103kW/125kw TDI PD Piezo Siemens injector failure thread

[Greg Roles]

Bottom line is the 103 can't fail because of the injector oil ingress issue, as you are right in that it will still run on 3. The harness is a different thing though, and I only recently had my 125kw injectors done under recall at 150k's, but I DID replace my harness with an Audi one a few years back when we all thought that was the issue. Wouldn't surprise me if this afflicts the 103 as well.

I'd be putting in a new harness, a pretty simple DIY if you are half handy, and much cheaper than an injector and seeing how you go. The Audi one I fitted had much beefier wire but was a nightmare as the wire colours were different, pretty scary.

[neromonk]

Well I'm sure that Greg knows a lot more about VWs than me and when he says that the 103 can't fail because of the injector oil ingress issue and it will continue to run on 3, then he must have his reasons.

My experience is limited to one 2007 VW Passat with a 103kW BKP engine but here is what's happened to mine.

My initial story is told in post #114 on page 12 of this thread. In a nutshell my car stopped very dead without warning in April 2011 and was towed to a dealer who replaced all 4 injectors and harness and claimed on my extended warranty.

In late 2013 I received the 23H9 service campaign letter from VW and so I booked my car in and got my injectors and harness replaced today and had a recall label stuck on my drivers door pillar.

Looking at the paperwork from today and comparing it with the paperwork received from the 2011 incident, I see that the part numbers for the injectors are the same, VW03G130073SX and so is the harness VW03G971033M.

So did I really need the new injectors? I have no way of knowing. Greg says that they can't fail for the reason that VW noted in their service campaign letter. I can only assume that my original ones failed for some reason. The replacement ones might have kept going for a long time (maybe). But now I am up to date with new injectors and my car has all of the recalls done that VW believe it needs, which can only help its longevity and resale value.

I'm sure that the dealer is more used to replacing injectors on the 125kW engines as when I initially booked in for 23H9 they didn't have my type of injectors in stock and I had to re-book and go back again a week later. So one would assume that plenty of the 125kW engines are being done. But from my own experience, the 103kW engines are also included in the recall.

Hope this helps.

[OilBurna]

They can fail for the 103kw pd engines hence the recall.


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[max55]

Not sure if this is correct place to post, but following my posts #206 and #221 re my 2008 GTI injector failure and having all injectors and loom etc replaced in October 2011, last Thursday, I was accelerating away from some lights when the car started shuddering. After a few minutes realised it was running on 3 cylinders and today Denlo VW at Parramatta confirmed that one injector had failed MECHANICALLY. What's more it had deposited metal particles in the engine including one larger piece which they will pull the sump tomorrow to try and find. What's going on? I'm not looking forward to the couple of thousand dollars to get it sorted.

[Umai Naa!!]

Much different setup to the diesel injection system discussed in this thread.

Although, it does baffle me as to how the injector in your case seems to have fallen apart. Perhaps it was incorrectly installed last time?

[max55]

Sorry, forgot to say, mine is a diesel.

[Umai Naa!!]

Oh right, so it's a GT? That makes more sense.

Again, I'd be looking at installation errors.

[alf]

Hi Folks,
Can anyone confirm whether an 08 Passat 125 TDI (My09) is susceptible to the injector problems? As I understand the engine is BMR and the last of the non-common rail ones. I don't have the VIN and do not particullarly trust that VW Australia will tell me anything other than everything is fine and there is never any problem with any VW (in fairness all manufacturers do the same).

I'm thinking of buying a Passat and obviously one which has had the injectors recently changed or qualifies for new ones is a big bonus. Is it better to spend a little more for a later car with the common rail motor? I'm generally more keen on buying the last of any particular design than the first...

Cheers
Alf

[OilBurna]

Should have a sticker withe recall code and date inside drivers front door pillar


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[Greg Roles]

Guys I donlt claim to know all, so could easily be wrong, but all my VW tech articles and discussions with mechanics / dealers leads me to believe the 125 has the oil ingress issues as these were the first piezeo injectors, and it seems oil in the piezo stack kills them. Hence they are now external to the oil in the CR MK6 onwards, much better design. The 103 has normal PD injectors, and as far as I know they are wired in parallel, unlike the series setup in the 125. Maybe they changed this mid cycle, I don't know, and we have not even touched on the wiring loom which is suspect as well. All I can say is my stock one had a LOT thinner insulation on it than the Audi one I replaced it with, and VW didn't bother touching it at the recall service.

No doubt a 103 could indeed totally stop, just from the way the Bosch ECU and wiring is setup, it would seem to be a lot less likely. The MKV Siemens setup is a nightmare, and glad they ditched Siemens for the MK6 onwards.

In the Audi and Skoda cars with the Bosch / Siemens setup from the same era, again the majority of injector failures were the 125.

For the post above, if your injectors are external you have common rail, they are under the cams in the PD setup. I'm afraid I'm petty sure the BMR is a PD engine, so your injectors are suspect.

As always, probably totally wrong, at least on something.

Myself, looking forward to moving to CR sometime soon.