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

[max55]

Following my post of 03-10-2011 and just to confirm, there was no warning prior to the engine cutting out. My local workshop suggested that I'd be best taking it to a VW dealer in the likely event that it was the injectors. So I had it towed to Penrith Volkswagen. I collected it today. Four injectors and harness replaced no charge without question, on a goodwill basis as it was at least 6 months out of warranty. Thanks VWA and thank you to this forum for moral support.

[haro]

Well I guess my father got a good run with his VW T5 Transporter (2.5L TDI) - its got over 400K on the clock as its a Maxi taxi here in Brissy.
One of his injectors failed on the freeway yesterday, he was able to limp the vehicle to the mechanic and they got a price of about $800 for a single injector!!! Price does not include diagnosis, install etc.

Painful stuff indeed & I feel sorry for my old man. Obviously no warranty on this one left.

At least he was able to save some money on his replacement turbo we recently got hehehe *fishing*

[benough]

400K though. That's a badge of honour.

I want 300K out of mine

[kaanage]

he was able to limp the vehicle to the mechanic

It must be a different injector/loom/ecu (not surprising given the difference in size/power/etc) since the failures discussed here kill the engine stone dead.

[davidno64]

Well now at 60,000 plus Km's, I have not had any more starting issues. But I did have what I thought was a bettery issue.
Vw could not fault it, so I replace it (the battery) and all Ok. But they had also changed the MAF loom to adress some issues.
Still remaining unresolved was an intermitant loss of power, seldom occours but potentially dangerous in traffic.

NOW, recently I copped a red light camera. Why, the bloody cars got worse intermitant and more frequent, also sometimes
very severe power loss. I got caught mid intersection with no power and stationary. Then delayed, the revs rose and the car
was drivable again. Normally after acelertion, then braking. Either I get a delayed throttle reponse or no throttle response
at all. Sometimes when taking certain roundabouts, either a delayed throttle response or no throttle response at all.

Took it to VW, they had if for 3 days and could only partly replicate the fault and only under the driving conditions
I reported to them. No fault codes, no total power loss. But certainly a part power loss/ delayed throttle response.
Picked up the car, partly repaired. They had found an air leak on the EGR and recitifyed it. It does seem a bit better.
The car gets returned to VW in a few days again to further diagnose the fault. As they can not identify the cause and
have not complitly fixed the issues.

I suspect this is an injection problem. Weather it be a physical issue the the injectors themselfs or the control to
them, an interupted signal. Anyway when I have an answer, I will post any updates but has anyone else had simlar
Power loss/Power delivery issues (specifically relating to the injectors).

[Transporter]

Well now at 60,000 plus Km's, I have not had any more starting issues. But I did have what I thought was a bettery issue.
Vw could not fault it, so I replace it (the battery) and all Ok. But they had also changed the MAF loom to adress some issues.
Still remaining unresolved was an intermitant loss of power, seldom occours but potentially dangerous in traffic.

NOW, recently I copped a red light camera. Why, the bloody cars got worse intermitant and more frequent, also sometimes
very severe power loss. I got caught mid intersection with no power and stationary. Then delayed, the revs rose and the car
was drivable again. Normally after acelertion, then braking. Either I get a delayed throttle reponse or no throttle response
at all. Sometimes when taking certain roundabouts, either a delayed throttle response or no throttle response at all.

Took it to VW, they had if for 3 days and could only partly replicate the fault and only under the driving conditions
I reported to them. No fault codes, no total power loss. But certainly a part power loss/ delayed throttle response.
Picked up the car, partly repaired. They had found an air leak on the EGR and recitifyed it. It does seem a bit better.
The car gets returned to VW in a few days again to further diagnose the fault. As they can not identify the cause and
have not complitly fixed the issues.

I suspect this is an injection problem. Weather it be a physical issue the the injectors themselfs or the control to
them, an interupted signal. Anyway when I have an answer, I will post any updates but has anyone else had simlar
Power loss/Power delivery issues (specifically relating to the injectors).

Just out of curiosity, what car is it, what year and is it a nanual or DSG?

[davidno64]

2008 Mk5 Golf GT TDI with DSG (Fortunatly, still under warrantie)

[MADHUN]

I'm having an issue with the PD Injectors on my Nov '05 build '06 plated DSG Golf, but I think it is isolated to the loom. I'll try to remember to come back here and update everyone, but since I've just clicked over the 235000 I'm not too dismayed with the outcome.

So far I have replaced

Thermo Fans
EGR Valve
EGR Cooler Valve

Other than consumables I would have to say I've had a pretty good run; it certainly wouldn't stop me from purchasing another.

[MADHUN]

As suspected it's a new loom; oil leaking through the injector plug seals. Might be time to whack the piggyback back in if that resolves the issue.

[davidno64]

Got my car back today. YAHOO!!!
Funny how you miss you own car and cannot beat the delivery power of a good TDI.
I had a loaner 1.4 TSI Mk6. Good car but certainly not a 2.0 TDI GT Mk5.

This probly should be in another thread,

Anyway, seems like it was not the injectors after all. Quite happy with what VW (Burwood)
had done. So far, so good, the car is driving well and power seems to be constant. My problem
was air leaks and not an injector issue at all. In fact I was told, when the injectors fail (at least
in referance to , issues in this thread). They fail, dead on the spot. Usally one that will take the
whole lot out (Computer shuts down). No warning?, no intermitant operation.

I had 2 air leaks. At the EGR, where the pipe wraps around from the back of the engine and meets
the EGR. Failed at the gasket, where the pipe meets EGR valve. This time they replaced the gasket.
That should have been done first time.
Any way the second leak was where the rocker fumes vent to the inlet. I had already fitted a
PROVENT, at that paticular point and using VW's fittings to this part, was a right angle elbow
(part of the feed back pipe). This had craked but not complitly through.
Now, the locking ring had totally fallen away. Allowing the fitting to work loose and hence a
second air leak. (possibly my fault).

Vw fixed this all under warrentie, including replacing the engine cover grommits and the bonnet underlay.
As they were both failing, with age? My hat off to VW, they were thorough and covered all work,
They could have denied part of the warrentie work, but didn't.