CEL HELP Please BEW TDI

[jdennison]

P0201 code 2004 Jetta Bew TDI when cold it's fine, when warmup it misfires and code P0201(open inj. circuit)is thrown.

I've recently replaced cyl 1 injector because it misfired when cold then would throw P0201 and P0301  until warmup and restart it ran fine. Now it's opposite except restart won't fix problem.

 

[rallydiesel]

First I would clean the large harness plug on the side of the head with electrical cleaner.

[Vincent Waldon]

Unfortunately there are very few TDI drivers on this forum, and even fewer BEW owners... most folks are rockin' IDI engines. 

On the other hand there are thousands of BEW owners over at www.tdiclub.com... a posting over there might yield some results for you as well.

[Powered by Spearco]

Can you give any other info on the car?  How many miles are on it? Do you have VagCom? Did you touqe the injector rocker down enough or to much?

I do work on these from time to time. R&R'ing cams, lifters and bearings, also whats known as the
"Chain Ectomy" on the Passat BHW TDI's.

[jdennison]

Car has 215,000 miles, I do have Vag-Com and took some readings with it using measuring block 08 18 23, The plunger on injector 1 where lash is adjusted had some wear marks, I didn't adjust lash exactly. I put new injector in and used old plunger because I was unsure how to adjust lash

[Powered by Spearco]

I have never changed out an injector but I just today did a camshaft, lifters and bearing shells an a '04 BEW TDI. It did start and run kind of choppy due to the wear on the cam and lifters, but after the new parts I needed to reset the injector lash to be shure it was in spec.
Its really easy. I roll over the engine to the injector that I'm adjusting so that the intake lobe on cam is pointing up and at the roller of the rocker. Loosen the jam nut, loosen the center 5mm allen a turn or two, then tighten it to a light seat then back it out 180*. Bentley says 225*. It runs better with 180*, tighten the jam nut and go to next cylinder. Just like adjusting valves on a Chevy SB.
Make sure that in Vag com, measuring blocks, group 4 channel 4. The torsional value is 0.0KW. Thats your timing. It might say the spec. is +/- 3, but 0.0 is the best.

The problem could have been an electrical connection or uneven wear to the rocker or injector, but check the torsional value.

[jdennison]

Wow thanks a lot for the info I appreciate you taking the time, The bentley manual way of adjusting lash kind of worried me

[the caveman]

I adjust the injector rockers a little more than what  the VW spec is( i'm sorry I don't remember what it is, but I do about half of what they say).If you do exactly as VW says, I find they will be noisy(esp cold) and not run as well as they should. But more importantly, if the rocker was worn, so is the cam. You should think about changing it.One will not wear without them other. Common problem with those engines.