Hi Guys,

 

I own the following vehicle: Superb MK2, Green line II, full service history, i've bought it with 191k miles and i've been running it all the way to 211k, never missing a beat, been driving it twice from UK to southern Germany, the car did drive spot on. Unfortunately couple of weeks ago as I was driving down M40, all of a sudden the engine clogged up twice, nothing popped up on the dash though and few seconds later smoke started popping up out of the bonnet. The worst thing which could happen to this ****ing engine happend, injector bolt 2 snapped, chucking injector 3 and 4 out of the engine block :(. Being back at the garage, we've put the whole engine back up and running but unfortunately there was smoke escaping through the top of the engine block, i could hear some metallic rattle while it was running and there was oil popping through injector 3 and 4 although all the seals have been replaced and the injector bolt was tightened to the exact newton meter the manufacturer does advise.  As I love the car, i've decided it may be worth buying a new engine for it. Rebuilding the old one would of been too much of a pain so i've managed to buy a 62K miles engine with the 4 injectors from a reputable ebay seller with 1370 transactions and 100% feedback.I've put the engine in, started it up and been driving it for about 60 miles, the car being brilliant, responsive, different engine sound and pretty much it did feel like a NEW CAR!. Unfortunately **** happened again ???????????? engine fault popped up, coil light came on. the engine started running on 3 pistons. Injector 4 failed. I've replaced it  with one from my original engine block, coded it using vcds, put it back up and 100 miles later, injector number 2 failed. The pair came with the engine block, obviously as i've swapped the engine i've coded all the injectors in and i've run the fuel pump 3 times, 30 seconds each time too prime the injectors prior to the first run attempt.  I literally dont know what to do anymore. I've swapped the engine, replaced two injectors on the new one and now the MPG is pretty awful, on a long run maybe i get up to 37 MPG but as i've swapped the second injector which failed and done a 3 mile run around town, my mpg was only 19 :(. I have access to ODB II and VCDS, can you guys please advise me what to do next and what to check or where to check. I find it pretty odd two injectors failing within 160 miles on a engine with 62k miles....

PS:  new oil, new filters all around and running on shell v power only.

Edited 7 February, 20197 yr by andreyyq

Have you had a good look in the old fuel filter for sparkly bits?

8 hours ago, SuperbTWM said:

Have you had a good look in the old fuel filter for sparkly bits?

Would be my suggestion too. Some sort of fuel contamination 

Hi gents. Thank you so much for replying. I will swap the  fuel filter and see what is going on after it. To be fair I can smell sulphur behind the car as it runs on idle, not sure if this could possibly point us in other directions too other than fuel contamination ?

Keep us updated.

 

There have been instances of the high pressure fuel pump cam disintegrating, sending metal swarf particles down into the injectors. You'll see it straight away if you open the fuel filter.

 

One or two bits here and there seem to be the norm from regular wear and tear but if you have a filter case full of it, you have a big problem unfortunately.

 

 

Your fault code points to an electrical problem in the injector circuits or injectors themselves :-

 

EOBD II Error Code: P0204

Fault Location:
Injector 4 (N33) - Circuit Malfunction/Open Circuit

Possible Cause:
Malfunction Indicator Lamp (MIL)(K83) active.
Lack/Loss of Power.
The engine may be harder to start.
Engine hesitation.

Wiring/Connector(s).
Injector 4 (N33).
Engine Control Module (ECM).

Possible Solutions:
Check/Replace all faulty Wiring/Connector(s).
Read Measuring Value Blocks (MVB).
Low side signal current < 2.1 A.

When is the code detected?:
The P0204 is set if the Engine Control Module (ECM) is detects a low or high voltage drop or resistance at the injector 4.

Description:
Engine Control Module (ECM) checks the injectors circuit resistance and monitors the voltage drop during normal operation. The Engine Control Module (ECM) will trigger the P0204 code when the resistance or voltage drop at the injector 4 is out of specifications.


VAG Error Code: 16990/9772/001542/20359
EOBD II Error Code: P0606

Fault Location:
Internal Control Module - Processor Fault - Confirmed - Tested Since Memory Clear

Possible Cause:
Malfunction Indicator Lamp (MIL)(K83) active.
Engine may not start.

Control Module faulty.

Possible Solutions:
Replace Control Module.

 

 

But it's very strange you've had the problem in 2 injectors now, which does seem to point to something in the fuel.

Maybee something in the fuel is causing a short somehow.

 

Think you would need an oscilloscope to look at the injector waveforms between a good & bad injector.

Edited 8 February, 20197 yr by PipH

23 minutes ago, PipH said:

But it's very strange you've had the problem in 2 injectors now, which does seem to point to something in the fuel.

Maybee something in the fuel is causing a short somehow.

 

Think you would need an oscilloscope to look at the injector waveforms between a good & bad injector.

 

If there's foreign matter getting into the injector and preventing it from opening properly, that's going to have an impact on the actuator (think of what happens when an electric motor gets jammed) and that could cause electrical problems further upstream. A good look at the fuel system is warranted I think.

thank you guys. I will have a look at the fuel filter and the whole fuel system this weekend. I will keep you all updated with what we've found out.

On 07/02/2019 at 20:41, andreyyq said:

 

 

How long were you waiting for recovery, looks like you've been living in the car 

Hi Silver !! The car broke down at 2:00 pm, at 2:45 RAC van came , the guy was scratching his head and raising his shoulders saying that he can't help me and I need a recovery truck. At 6:45 pm the truck was there. It was not fun at all as it was -2 outside, no heating and no services within 15 miles lol.

 

PS: regards the fuel line, i've checked it all. Took the fuel filter out, inspected it, stuck a very strong magnet in the fuel filter box, rubbed the filter with it, there is no metal whatsoever nowhere. Now I am puzzled. I've been either scammed by the ebay seller and the injectors he sold me along with the engine are all crap or I don't know. I've replaced injector 2 and 4 up to now.Two remaining now on the block i've bought  and 2 remaining on my old engine block. I guess when the next 2 will fail I will replace them as well with the ones i've originally had and if the injectors keep breaking down after i've used all the spares  then I guess that will be the end of it's days.  And the MPG is absolutely shocking. I am looking at about 30 MPG as we speak but to be fair I am trashing it as much as I can as the engine is warranted for 90 days so if something is prone to fail it better fails now. Even driving it nicely makes no difference, it averages 27 to 30 MPG. I really don't get what's going on ???  The engine clearly feels far healthier, better throtle response, it sounds much better, it runs much smoother. No idea what's going on. Cheers for all the support.

On 08/02/2019 at 10:25, Shaunieboy said:

Keep us updated.

 

There have been instances of the high pressure fuel pump cam disintegrating, sending metal swarf particles down into the injectors. You'll see it straight away if you open the fuel filter.

 

One or two bits here and there seem to be the norm from regular wear and tear but if you have a filter case full of it, you have a big problem unfortunately.

 

 

 

Slightly confused - the fuel filter is surely fitted before the high-pressure fuel pump so if it fails it would send bits of metal the other way towards the injectors through the high pressure metal pipes.

 

Used to be a bad fail on some earlier CR Fords where the only way to properly sort was to replace high-pressure fuel pump, injectors and the pipes otherwise you always had a battle with bits of metal taking out the injectors. Sadly this was an expensive job. The Ford diesel pump had metal components with inconsistent case hardness and once this wore through the metal component disintegrated at a rapid rate sending particles of metal out with the diesel. First indication of a problem would be some injectors failing that when replaced would fail again sometime after.

 

Saying that if the original poster's engine has been swapped then it'll be running on a different high-pressure fuel pump as it is cam belt operated.

 

 

 

 

Edited 10 February, 20197 yr by bigjohn

2 minutes ago, bigjohn said:

 

Slightly confused - the fuel filter is surely fitted before the high-pressure fuel pump so if it fails it would send bits of metal the other way towards the injectors through the high pressure metal pipes.

 

 

 

 

 

 

 

It's absolutely possible, there's a fuel return line to the fuel filter from upstream.. These cases seem to be seen in American VAG CR diesels mostly (possibly due to their poorer quality fuel standards).

1 minute ago, Shaunieboy said:

 

It's absolutely possible, there's a fuel return line to the fuel filter from upstream.. These cases seem to be seen in American VAG CR diesels mostly (possibly due to their poorer quality fuel standards).

 

Good point 

Shouldn't new injectors be coded? 

 

https://forums.ross-tech.com/showthread.php?3396-Coding-injectors-CAYC-engine-1-6TDi

Hi Jafo,

 

i've coded the injectors right away after i've swapped the engine and as they've started failing i've coded the replacements as well...

8 hours ago, bigjohn said:

 

Slightly confused - the fuel filter is surely fitted before the high-pressure fuel pump so if it fails it would send bits of metal the other way towards the injectors through the high pressure metal pipes.

 

 

 

 

From the return line maybe? Take a look at each injector, the fuel goes to each injector which in turn returns to the tank at low pressure

 

When a HPFP grenades itself, for the dealer to warranty all the new expensive parts they will pretty much have to change the entire fuel system to make sure nothing can ruin the new components. Luckily, it doesn't seem a very common occurrence but I've heard of it happening 

Edited 10 February, 20197 yr by SuperbTWM