VW Caddy 1.6 TDI (2011) - Damaged Injectors 3 times in 6K km - Possible Solutions?

Hello.

The topic was already in 2015 but it has not been resolved and unfortunately it happened to me now.
In short Caddy 1.6 tdi 102 ps mileage 248 tkm 2011 within 6 thousand km three times damaged the injection in the electronic part what is best is what about 2 thousand km. First went first, then fourth now third. From posts from 2015 I read that the same thing happened with new injections bought in the ASO, they lasted from several hundred kilometers to max one thousand two. (I exchanged for stimulants, every time oil filters, generally oil and filters every 10 tkm statoil and schell fuel). I can exchange in ASO all 4 new costs of one 2760 PLN only if the situation of my colleagues will not repeat ... maybe someone knows the solution causes and will help. Thank you in advance

Berserkers wrote:

(I exchanged for stimulants, oil filters every time, generally oil and filters every 10 tkm, statoil and schell fuel).

What does this have to do with the electronic part?
Already a few times I have processed the problem of continuous defects in piezoelectric injection in cars. It always ended up with the fact that the injections were not regenerated properly.
For me, it's not just the earnings reasons that some workshops exchange a set at a time.

And how do you relate to new injections bought from an ASO that have died after max 1 thousand km, have been replaced and have fallen again after about 1 thousand km?

a new injection from VDO can now be bought for less than PLN 1200 ...
but not about it ... check if after unscrewing / removing the fuel filter cover visible
there are metal filings on the filter cartridge and inside the fuel filter tank ...
once you check, let me know ...

Berserkers wrote:

I can exchange in ASO all 4 new costs of one 2760 PLN only if the situation of my colleagues does not happen again ... maybe someone knows the cause solution and will help. Thank you in advance

If you go crazy, in the event of a fault, you have free assistans throughout Poland
in that topic (I superficially glanced) there was an internal error in the P0606 controller, which was probably generated by a short in the injector electronics. Does he also appear with you?
And what do injector corrections look like? Compression pressure?

masay1 wrote:

a new injection from VDO can now be bought for less than PLN 1200 ...
but not about it ... check if after unscrewing / removing the fuel filter cover visible
there are metal filings on the filter cartridge and inside the fuel filter tank ...
once you check, let me know ...

There were no swarf the first and second time, tomorrow I will tell the mechanic to check it, as to the injection for VDO for 1200 PLN can you tell me what it is? because I'm not very much in the subject

Added after 1 [minutes]:

ptr92 wrote:

Berserkers wrote:

I can exchange in ASO all 4 new costs of one 2760 PLN only if the situation of my colleagues does not happen again ... maybe someone knows the cause solution and will help. Thank you in advance

If you go crazy, in the event of a fault, you have free assistans throughout Poland
in that topic (I superficially glanced) there was an internal error in the P0606 controller, which was probably generated by a short in the injector electronics. Does he also appear with you?
And what do injector corrections look like? Compression pressure?

Tomorrow the mechanic will check corrections, pressure and error codes and I will post it immediately. As for free assistans, unfortunately the car flies in Germany

Siemens VDO; the same company that goes to the first assembly ...
you can get, for example, in Inter cars ... it's best to look for the original number
you probably have: 03L130277S; but you still have to check it by VIN number ...
see this filter cartridge and let me know ...

masay1 wrote:

Siemens VDO; the same company that goes to the first assembly ...
you can get, for example, in Inter cars ... it's best to look for the original number
you probably have: 03L130277S; but you still have to check it by VIN number ...
see this filter cartridge and let me know ...

good to know, today I have launched three VW services ... tomorrow I will check the abovementioned info and throw it in.

Thanks

Added after 14 [hours] 14 [minutes]:

masay1 wrote:

Siemens VDO; the same company that goes to the first assembly ...
you can get, for example, in Inter cars ... it's best to look for the original number
you probably have: 03L130277S; but you still have to check it by VIN number ...
see this filter cartridge and let me know ...

No swarf in the fuel filter

when it comes to these engines, it happened that damage to the injectors was caused by "flaking" of the high pressure pump ...
I had several such cases and the repair costs are "quite" high ... new pump, injection (or regeneration) fuel lines
and it is also recommended to replace the fuel tank ... and this is due to the inability to sufficiently remove swarf from its interior ...

but you write that: "No filings in the fuel filter" thus the above diagnosis is out ...

the next reason for damage to injectors in these units are the injectors themselves ...
more precisely, their delicate structure and very high sensitivity to the quality of refueled fuel ...
I know what I wrote above seems to be at least "stupid" but I assure you that it is ...
injectors "let go" on the so-called "transfers" which can be easily diagnosed ... and very often
it happens that they do it in turn ... first "strikes" one and in a month another, or several at once ...
this is quite extensively described in the service literature (which I cannot share) of course the manufacturer
Blames fuel quality with all fault ;; more precisely, its lack ... which is only partly true ...
Fuel quality is decisive here, but Poor Injector Quality also ...
Of course you should diagnose the entire control system as well as the fuel system itself, but if yours
mechanic won't find anything It doesn't mean that you don't know ... it's just the way it is ...
and the culprits are: the delicate construction of the injectors + the poor quality of the fuel ...
however, if a mechanic would detect any defects, they must be removed
and before the installation of the new batch of injectors ...

nothing more help I can't ...

So it was, first flew one after three weeks, the second and after several days the third. I decided to buy new and exchange, before I do it I will put in Bosch's car service in Piła so that they can check the car again '' thoroughly '' because this one does it casually in a friendly manner without a queue ... Thank you for help was definitely helpful , it's a pity that I have so far to you I would gladly decide to repair and diagnose with you.

Regards

Added after 36 [seconds]:

Berserkers wrote:

So it was, first flew one after three weeks, the second and after several days the third. I decided to buy new and exchange, before I do it I will put in Bosch's car service in Piła so that they can check the car again '' thoroughly '' because this one does it casually in a friendly manner without a queue ... Thank you for help was definitely helpful , it's a pity that I have so far to you I would gladly decide to repair and diagnose with you.

Regards

Ps: injection I have CONTINENTAL

Siemens, VDO, Continental ...
it's the same story ... read The company ...
sometimes they differ only in packaging ...
but it doesn't matter ...

Have a nice and good luck ...

Mesay1, is there any chance to contact you?

I think so...
and how can you help? ..

Hello everyone.
I have been swinging with the problem of my Caddy 1.6 tdi 102HP engine for a long time. What a mechanic is a different idea, but there is no solution.
Most indicate the injection, but everyone wants to replace them to replace, and they are not sure, because the control shows nothing.
I will cite quite strange symptoms. The car normally runs without problems, at a standstill it keeps with revolutions of about 850 / min and oil temperature of about 85 degrees C. Ni from pear, than from parsley, after a short drive from starting, it automatically turns up to 1000 / min at a standstill. By the way, you can hear, as if the engine worked in a different way, as if higher sounds, not diesel, but gasoline. Something like a turbo hole appears. Terribly mussels at lower speed, and from around 2000 gathers like stupid. These symptoms last until the oil temperature is reached (I emphasize the oil, because the coolant is 90 degrees) 100-105 degrees. After catching this temperature, the sound changes to low, thick, bass, and the revs drop to around 850 / min. After a few minutes, the oil temperature drops to 85 degrees. In general, I noticed that the car does not heat up on the road. I noticed that the fluid temperature can drop to 80 degrees, which is strange, because the car, e.g. for 150km, is kept at a constant speed of 120-130km / h
The second strange symptom. The car is driven correctly and suddenly you feel jerking, snorting, choking and choking, clattering. This can be felt most often in third gear at 1800 rpm and suddenly pressing the accelerator pedal. After a few km it snorts harder and drives normally.
Caddy has run 115,000 (I personally led from the salon and I did all the km personally). In the meantime, at 75,000, the EGR was replaced with the radiator. Apart from that, nothing was done, everything in the original.
Maybe someone had something similar? Can anyone help?
Greetings to all.

Has anyone finally found this problem with the injectors firing? Someone wrote somewhere that it was a problem with the gas potentiometer and after replacing it the problem disappeared? Is this true or false... because I wonder what gingerbread has to do with a windmill??? Recently, the mechanic found that when the injector power harness was started, when the wires were moved, it turned off the unfortunate first injector (repaired 3 times because the coil was failing and finally he gave a new one)... after disassembling the harness, it was insulated again, pressing the pins during injection, the car came back to life, but I don't know if that's it. temporary. Let me just say that all injectors have been rebuilt, including the fuel pump. A new EGR set was replaced, the entire fuel system including the tank was cleaned, and the timing belt was replaced. Ok for now, but reading your comments, I live in damn uncertainty when I get behind the wheel. Let me know if anyone has diagnosed it???

Connect an oscilloscope and see what PCR2.1 spits out on the injectors, what is the damage to the injector, what is the resistance and capacity of the stack when cold and hot? What is the stack resistance at a breakdown voltage of 1000v? And what is the stack resistance measured to the injector housing? I suspect some damage to the beam or the PCR2.1 itself. Check the controller programming counter, maybe someone once uploaded something and the software is falling apart (this is my guess based on several cases)

Welcome,

I have a similar problem.
VW Caddy 1.6 TDI, 89 thousand mileage.

At about 60 thousand one injection died.
At about 65 thousand the EGR was replaced.
At about 83 thousand in 2022 I did a chip tuning with a dynamometer etc, so that it wouldn't be that I was tinkering in the "shed".
And it started, after 2 months after the chip the car started to start hard in the morning in summer.
Then there was a tearing sound after starting, which stopped after a while.
Diagnosis: faulty injection and other injectors barely holding.

So I replaced the injection and reversed the chiptuning at the same workshop.
I asked, of course, that he review everything, because, as it happened, the problems appeared after the chip.
I didn't get anything in, seemingly everything was ok, he restored the factory program and it was seemingly ok.

Shortly afterwards, the firing problems occurred again in the summer morning.
Now diagnosis: EGR to be replaced and all injectors.

I'm afraid when I make the repairs it will be for a while.

Please explain how a bad program can damage the injectors.
And can anyone recommend a workshop or someone with an oscilloscope to check if indeed, i.e. a colleague wrote, the soft can be loose and if this can cause damage to the injectors.

Too long an opening time for the injectors causes the stacks to degrade very quickly. Tough topic with pcr, in order not to tire the injectors electrically we raise the pressure to keep the opening time, but then the valves get their ass....

Ok, and can the fuel pressure regulator on the injection rail also somehow damage the injectors?

I'm already looking for anything because the car is nice but reading the forums this VW 1.6 TDI can really cause a lot of problems

I don't have any filings in the fuel filter, it's clean so I assume the pump is ok and the fuel tank is too.

Replacing the injectors and blinding the EGR is a big expense, and whether it will help is unknown, as quite a few people have had a similar problem in the form of replacing the injectors, and after a short time, damaged again

And a question, has anyone remanufactured piezo injectors?

These injectors can be successfully remanufactured, but it is necessary to know how and on which parts. The regulator is unlikely to do this, as the pressure sensor keeps watch.