1.6 TDI VDO Injector failure root cause analysis

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OLS84
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Re: 1.6 TDI VDO Injector failure root cause analysis

Post by OLS84 »

The first one in cylinder 1 failed at 9k and same one has failed again at 18k. Not sure if a reconditioned injector that was fitted initially but from what I can see it was done at VW out with its warranty period.
It’s a quick check to diagnose them. I was getting approx 199k ohms across injectors 2,3 and 4. Injector 1 measured approx 8k ohms. Confirmed it with a scan. Just hoping whatever causes them to fail isn’t going to continue every 10k miles :mad:
Last edited by Giddy on Mon Nov 22, 2021 9:11 pm, edited 1 time in total.
Reason: combined two posts in one
BenT
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Engine size/power: 1.6 CR TDI (102bhp)

Re: 1.6 TDI VDO Injector failure root cause analysis

Post by BenT »

Thanks for posting back! That sounds like terrible misfortune. Perhaps the "S" injectors are no better than the "B" ones, although it would be interesting to know what the difference is between these as this might give a clue to what's going on (assuming that Siemens know what's causing the trouble!). I do wonder though - it sounds like your van's done a very low mileage and I wonder if it's done a lot of short trips? If so, it might have spent a lot of time trying to regenerate thus frying an injector in the process. Hopefully the rest of your ownership will be uneventful and enjoyable!
ransomz0
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Re: 1.6 TDI VDO Injector failure root cause analysis

Post by ransomz0 »

BenT wrote: Sat Nov 20, 2021 5:30 pm I'd be very interested to hear from anyone who's had this failure - did it happen during regeneration, or at another time...
@BenT how do you establish if the engine is doing a regeneration .

I had 4 B suffix injectors fail in a van with c.27000k miles on it. These all failed over the the first 2k miles which I did in the van (recent purchase). I can't tell whether the van had any issues prior to my ownership. Its 2016 model year (sept 2015 registered) so I was a bit surprised it didn't have the new S injectors. I was suspicious someone might have swapped new for old prior to my purchase.

I've only done 1000k since all were replaced, I carry a spare now. If it happens again - goodbye caddy.
Caddy Maxi C20 Startline 1.6TDI 2015 Mk4 facelift
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BenT
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Engine size/power: 1.6 CR TDI (102bhp)

Re: 1.6 TDI VDO Injector failure root cause analysis

Post by BenT »

Sorry to hear about that, reliability aside it's the expense too. If these were luxury cars it might be excusable, but on vans predominantly used for works it's incongruous. I think some of the early face lift vans did have the old injectors, there's a chap called Will Evans who does youtube videos on these vans and he noticed this. If you still have them you could check the date stamp (four digit code, starting with O or P for 2015/2016).

When mine regenerates, the exhaust sounds boomy, the engine runs at a fast idle at standstill (1000 RPM rather than the usual 800), the fans run when I come to a standstill, plus with an acrid whiff of unburnt fuel normally. The engine tone is a little different too. But the best bit - the turbo lag disappears :D

This normally lasts for about 4 miles driving sedately - even at town speeds. As soon as the engine drops down to normal idle speed at standstill you know it's finished (unless it's very cold outside, when it'll run at a fast idle anyway).

I can't see any other way that four adjacent piezo wafers in the stack could have melted simultaneously. If it was just shorting out due to wear and tear then surely only the one would have failed? But for four of them to have gone, presumably at the same time, I can't help but think that they've been fried electronically! Especially since they were at the top of the stack where electrical loading's presumably the highest.
ransomz0
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Re: 1.6 TDI VDO Injector failure root cause analysis

Post by ransomz0 »

Hi,

Thanks for the info. Yes I am worried it is the ECU which is frying the injectors........

Since I have had the van I have never noticed it regenerating based on your description.

I have got rid of the old injectors but have a picture of one, is the code C001 ?

P.S. The injectors didn't got at exactly the same time. One went after I purchased the van #1, another one went a number of weeks after #3 and i decided to replace 4 as part of the same job. #2 went a few weeks after that. So 3 failed and I replaced 1 as a preventative measure. Sorry my previous post was a bit midleading as I said 4 had gone.
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BenT
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Engine size/power: 1.6 CR TDI (102bhp)

Re: 1.6 TDI VDO Injector failure root cause analysis

Post by BenT »

No problem! Actually, I'm biased... I was (am) really hoping it's DPF regeneration related, because then there's something at least we can do to stop the failure from happening. But if it happens randomly then there's also the factor of not knowing when it might happen (entering a dual carriageway from a slip road springs to mind...).

If you look right at the top of the lettering, it's where it says OF29 (or OE29, it's difficult to see). That means:

O =YEAR = 14/15
E = MONTH = MAY
29 = self explanatory

I don't know if Siemens started counting with "A" codes in 2000 or 2001, hence I'm not 100 % certain of the year. Mine's a 2012 Caddy with LA14 stamped on the injectors, which I took to mean 14th January 2012, which would make yours from 2015.

Hope your luck improves. I intended to get rid of mine ASAP because it worries me, but I still have it 2 years later :)
BenT
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Posts: 11
Joined: Fri Nov 19, 2021 9:26 pm
Engine size/power: 1.6 CR TDI (102bhp)

Re: 1.6 TDI VDO Injector failure root cause analysis

Post by BenT »

Of course, there is another question to ask. Has anyone had an injector fail after DPF removal? Assuming that a remap's been carried out to stop it from permanently running in regen mode, that would rule it out! I'm not sure I want to know the answer though...
ransomz0
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Re: 1.6 TDI VDO Injector failure root cause analysis

Post by ransomz0 »

Yes I have the vehicle production date as 23 July 2015. So the stamp adds up.

I'd like to know if DPF delete has a bearing on injector issues .... Could be money well spent.
Caddy Maxi C20 Startline 1.6TDI 2015 Mk4 facelift
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