Chaps

 

I dropped a cylinder on the M4 yesterday, and managed to limp home. There was no smoke out the back until I got off the motorway and sat in traffic for a few mins.

 

Diagnostics said Cylinder 4 missfire, so I pulled the plug. It was soaking wet in there so I left it overnight to evaporate.

 

Put a compression tester in there tonight, and got 180PSI as the first reading. Took 2 more, and it jumped up 20PSI with each attempt to read it.

 

Pulled the compression tester and the cylinder was flooding with petrol, you could hear it pouring in. The injector appears to be stuck wide open.

 

The battery is now flat (separate issue, but caused from all the cranking yesterday/today) so I can't continue with my compression tests, but the first test of Cylinder 3 was 150PSI, but didn't get enough rotations to be sure, and hopefully it is more like 160PSI.

 

Anyway, once the fuel has evaporated again and I've done a compression test and I'm happy that all 4 cylinders are OK valve wise etc (will disconnect the fuel pump fuse for the next run)....I want to see about repairing this mess.

An injector is £110, which isn't too bad. Taking the inlet off doesn't look too tricky.

 

Apparently pulling the fuel rail could result in injectors coming out of the head and needing resealing - is this a big risk/big job? I'd need a resealing tool on hand if it happened, but would rather not buy one if I don't need it.

 

Could anything else be at play here? I.e. a reason for the injector to fail? Could it be a victim of something else? Interstingly on the 2 longest journeys I have done on this car, I have seen an ECU code about it running too rich. I do wonder if this has been occasionally sticking open at times and it's only just become terminal.

 

I will drop the oil, as there is so much petrol in the cylinder I would expect some of it to have watered the oil down by now.

 

Is there a resource/forum with helpful people lying around waiting to help with this engine?

 

Also, what engine bay fuse is the fuel pump?

 

Cheers

 

C

Had exactly the same problem on my petrol MK2 VRS. 
 

Driving fine, all of a sudden a smoke screen behind me and horrendous misfire. Stopped, turned off but wouldn’t start after - would only turn and turn and turn. I got Bosch injectors from CarParts4Less (euro car parts online only sister site) for £290 with discount code. Also had to have new coil packs, spark plug, the valves cleaned and fresh oil of course. 
 

Interestingly so much fuel was spewed into the cylinder that the pistons couldn’t move and it gave the impression the engine was locked on timing (thanks to RAC for constantly turning the engine to try and get me going instead of just towing me like I asked)
 

It’s a fairly common fault on VAG 2.0 TSI engines, particularly the Audi version if you read up, so you are probably just unlucky like I was. 

Odd that you had 3 go at once!

 

Having valves cleaned sounds like was just done because easy while the inlet is off?

 

Can't see how it would have affected your coil packs either, though I have already just changed all mine, and the plugs.

 

I'm half tempted to change all the injectors while I'm in there.

Odd that you had 3 go at once!

 

Having valves cleaned sounds like was just done because easy while the inlet is off?

 

Can't see how it would have affected your coil packs either, though I have already just changed all mine, and the plugs.

 

I'm half tempted to change all the injectors while I'm in there.

 

I can get 4 injectors for £307 from the site you mentioned. Tempting.

17 minutes ago, BristolBikerMan said:

Odd that you had 3 go at once!

 

Having valves cleaned sounds like was just done because easy while the inlet is off?

 

Can't see how it would have affected your coil packs either, though I have already just changed all mine, and the plugs.

 

I'm half tempted to change all the injectors while I'm in there.

 

I can get 4 injectors for £307 from the site you mentioned. Tempting.

If you can hang on for a week for delivery they were closer to £200 on AUTODOC, comes from Germany though. 
 

I had 2 injectors actually go, 3rd misfire & random misfire codes were just there for the party I think. When it went it really went, I thought the chain had gone to be honest. All 4 were replaced. My father in law owns a garage so it just went there and came back fixed, I only had to source the injectors as I managed to get them cheaper than he could (odd). 
 

In regards to the coil pack, once the new injectors were in it was running but a bit rough and it had a code for the coil pack, so that was done too. Not exactly sure what the reason was but I will ask 👍🏼

Will speak to my trusty mechanic tomorrow, but hopefully he just recommends one injector and new oil. Would be easier to do 4 if the injectors come off though.

 

I know the PO had a new inlet manifold fitted not long ago, reckon they would have cleaned the valves then anyway.

Unless the oil level has gone up noticeably I wouldn't change the oil, the lighter petrol will quickly evaporate with the engine heat and go through the PCV system.

You can get the injectors flow tested and cleaned. That's what I did with mine with the IM removed.

 

But then £200 for 4 x new Bosch is a very good price indeed. And it sounds like one has failed without question anyway.

 

It will be very apparent if the intake ports and valves have been cleaned or not.  Its not a quick job even after the IM has been removed so I wouldn't assume it has been done.

 

You can't predict where the injectors will stay when the IM is removed so a seal tool or be prepared to use one of the improvised approaches. 

I can get the injectors for 290 for all 4. 

 

Not going down the £200 route as they'll get stopped in customs and slapped with a brexit fee.

 

I'm debating whether just to replace the one injector, and get seal kits for the ones that come out. Or do them all.

How many miles?

 

If keeping the original 3, I'd at least get them cleaned and flow tested and leak tested and that costs about £20 (actually on checking cost £25 each + postage) each plus postage with new seals installed. The VW injector seal kit complete is about £10-£12, (actually the genuine part cost me about £13), it comes with the 3 legged stand off spacer as well. I have one brand new kit, as I did not use it. 

Edited 8 April, 20215 yr by TheClient

106k miles, 09 plate.

 

I've just spoken to a local VAG specialist who said he wouldn't use Bosch injector from ECP as they are remanufactured and not reliable.

 

He said VAG ones are 175ea plus VAT

 

He also said this is uncommon and he's not had one stuck open before.

 

Not sure whether to believe any of that... I'm still tempted to just fit 4 injectors from Bosch and be done with it.

 

 

 

 

He may well be speaking genuinely of personal experience. But, there have been a few posts on that exact scenario on here over the last few years. Including a reply from a member in thread replies above confirming same.

 

I'd prefer new rather than remanufactured. Surely that is just new seals, tested and cleaned?  Is he sure they are remanufactured, surely they have to describe as so? 

 

If the are remfr, I'd rather stick with what you've got after cleaning and testing.  Ideally match the replacement which if they are original will be a VAG part but made by Bosch. The question is there any difference at all in the bosch aftermarket compared to the VAG original Bosch supply I don't know, but I imagine you would not notice it.

My originals in my 2011 were 06H 906 036G .

 

The carparts4less comes up as £90 and ECP with discount about £109 from what I can see. That is the Bosch aftermarket equivalent.

 

See my thread here for more information on the port and valve clean.

 

 

 

 

Edited 8 April, 20215 yr by TheClient

I'm struggling to believe that those Bosch ones are remanufactured as it doesn't state it.

 

I'm also struggling to believe there's anything wrong with Bosch ones, their reputation for fuel injection is strong.

 

Ultimately if a few fellow forum members can assure me they have several k miles on Bosch injectors I'm good to go.

 

Cleaning sounds ok, but for an extra 60 per cylinder I get new injectors.

Yes, it is not a lot more to pay whilst the IM is off.  I had no real problems with the injectors so I had cleaned and flow tested.  From my quick review, Opie Oils do the CCZ type Bosch GDI injectors about £70 each and they do not state remfr. So that is around £280 a set from a site sponsor and may be slightly less for the 4. 

The Bosch ones I got were definitely not remanufactured. Brand new sealed in the box and paperwork stated brand new. I’ve not known Euros to sell remanufactured parts ever. 

How many miles since you fitted them? 260 including discount at Opie oils for all 4.

 

Thanks all for your help so far.

Also is the inlet manifold gasket reusable?

 

Any other parts/special tools needed?

3 hours ago, BristolBikerMan said:

How many miles since you fitted them? 260 including discount at Opie oils for all 4.

 

Thanks all for your help so far.

I’ve done 800 and the car has never ran better, it’s on 108800 miles and is returning 35+ MPG and feels a lot more responsive. 

4 hours ago, BristolBikerMan said:

Also is the inlet manifold gasket reusable?

 

Any other parts/special tools needed?

It has been reinstalled by others.

 

But I used a new one.

 

A short torx bit and short universal joint will help with the IM nose support bracket which is a right pain. 

 

Some scrapers and picks if your going to clean valves / ports.

 

 

Is there also a spline type socket required?

Actually your right, the dreaded nose clamp was spline, m12 from memory it needs to be as short as possible. There is a rigid coolant line in the way. Long reach torx bit or torx with extension bar for IM screws. Can't remember size. It will be on net. T25 or 30 likely.  

Got all of that stuff already so good to go.

I found a guide written up on a few forums by the same guy for cleaning ports. He took detailed photos and put arrows on them to the bolts etc, but his photobucket account is giving a permission denied error.

 

Don't suppose you found a paper manual or anything? It's annoying not being able to buy a Haynes for this model, I prefer paper rather than unlocking phones and viewing videos etc.

 

I have the VAG VirtualBox image workshop manual, but its too complex to use out in the garage.

There's a decent video from an American guy workshop I his garage on a golf gti. I watched it twice before doing it. It's pretty self explanatory but it was good to confirm all the connectors for example. Very easy to rip one off by not disconnecting.   I'll find it. 

 

Here it is.

 

https://m.youtube.com/watch?v=5WYS5pMPm8g

 

 

 

Edited 9 April, 20215 yr by TheClient

Nice one. 

 

I did a compression test this AM and getting 165PSI on cylinders 1-3. Cylinder 4 was 180 but its still spewing fuel in. As its significantly higher and its only petrol in the bore, I'm not expecting it to be down on comp.

 

I've ordered the injectors and will arrive next week. So will strip the manifold off this weekend and wait for the injectors, then do an oil/filter change and fire it up.

 

Did you find it necessary to leave the car jacked up? I don't want to leave any kit outside for a week if I can avoid it. I want the bonnet shut and the car on the floor while I'm waiting for the injectors. Will block the ports with shop towels.