2012 Caddy CAYE injector no voltage

[owenappleton]

Hi. I’ve just been working through a few issues with my 2012 Caddy with the CAYE 1.6tdi. Basically, it started fine when I bought it but had no power and a serious fuel leak around the injectors. I replaced injector No.1 and all the damaged connectors and that solved the power issue, then discovered that the clamp bolt for injectors 3 and 4 had sheared and a ‘mechanic’ had bodged it by actually gluing the injectors in with white silicon bathroom sealant!

I removed all four injectors, the top cover and the camshaft cradle to retrieve the broken bolt and then reassembled with new copper seals/O rings and stretch bolts. After putting everything back together and priming the system with VCDS, the engine cranks but won’t start. There appears to be no power at the injectors and I’m getting a 7594 Supply Voltage - Open Circuit fault. I’ve checked all the connectors for damaged pins and cleaned but no joy. The engine starts briefly with a spray of Easy Start but won’t stay running.

Any thoughts please - it’s driving me mad!?

[owenappleton]

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[owenappleton]

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[owenappleton]

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[owenappleton]

Solved. After putting a full belt/tensioner/water pump kit on since I was half way there checking the timing, it still wouldn’t start after putting everything back together. Still no supply voltage. I removed the injector connections one by one and tried cranking - it tried to start when number 2 injector was disconnected. Nos 1&2 are ‘Group A’ I believe. So I plugged in this lead to an old injector without installing it in the engine and it started, though obviously only running on three cylinders. Replaced No. 2 injector with new and it started and ran fine. So, a short on this injector in Group A seemed to be resulting in power being cut to all injectors. A bit of a roundabout way to go about it but at least it’s fixed.


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[Crasher]

Yes this is a common one and annoyingly hard to find the first time. I had the same thing with Toerag parking sensors, blank screen and a very similar code so I thought controller, but no. So I went through all eight sensors and when I disconnected the last one, the screen came back and the code went. It used to happen on the PD piezo injectors but unplugging those was a pain as they are under the cam cover and oil goes everywhere. I used a new plug and the socket off an old head harness to make an external breakout adapter with labeled wires for each injector. I used it once, then VAG issued a recall and I never needed it again