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

[Friction Nut]

Can anyone advise which year models this campaign applies too?

[Greg Roles]

MKV 125kw GT TDI and Passat from late 2007- late 2009. It *may* also cover certain 103kw diesels from the MKV era as well, but the letter wasn't sent to 103kw owners as far as I know. You are best to ring your local VW dealer and quote your VIN number, they can look it up.

[Friction Nut]

Thanks. Mine is a 2010 and has on one occasion almost shut down on me during a slow acceleration from about 10-15 kmh upwards. Engine near died and ran very rough with coughing and spluttering for about 4 seconds. Had me very concerned. That was about a month ago and hasn't done it since but can't seem to pin point the reason. Perhaps a bit of dirty diesel but surely the filter would have caught that.

Any body got any possible reasons. I called vw and they said my car is not a part of any campaign so hopefully it's nothing serious. Just out of warranty.

[flat04]

Oh no, 2006 Golf 103 TDi owner here.

Vehicle stopped suddenly in traffic and wouldn't restart.
Towed to dealer and they rang saying that 4x injectors and the wiring harness need replacing.

Rang VWA and they said that because the vehicle is not part of the recall they wont help with any of the $4500 cost of replacement for the parts.

What to do now?
Logic tells me that all 4 injectors wouldn't fail all at once. It sounds like if there is a single failed injector and it is unplugged then the car should start and run on 3. If that's the case and the dealership can detect the failed injector then do I just get that one replaced and the wiring loom at the same time?

Has anyone else had the failure in their 103tdi that has been outside of the recall?

Can I keep on VWA case after they have said they wont help? Any tips on how best to do that?
From all the reading of the 23H9 campaign it has failed for exactly the same reason, oil in the injector circuit.

Vehicle details:
2006 Golf
Model No: 1k116c/07
Kilometers: 138,000

Thanks for any advice.

[harlie]

Yes, they should be able to determine which one it is.

They gave me the same story when mine stopped – must replace all for 5k. I am sure the people handing out this advice don’t know it is a different system from the 125kw engines in the recall, they have a one fix for all.

I just replaced one (#2) + harness. @106km

11 months later it stopped again, they said harness, replaced it again.

6 months later it stopped again, they found a fault with the engine harness, which I suspect could have been my problem from the start….

[Greg Roles]

Bottom line is the 103 can't fail because of the injector oil ingress issue, as you are right in that it will still run on 3. The harness is a different thing though, and I only recently had my 125kw injectors done under recall at 150k's, but I DID replace my harness with an Audi one a few years back when we all thought that was the issue. Wouldn't surprise me if this afflicts the 103 as well.

I'd be putting in a new harness, a pretty simple DIY if you are half handy, and much cheaper than an injector and seeing how you go. The Audi one I fitted had much beefier wire but was a nightmare as the wire colours were different, pretty scary.

[neromonk]

103kW BKP injectors replaced under 23H9

Well I'm sure that Greg knows a lot more about VWs than me and when he says that the 103 can't fail because of the injector oil ingress issue and it will continue to run on 3, then he must have his reasons.

My experience is limited to one 2007 VW Passat with a 103kW BKP engine but here is what's happened to mine.

My initial story is told in post #114 on page 12 of this thread. In a nutshell my car stopped very dead without warning in April 2011 and was towed to a dealer who replaced all 4 injectors and harness and claimed on my extended warranty.

In late 2013 I received the 23H9 service campaign letter from VW and so I booked my car in and got my injectors and harness replaced today and had a recall label stuck on my drivers door pillar.

Looking at the paperwork from today and comparing it with the paperwork received from the 2011 incident, I see that the part numbers for the injectors are the same, VW03G130073SX and so is the harness VW03G971033M.

So did I really need the new injectors? I have no way of knowing. Greg says that they can't fail for the reason that VW noted in their service campaign letter. I can only assume that my original ones failed for some reason. The replacement ones might have kept going for a long time (maybe). But now I am up to date with new injectors and my car has all of the recalls done that VW believe it needs, which can only help its longevity and resale value.

I'm sure that the dealer is more used to replacing injectors on the 125kW engines as when I initially booked in for 23H9 they didn't have my type of injectors in stock and I had to re-book and go back again a week later. So one would assume that plenty of the 125kW engines are being done. But from my own experience, the 103kW engines are also included in the recall.

Hope this helps.

[OilBurna]

They can fail for the 103kw pd engines hence the recall.


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[max55]

Not sure if this is correct place to post, but following my posts #206 and #221 re my 2008 GTI injector failure and having all injectors and loom etc replaced in October 2011, last Thursday, I was accelerating away from some lights when the car started shuddering. After a few minutes realised it was running on 3 cylinders and today Denlo VW at Parramatta confirmed that one injector had failed MECHANICALLY. What's more it had deposited metal particles in the engine including one larger piece which they will pull the sump tomorrow to try and find. What's going on? I'm not looking forward to the couple of thousand dollars to get it sorted.

[Umai Naa!!]

Much different setup to the diesel injection system discussed in this thread.

Although, it does baffle me as to how the injector in your case seems to have fallen apart. Perhaps it was incorrectly installed last time?

[max55]

Sorry, forgot to say, mine is a diesel.

[Umai Naa!!]

Oh right, so it's a GT? That makes more sense.

Again, I'd be looking at installation errors.

[alf]

Hi Folks,
Can anyone confirm whether an 08 Passat 125 TDI (My09) is susceptible to the injector problems? As I understand the engine is BMR and the last of the non-common rail ones. I don't have the VIN and do not particullarly trust that VW Australia will tell me anything other than everything is fine and there is never any problem with any VW (in fairness all manufacturers do the same).

I'm thinking of buying a Passat and obviously one which has had the injectors recently changed or qualifies for new ones is a big bonus. Is it better to spend a little more for a later car with the common rail motor? I'm generally more keen on buying the last of any particular design than the first...

Cheers
Alf

[OilBurna]

Should have a sticker withe recall code and date inside drivers front door pillar


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[Greg Roles]

Guys I donlt claim to know all, so could easily be wrong, but all my VW tech articles and discussions with mechanics / dealers leads me to believe the 125 has the oil ingress issues as these were the first piezeo injectors, and it seems oil in the piezo stack kills them. Hence they are now external to the oil in the CR MK6 onwards, much better design. The 103 has normal PD injectors, and as far as I know they are wired in parallel, unlike the series setup in the 125. Maybe they changed this mid cycle, I don't know, and we have not even touched on the wiring loom which is suspect as well. All I can say is my stock one had a LOT thinner insulation on it than the Audi one I replaced it with, and VW didn't bother touching it at the recall service.

No doubt a 103 could indeed totally stop, just from the way the Bosch ECU and wiring is setup, it would seem to be a lot less likely. The MKV Siemens setup is a nightmare, and glad they ditched Siemens for the MK6 onwards.

In the Audi and Skoda cars with the Bosch / Siemens setup from the same era, again the majority of injector failures were the 125.

For the post above, if your injectors are external you have common rail, they are under the cams in the PD setup. I'm afraid I'm petty sure the BMR is a PD engine, so your injectors are suspect.

As always, probably totally wrong, at least on something.

Myself, looking forward to moving to CR sometime soon.