1.6 TDI CAYC: Running on 3 Cylinders Only

The following error has been saved.

Wednesday, June 14, 2017, 18:06:08:40163
VCDS, a Windows-based VAG/VAS emulator, runs on Windows 7 x64.
VCDS Version: DRV 17.1.3.0 HEX-NET CB: 0.4341.4
Data as of: 20170508 DS267.9
http://shop.dieselschrauber.de


Vehicle Identification Number: VSSZZZ5PZBR009636. License plate:
Mileage: 152,430 km. Repair order:


Vehicle type: 5P (7N0)
Scan: 01 03 08 09 15 16 17 19 25 42 44 46 52 56

Vehicle Identification Number: VSSZZZ5PZBR009636
Mileage: 152,430 km

01-Motor electronics -- Status: Error 0010.
03-Brake electronics -- Status: OK 0000
04-Steering angle sensor -- Status: OK 0000
08-Climate control/heating unit -- Status: OK 0000
09-Central Electrical System -- Status: Error 0010.
15-Airbag -- Status: OK 0000
16-Wheel steering electronics -- Status: OK 0000
17-Terminal block insert -- Status: OK 0000
19-Diagnosis interface -- Status: OK 0000.
Immobilizer system -- Status: OK 0000
42-Door Electric Driver -- Status: OK 0000
44-Steering Assist -- Status: OK 0000
46-Comfort System -- Status: OK 0000
52-door electric passenger door - Status: OK 0000.
56-Radio -- Status: OK 0000
"Die Sonne scheint hell, und die Vögel zwitschern fröhlich. Ein leichter Wind weht durch die Bäume, und die Blätter rascheln leise. Es ist ein wunderschöner Tag, um draußen zu sein."
Address 01: Engine Control Module (J623-CAYC)
Label file: DRV\03L-906-023-CAY.clb
Part number SW: 03L 906 023 AB
Part number HW: 03L 906 023 GG
Part: R4 1.6L TDI H23 9979
Revision: --H23--- Serial Number:
Encoding: 00114014030400080000
Operating number: WSC 99999 1023 2097151
ASAM Dataset: EV_ECM16TDI02103L906023AB 003013
ROD: EV_ECM16TDI02103L906023DB.rod
VCID: E680F07519FBAE71F3-80B2

"One error found:"
9840 - Fuel injector, cylinder 4 (N33)
P0204 00 [175] - Electrical circuit fault.
Warning light ON - confirmed - checked since last reset.
Environmental conditions:
Error status: 00000001
Error priority: 2
Error frequency: 1.
Mileage: 152,408 km
Date: 2017.06.14
Time: 16:04:40

Motor speed: 2731.25 RPM.
Normalized load value: 6.7%
Vehicle speed: 73 km/h
Coolant temperature: 89 °C.
Intake air temperature: 40 °C
Atmospheric pressure: 980 millibars.
Voltage at terminal 30: 13.892 V.
Lost learning counter via OBD: 40.
Error information regarding the selected piezo power level: LF_STATE_PPS_SPI[0]: 0.
Fuel injector 3: Capacitance - CAPA_INJ_MAIN[2]: 29.1330 µF
Main injection voltage for cylinder 3: 1488.0 µAs.
Measured energy of the main injection, cylinder 3: 37.995 mJ.
Supply voltage for analog output 1-VCC_1: 5.00 V.
Supply voltage of analog output 2-VCC_2: 4.97 V.
Fuel injector 3: Voltage - V_INJ_MAIN[2]: 51.07 V

Readiness: 1 1 0 0 0

Then I moved the cables from cylinder 4 to cylinder 3, and from cylinder 3 to cylinder 4.

New error.

9839 - Injector valve, cylinder 3 (N32)
P0203 00 [101] - Electrical fault in the circuit.
unconfirmed - checked since last deletion.
Environmental conditions:
Error status: 00000001
Error priority: 2
Error frequency: 1.
Mileage: 152,431 km
Date: 2017.06.14
Time: 18:32:29

Motor speed: 865.50 rpm.
Normalized load value: 23.5%
Vehicle speed: 0 km/h
Coolant temperature: 76 °C
Intake air temperature: 41 °C
Atmospheric pressure: 980 millibars.
Voltage at terminal 30: 12.085 V.
Lost learning counter via OBD: 40.
Error information regarding the selected piezo power level: LF_STATE_PPS_SPI[0]: 0.
Fuel injector 2: Capacitance - CAPA_INJ_MAIN[1]: 32.1019 µF
Main injection voltage for cylinder 2: 1470.9 µAs.
Measured energy of the main injection, cylinder 2: EGY_INJ_MAIN[1]: 3.183 mJ.
Supply voltage for analog output 1-VCC_1: 5.00 V.
Supply voltage of analog output 2-VCC_2: 4.96 V.
Fuel injector 2: Voltage - V_INJ_MAIN[1]: 4.34 V.

Also muss der Injektor Zyl. 4 einen Defekt haben. Steuergerät glaubt ja jetzt, dass der 4. der 3. It is a cylinder.

"Today, I installed a used injector with the same part number. The injector was previously replaced by VW due to issues with the glow plugs, but it was working."

No more errors saved, but it's still running on 3 cylinders.

MWB (Mean Well-to-Well) of injection quantity deviation, with a range of 0.8 to a maximum of 1.5.

DE00365-ENG99400 Fuel injection quantity deviation, cylinder 1 - FAC_CYL_BAL1, 0.8531 mg/stroke.
IDE00366-ENG101187 Fuel injection quantity deviation, cylinder 2 - FAC_CYL_BAL2, -1.1388 mg/stroke.
IDE00367-ENG101684 Fuel injection quantity deviation, cylinder 3 - FAC_CYL_BAL3, -0.9772 mg/stroke.
IDE00368-ENG103465 Fuel injection quantity deviation, cylinder 4 - FAC_CYL_BAL4, 0.8879 mg/stroke.

Then, I checked the compression using a standard compression tester. All cylinders showed readings around 289 PSI when starting the engine, which indicates that the compression is within the acceptable range. However, I'm not entirely sure how much I can rely on this reading, as I don't have any specialized mechanical tools for a more precise measurement.
Then, I connected the oscilloscope (unfortunately, not a digital one) and got this result for all the cylinders. In my opinion, this should also be correct.

I vaguely remember that the new injectors "come pre-filled." Could it be that the used injector no longer has this "diesel cushion" and that it's not working properly because of it?
I can only measure the return flow, but I would need to build some adapters for that.

Hi,

I suspect that the injector in question is simply electrically faulty. Even if it was stored "dry," the pressure in the rail would have long since forced its way through.

Best regards, Rainer.

Then it should register an error again. With the defective original parts, the light would immediately come on after being turned off, and the engine would start.

I still have 3 more, and I'm going to try those as well.

Hi,

I've read your post again (carefully). So, I think we can agree that the replaced injector is electrically defective.
I thought your used injector (in cylinder 4) would give the same error message... so the used injector isn't throwing any errors, it's being controlled like the other three cylinders according to the oscilloscope, and yet the engine is still running on three cylinders even though the idle speed control shows 0.8879 mg/stroke?

How did you arrive at the statement "running on 3 cylinders," is that only when idling or generally while driving?

How does the car perform above the idle speed, with full power available or not?

Best regards, Rainer.

The new used car no longer has any issues.
The engine shakes violently when idling, and when driving, it lacks power and runs roughly, like it's only running on three cylinders.
When accelerating, I also hear an unpleasant knocking sound. It's not the knocking that's common in many 1.6-liter engines.

"What I also don't quite understand is that, with a faulty injector on cylinder 4 (initial condition), I had these diagnostic trouble codes:"

IDE00439-ENG102776 Injector valve 3: Capacity - CAPA_INJ_MAIN[2] 0.0000 µF
IDE00440-ENG104221 Injector valve 4: Capacity - CAPA_INJ_MAIN[3] 6.9744 µF
IDE03894-ENG104143: Injector valve 2: Voltage - V_INJ_MAIN[1] 112.93 V
IDE03895-ENG101536: Injector valve 3: Voltage - V_INJ_MAIN[2] 0.00 V
IDE05636-ENG103475 Voltage charge of the main injection, cylinder 3: CHR_INJ_MAIN[2] 0.0 µAs
IDE05637-ENG101402 Voltage charge of the main injection, cylinder 4: CHR_INJ_MAIN[3] 770.8 µAs
IDE05648-ENG103761 Measured energy of the main injection, cylinder 3: EGY_INJ_MAIN[2] = 0.000 mJ.
IDE05649-ENG100583 Measured energy of the main injection, cylinder 4: EGY_INJ_MAIN[3] = 42.589 mJ.

Why do I always get no readings from injector 3?

With new used items:

IDE00439-ENG102776: Injector valve 3: Capacitance - CAPA_INJ_MAIN[2] 5.9687 µF.
IDE00440-ENG104221 Injector valve 4: Capacity - CAPA_INJ_MAIN[3] 5.6606 µF
IDE03895-ENG101536: Injector valve 3: Voltage - V_INJ_MAIN[2] 121.64 V
IDE03896-ENG102925: Injector valve 4: Voltage - V_INJ_MAIN[3] 123.34 V
IDE05636-ENG103475 Voltage charge of the main injection, cylinder 3: CHR_INJ_MAIN[2] = 724.1 µAs
IDE05637-ENG101402 Voltage charge of the main injection, cylinder 4 - CHR_INJ_MAIN[3] 705.1 µAs
IDE05648-ENG103761 Measured energy of the main injection, cylinder 3: EGY_INJ_MAIN[2] = 44.041 mJ.
IDE05649-ENG100583 Measured energy of the main injection, cylinder 4: EGY_INJ_MAIN[3] = 43.579 mJ.

Quote:

What I also don't quite understand is that, with a defective injector on cylinder 4 (initial state), I had these diagnostic trouble codes: IDE00439-ENG102776 Injector valve 3: Capacitance - CAPA_INJ_MAIN[2] 0.0000 µF IDE00440-ENG104221 Injector valve 4: Capacity - CAPA_INJ_MAIN[3] 6.9744 µF IDE03894-ENG104143 Injector valve 2: Voltage - V_INJ_MAIN[1] 112.93 V IDE03895-ENG101536 Injector valve 3: Voltage - V_INJ_MAIN[2] 0.00 V

Error in the cylinder designations, either in the engine control unit or during the diagnostic process? Frankly, I have no idea.
Has the vehicle received the emissions update yet? If so, the software version of the engine control unit should be reasonably up-to-date.

No juice, uneven rotation, and a nozzle with a used injector:
Have you already compared the injection timing of the injectors with each other?
It would be helpful to have values for injector control pressures and switching times from functioning 1.6 TDIs.

Best regards, Rainer.

Do the correction values need to be adjusted after replacing the injectors?
Or has this already been done, but it wasn't mentioned in the text?

I haven't checked the switching time variations yet, but I will do so tomorrow.
According to the software version, he should have already received the update.

Correction factors were adjusted, of course, but I don't think that would have such a significant impact.

I took another look, and I couldn't find any calibration values or switching time deviations in the datasheets.

I've now, despite the risk of damaging the engine control unit, disconnected the injectors while the engine is running, and it's running on 4 cylinders. The RPM difference between all the cylinders is almost the same.
It will continue to run on 3 cylinders until the error memory is cleared or the ignition system is replaced.
Despite that, I still hear/feel the typical "running on 3 cylinders" sound/feeling while driving.

Hi,

Quote:

Then I plugged the cables from cylinder 4 to cylinder 3, and from cylinder 3 to cylinder 4.

The CAYC is a CR (Common Rail) engine, right? By swapping the cables, you'll achieve a firing order of 1-3-4-2, which will result in an injection timing that is shifted by 180 degrees for cylinders #3 and #4.
Ich würde testweise den Injektor durchwechseln, aber nicht den (Steuer-)Anschluß. HDo you have LLR values?
hg
Herbert.

I was just trying to figure out if the problem was with an injector or a wiring issue. That's why I swapped the connectors.

I've now installed a different injector on cylinder 4, and no error codes are being stored anymore.

Are you referring to LLR as the fuel injection quantity deviation? I posted about it in my first post.

I've now made some adjustments for small quantities, and the engine is running normally at idle, except for the rattling sound from the dual-mass flywheel (DMF). When accelerating up to about 1800 RPM, it feels a bit rougher than I'm used to with these engines; it might be related to the DMF.