2011 1.6 tdi not starting after injector change

[Ricky302]

Hi everyone,

I sold my caddy to a friend last November and he's done 1000 miles and last month injector 3 went on it, he replaced it and and it ran for 10 seconds then died, it wouldn't start again and just cranks over, so suspecting an air lock we try bleeding the line by running the in-tank fuel pump for 3 minutes (like you would do if changing the fuel filter) but still no start, so, out comes the vacuum pump and, attach it to the return line from the HPFP to the filter, lots of air bubbles then a good flow of clear diesel, connect the line back to the filter and try to start it, nothing, just cranks over but still no start.

So we try a bump start on a tow, it starts but runs rough and will not rev, then dies, and won't start on the key again, just cranking over, I'm starting to run out of ideas.

Any help would be greatly appreciated, thanks.

[Doc]

Try unplugging the injector you've replaced, it may be faulty and shorting out the ECU.

[Ricky302]

All the injectors check out with the correct ohm reading, around 200K ohms.

[Scoobysrt]

Did you code the new injector in with vcds?

[Ricky302]

Yes, injector was coded, checked rail pressure today and it was 150 bar so half of what's needed to start, may have to check injector leak off to see if excessive, has anybody any other ideas?

[BenT]

No offence intended whatsoever, but are you sure that both the new injector and the one it's clamped with are sealing properly in the head via the copper washers? If there's any blow-by past the seal it might be causing problems... I tried re-using a copper washer a few months back and the result was not good! Not suggesting you've done this of course. No way to detect it easily either, without taking them out again. Does it start and run with the new injector electrically disconnected? The engine should start and run on three cylinders, but not two.

[Killomiter]

If all else is good the BenT is on the money - leak of pressure or bad seal like the copper is placed sideways down the orifice or the like

[Ricky302]

Thanks for the replies guys it wasn't me that replaced the faulty injector but my mate, the new owner, he said he replaced the copper washer with a new one and torqued the bolt to the correct setting, I'm calling round to his when the weather settles and we'll maybe take the injector back out and check it again.

[Scoobysrt]

Make sure there isn't 2 copper washers on it, the old one and the new one, it's more common than you think that the old one gets forgotten and left.

[Ricky302]

Got it sorted turned out to be #4 injector stuck open, so rail pressure couldn't build up, replaced injector and it's now driving sweet, only problem now is noticed small crack in cam cover so that will have to be replaced thanks for everyone's help.

[SkyRocket1976]

Got it sorted turned out to be #4 injector stuck open, so rail pressure couldn't build up, replaced injector and it's now driving sweet, only problem now is noticed small crack in cam cover so that will have to be replaced thanks for everyone's help.

Hi Ricky302,

Ancient thread revival but can I ask how you found out injector #4 was stuck open?

Having a similar issue and at a loss as to what to check next and how to check it.

Many thanks