My 2008 2.0 TDi VW Passat DSG broke it's crankshaft on approximately 130000 km. The engine start to make an almost un-noticeable noise around a month or so back and it became progressively louder with time. The noise became quite loud during the last week and both the VW dealership and an independent VW mechanic suspected that one of the injectors were faulty, and indicated that the noise is due to that (a "Diesel knock"). Well, three days later the crank shaft broke on the 4th big end journal. The 4th main bearing cap were also cracked and broken. No signs of bearing failure on the bearing shells or caps were found, all piston seemed to be in a good condition and were able to move when the crank shaft were rotated, no valves were bend and the timing belt were still intact. This car was mostly driven by my wife and the DSG did not allow over-revving. The engine never overheated and it did not use any oil.
The failure was most probably due to inferior material. Can anybody perhaps advice otherwise?
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