2.0TDi Not Firing After Breakdown and Fuel Pump Replacement

[G60JONNY]

Hi there lovely forum folk!


The Mrs' 2.0TDi died on the motorway a couple weeks ago, lost all power then engine cut out completely. It was identified as high pressure fuel pump so this has been replaced, however it won't start at all!!


Got fuel to the rail and to the injectors so the pump is now working (didn't have fuel to the injectors before when cranked) but the bitch won't fire. Turns a treat and makes all the right noises but....nothing! Will fire and run (badly) with easy start sprayed into the inlet but it seems like its not feeling enough?! Does the pump need coding?


No fault codes on VAG-COM either. Any help massively appreciated! :-c

[Crasher]

Which engine code, BKP?

[G60JONNY]

Not entirely sure, it’s now away with the mechanic who fitted the pump. It’ll be on the V5 tho, right?

[G60JONNY]

Which engine code, BKP?

Got the engine number CBA 601905.....does this help?

[Crasher]

A very early common rail TDI engine, we need some fuel rail pressure data but IF the high pressure fuel pump failed in the usual way, just fitting a new fuel ump is often not enough.

[G60JONNY]

What else will/could it need? My T5.1 did something similar, cost a small fortune to rectify!

[Crasher]

It is virtually identical, we have a T5 facelift into today running rough with suspected fuel pressure problems, my tech is just scanning it now.

[G60JONNY]

According to the mechanic I need three injectors! It’s pretty much a write off at that!

[Crasher]

Yes, we see it on a regular basis right across the VAG range with the early common rail, especially the CAYB and C 1.6 units.

[G60JONNY]

Are there any VAG group cars that don't have an injection system made of chocolate?!

[Crasher]

Yes, those that don't use the Devils own urine...

[G60JONNY]

And what are the thoughts on the 1.4 TSI engine?

[Crasher]

I am sorry, this is a public forum and foul language is not allowed… all I can say is they are 54i7…

[G60JONNY]

Well, the time has come to depart from the ****** VW brand, the Passat is now up for sale as she doesn't trust it any longer. After the T5.1 let me down in exactly the same way a few years ago I've never looked back from my Mercedes Vito, it's bulletproof. Thanks to all on the forums over the years, some great info and help out there! :beerchug:

[G60JONNY]

Starts occasionally, ticks over badly and won't rev and is ready for breaking tbh! Help peeps?!Pressure on the rail is 200+ bar after having new pump, reconditioned injectors by Diesel Bob, new high pressure fuel pump. Started, but won't run well, lumpy as **** but won't rev/boost and cuts out! Possible timing?? Help please before i break it for parts?

[Crasher]

Do you have VCDS?

[G60JONNY]

Yes I do

[Crasher]

Have you checked the IMA numbers on the injectors with those registered. I don't know if recon injectors keep this value, I know the new range of Bosch recons have a new number applied. The valve timing could be wrong but if you use the right tools you have to try pretty hard to get it wrong. No fault codes obviously?

[G60JONNY]

HI Crasher and thinks for your help on this one. So, huge steps in the right direction! Turns out the reconditioned injectors were supplied with the wrong copper seals and therefore wouldn't maintain a seal when running. A trip to TPS and the damn thing spun up first time and hasn't missed a beat since! Go figure! Hopefully I can park this one for now and the shed keeps going for the foreseeable future. Thanks again for your time, J