Was cruising through the city at 1 AM on the 26th of August. Just casual traffic light to traffic light cruising with a couple passengers on board. Suddenly the yellow CEL and glowplug light turn on and Stop-Start Error is being displayed on the Maxidot. The ride gets jerky. When I try to accelerate, barely any power. Stopped and re-started the car. The engine vibrates way more than usually, has trouble maintaining revs, little power. Stopped again and took a quick look under the bonnet. Everything looks fine, no leaks, no weird smells.

 

Took the car off the road to the nearest petrol station (a kilometer away at most). Doesn't want to rev past 2000rpm, but is okayish doing 50km/h but no more. Did a more thorough visual inspection, checked the fluids. All still looks good under the bonnet. Was baffled by the Stop-Start error.

 

Since I was in the middle of the city at night, there wasn't much traffic. Couldn't leave the car parked anywhere near the petrol station. Decided to park the car as close as possible to the nearest repair shop. 2.5 kilometers later and left the car to sit.

 

 

Returned first thing Monday morning on the 28th of August with a laptop and VCDS. This is what I got:

 

-------------------------------------------------------------------------------
Address 01: Engine (J623-CAYC)       Labels: 03L-906-023-CAY.clb
   Part No SW: 03L 906 023 JJ    HW: 03L 906 023 JH
   Component: 1,6l R4 CR td H43 8805  
   Revision: --H43---    Serial number:               
   Coding: 00114036032401080000
   Shop #: WSC 33361 790 00101
   ASAM Dataset: EV_ECM16TDI02103L906023JJ 003004
   ROD: EV_ECM16TDI_SK46.rod
   VCID: 77FD8DF9CE1CD7FAF8-8022

2 Faults Found:
9838 - Injector: Cylinder 2 (N31)
          P0202 00 [236] - Circuit Malfunction
          MIL ON - Intermittent - Confirmed - Tested Since Memory Clear
             Freeze Frame:
                    Fault Status: 00000001
                    Fault Priority: 2
                    Fault Frequency: 1
                    Mileage: 239386 km
                    Date: 2017.08.27
                    Time: 00:46:08

                    Engine speed: 1597.00 /min
                    Normed load value: 47.8 %
                    Vehicle speed: 42 km/h
                    Coolant temperature: 79 °C
                    Intake air temperature: 16 °C
                    Ambient air pressure: 1000 mbar
                    Voltage terminal 30: 14.344 V
                    Unlearning counter according OBD: 40
                    Incorrect information on selected Piezo power level-LF_STATE_PPS_SPI[0]: 0
                    Injector valve 4: capacity-CAPA_INJ_MAIN[3]: 32.1019 µF
                    Voltage load of main injection cylinder 4-CHR_INJ_MAIN[3]: 1440.4 µAs
                    Measured energy of main injection cylinder 4-EGY_INJ_MAIN[3]: 8.703 mJ
                    Supply voltage of analog output 1-VCC_1: 4.98 V
                    Supply voltage of analog output 2-VCC_2: 4.99 V
                    Injection valve 4: voltage-V_INJ_MAIN[3]: 12.09 V

9772 - Internal Control Module
          P0606 00 [032] - Processor Fault
          Intermittent - Not Confirmed - Tested Since Memory Clear
             Freeze Frame:
                    Fault Status: 00000001
                    Fault Priority: 2
                    Fault Frequency: 1
                    Mileage: 239386 km
                    Date: 2017.08.27
                    Time: 00:46:07

                    Engine speed: 1571.50 /min
                    Normed load value: 48.6 %
                    Vehicle speed: 42 km/h
                    Coolant temperature: 79 °C
                    Intake air temperature: 16 °C
                    Ambient air pressure: 1000 mbar
                    Voltage terminal 30: 14.456 V
                    Unlearning counter according OBD: 40
                    Accelerator monitoring level-PV_AV_MON: 48.828125 %
                    Injection release status-LF_INJ_AD_ACT: 0
                    ASR-torque request-LV_TCS_INC_40: 00000000
                    Cruise control torque request-LV_TQ_CRU_ACT_40: 00000000
                    Transmission control module torque request-LV_ETCU_INC_40: 00000000
                    RPM monitoring level-N_32_MON: 1504 /min
                    Engine torque-TQI_SP: 127.72 Nm

Readiness: 0000 0000

-------------------------------------------------------------------------------

 

Drove the car a couple hundred meters to the repair shop and left it with them.

 

They called and said the injector for cylinder 2 needs replacing. Asked if they can repair it. Said no, they only replace them. Alright, told them to go on ahead.

 

Picked up the car an hour ago. They told me the reading for the 4th cylinder injector is poor. Works, but requires replacement in the future.

 

 

Got the keys and started the car, started like it always has - very well. But immediately I could tell the car is vibrating more than it should. Drove home. It seemed to lack some low end pull. The interior panels rattled from the vibration, more than they ever had, at least that was what I noticed for the first kilometer or so. Seemed hesitant to accelerate. Didn't really dare to try, had to get home first thing. When I pulled in, the car was still shaking. Popped the bonnet after parking and the engine vibrated noticeably more than I've seen it before. Just shut it off and left as is.

 

 

If nothing else, it was a Superb story I could share. I'm still puzzled by the fact that the car gave a Stop-Start Error. Seems like a stretch to me to group an injector failure into error message. Whatever happened, did it really take out two injectors at once? I'm feeling a bit ripped off for paying a fair bit of money with still having the car not run right and being without a car over a week. If you're wondering about the fuel filter, I changed that myself in March (Done little over 7000KM since that)

 

The final bill was €440.38 (with VAT). I know injectors are expensive, but aren't they fixed commonly? Your thoughts about the situation are welcome.

Edited 4 September, 20178 yr by TLV

I ask, I answer.

 

Found this useful bit of information on http://caddy2k.com/forum/viewtopic.php?t=29215

 

Quote

 

 The electrical portion of the injector fails, the insulation cracks and the coil becomes open circuit.
It is very common on the 1.6TDIs, so much so that the injector supplier was changed in 2013.

 

There have been several attempts to chase VW for a recall on these injectors but IMO they have too many ways out. The easiest answer is for a dealer to blame poor fuel
 

 

 

 

I've read about several cases of having to replace all four injectors at once on said engine. Looks like I'll have to chew up the cost. I've also read about some people getting their injectors replaced by the dealer for free if the car has gotten the emissions update.

Edited 5 September, 20178 yr by TLV