VW Passat 2013 - CAYC 1.6 TDI - noisy and rough idle when warm.

Hi Roverfan thank you for your time it's appreciated. These injectors seem very sensitive. I had a BMW 120d a while back. All I did was stop it for 5-minutes and restart the engine three injectors open circuit. It took BMW six weeks and four mechanics to work out why by replicating on a car from the forecourt. To replace 4 injectors wouldn't be far off the price of the car. Someone who can get the solenoid or piezo for injectors and calibrate must be a good earner.

Yes they are very sensitive, which reminds me that the one trick I have discovered to bring down their positive deviations is "Full demand for power uphill in 2nd gear" or wide open throttle as the Americans would call it (fast regular driving does not work)
I don't know if that would help in your case but I have found it has lowered a creeping high deviation a couple of times for me.


Had a little study of the figures from my car compared to the passat but didn't see anything in particular except what we already know.

Thanks Roverfan maybe worth a try. I rang around a few places to try and get some used injectors no luck so far even the Refurbs don't warranty for long apparently they're that bad.

Thought I'd just add another update, So we replaced injectors with yet another set refurbed from Germany (be careful on import tax cost my mate over £70 to get them released) anyway these coded well with VCDs and seemed to cure the issue, engine reached temperature and tick over nice no hesitation on acceleration, Injector deviation good and eventually settled even better than in the picture (see attached). Asked my mate to do a test drive and when he returned it was running on 3 cylinders. Ran diags and P020100 error injector 1 circuit, injector tested OK but resistance climbed very slowly to around 200K. So replaced with the working bad one fault cleared with no return and it ran once more but noisy even after coding. So now stuck with 3 good injectors.
So the one that failed from Germany will be refunded. Then finally my friend got a response and spoke with the supplier of the first refurbed bad injectors, it turns out that the new injector nozzles fitted were faulty and he had many complaints and he will now repair and return free of charge. These have been posted and hopefully we will get returned shortly one of these fitted and coded soon. I'm guessing when they refurb and test they do not test for a long enough period to confirm that they are functioning with a chance of lasting.




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As I have said elsewhere, I won't fit refurbished injectors from anyone, time is money. If you are doing it DIY then it's not such a big deal but if it is for a customer it becomes embarrassing, inconvenient for everyone and money down the drain such as a new injector bolt. Even if everything went smoothly is is 2 hours so £132 lost.

Hi Crasher, My self and friend agree it may be a few quid cheaper if any, but the head ache and labor would have been off the scale, and with the warranty on the injectors not being very good and reliability as we found is also ridiculous. The local Bosch diesel injector specialist quoted £160 per injector and only 3 month warrantee on these, (i used them years ago on a different matter and ended up doing the job myself after spending nearly 2 weeks wages there) The German supplier offers 12months but as we don't live in Germany its not really practical.

Hello i have jetta 2010 which have 1.6 tdi cayc engine.
I reamed the injector seat but i do not know the thickness of the washer to use because i bought that car secnod hand and it could be reamed before.
Is there anyone who knows to standard dephtnes of injector hole from top of head to the copper washer seat?

Cutting the injector seats is strongly discouraged by VW.

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Originally Posted by Crasher

Cutting the injector seats is strongly discouraged by VW.

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Hi guys was this problem sorted iv one the very very same!! And i cannot figure it out? Any help appreciated