn't willing to spend an endless amount of money, so start with a suggestion. After all, a PD element costs a lot of money.

Alternatively, I strongly recommend reading the technical articles to at least get a basic understanding of how such an engine works.

Sorry, I didn't mean to offend, but I find it strange when a mechanic talks about customers and then doesn't know the basics.

Hello,

My advice: refuse the repair and send the customer back to VW. If you're not a skilled mechanic with inside knowledge of the pump-injector-TDI system, you won't do yourself any favors with the repair. Just the lack of specialized tools will make it a nightmare. This will only lead to problems with the customer later, especially regarding warranties, etc.

By the way, I really like this clientele. Get the engine tuned for expensive money at ***, drive like a proverb, and then want to get it repaired for free at a friend's workshop.

If you're also considering 'chipping,' then let's discuss the pros and cons.

Okay, here's the translation, keeping the HTML tags, BBCode tags, and URLs intact:

Okay, I'd have found it easier with the car if I had received everything completely! And with a better error description! I might not have the knowledge of the engines yet, but everyone starts somewhere! I also have other areas where others struggle, and those are my strengths. But luckily, the problem has been solved: the 1st piston has broken in the cylinder, according to information from a well-known tuner! This isn't the first time I've heard of this!

Thanks to you all!

The rest will be fine, and maybe I can contribute something useful to you soon!

Okay, then,

Since you wrote in your first text that you had controlled everything (head block turbo) and there were no errors, that's a bit confusing.

This wasn't an accusation. You can't possibly know everything, and I know that too. But I just wanted to point out that you could have problems with the customer if you made a mistake. The tip is to find a suitable test device if you have more VAG vehicles in your workshop. Unfortunately, in the case described, that wouldn't have helped much due to the engine removal.

PS: Where exactly did the piston break? Shouldn't there also be other combustion marks to be found in the combustion chamber?