New Injector problem

[silverfox]

I had the usual injector failure problem. Engine cut out and wouldn't restart. Garage diagnosed as injector failure and Seat agreed to replace all four injectors and wiring loom.

However, after replacing the parts and resetting fault codes the car fired up but then started to run with a misfire. Now the computer is logging a fault code P0200 - injector circuit open.

Anybody able to shed any light on this? 6 WEEKS later and still no luck. ECU has been checked out but no faults found. All wiring from ECU to injectors has been tested by two different garages.

If I put the 4 old injectors back in, the car won't start. Four new injectors in result in a misfiring car and the P0200 error.

Please help me someone!

 

[silverfox]

No suggestions from anyone?

P0200 error states "injector circuit malfunction"

If injectors are replaced and wiring loom to injectors is replaced and ECU is tested ok, what's left to test?

 

[benrobbo]

i heard from one of my friends that works at seat that he has had the loom that runs from the ecu to the injectors on rare occasions rubs on the body and shorts the wireing, best way is to check continuety between the loom and the ecu but i dont know what pins to check, so you could start off by looking at the loom carefully and following it back to make sure. if nothing maybe its a faulty injector loom or injector?
sorry not much help

 

[silverfox]

i heard from one of my friends that works at seat that he has had the loom that runs from the ecu to the injectors on rare occasions rubs on the body and shorts the wireing, best way is to check continuety between the loom and the ecu but i dont know what pins to check, so you could start off by looking at the loom carefully and following it back to make sure. if nothing maybe its a faulty injector loom or injector?
sorry not much help

thanks for the response mate,
wiring loom to injectors is brand new, as are all four injectors. Though, that's not to say they couldn't be damaged in transit so worth testing for continuity I guess. Your help is appreciated.

 

[MJ]

the looms not been installed correctly and is open on one of the injectors.

 

[silverfox]

the looms not been installed correctly and is open on one of the injectors.

Thanks (again!) MJ

Just been in to the garage and asked them to check your theory. As it happened, they were half way through removing the rocker cover, so they had a quick check that all connections were sound and they were. I saw them check them myself. Re-tested the continuity through the wiring loom and it appears to be fine. They've also checked continuity on the old wiring loom and that seems fine too so next step is to swap in the old wiring loom to see if we get the same fault.

From what I hear, the car will run, but idles very erratically. However, when they rev the engine to 2k(ish) it sounds ok.

 

[silverfox]

Still got no car. Still chasing tail with the same fault. It's been about 9 weeks now.

Anyone got any ideas what else I can get the garage to try/test. As far as i can see, P0200 error suggests some kind of wiring fault in the injection system - between the ECU and the injectors. But this has been tested time and time again over the last two months and still can't get it to run properly. Every time they fire up the car it smokes really bad and it's starting to block the DPF. Need to get the car running properly soon to be able to carry out a DPF regen.

 

[Marshall]

Could it be that the ecu is faulty giving an injector code but the ecu itself is faulty?
Just an idea if you have checked everything else.

 

[silverfox]

Could it be that the ecu is faulty giving an injector code but the ecu itself is faulty?
Just an idea if you have checked everything else.

Thanks Kev,

ECU has already been sent away for testing and come back with no fault found.

 

[silverfox]

UPDATE.

Garage have done some further testing. They've tried removing the glowplugs and putting a measuring rod down the hole to get an approximate measurement of top of piston cycle. Cylinder 3 appears to be sitting a couple of mm lower than the other three which to them could indicate a bent conrod.

Obviously, i know this a major job to fix but just wondered if there is any definitive way to prove this theory without taking head/sump off. Also, could this fault (lack of compression presumably) result in the error 'P0200 - Injector Circuit Malfunction' If so, it could finally be the breakthrough i've been looking for, albeit an expensive one!!

 

[Dangerous Dave]

UPDATE.

Garage have done some further testing. They've tried removing the glowplugs and putting a measuring rod down the hole to get an approximate measurement of top of piston cycle. Cylinder 3 appears to be sitting a couple of mm lower than the other three which to them could indicate a bent conrod.

Obviously, i know this a major job to fix but just wondered if there is any definitive way to prove this theory without taking head/sump off. Also, could this fault (lack of compression presumably) result in the error 'P0200 - Injector Circuit Malfunction' If so, it could finally be the breakthrough i've been looking for, albeit an expensive one!!

I doubt it as the ECU is reporting an electrical fault, it must be something they replaced as the fault wasn't there before replacing the wiring loom or injectors.

I would get it to anther garage for it to be checked over still sounds like a wiring fault or a faulty replacement injector. If they have followed the fitting instructions incorrectly they could also be checking it incorrectly.

 

[silverfox]

Thanks but this is the second garage I've had check it out. First garage replaced injectors and wiring loom but couldn't get it running properly and kept getting this P0200 error. So i took it to garage number two, who have tested all the wiring from ECU to the injectors numerous times now and everything is perfect. ECU was sent away for testing but came back with no faults. The injectors appear to be working as the car will run but seems to be totally misfuelling - rough idle and smoking like a chimney!

 

[Stealthy]

and compression is OK?

 

[silverfox]

and compression is OK?

Not sure about compression test, think they were gonna test it today.

 

[Marshall]

Well if 1 piston is sitting lower than the rest this would cause low compression causing a misfire and unburnt fuel.
Also the ecu may condemn the injector circuit because it will know that the cylinder is not burning properly, so yeah this may be causing your fault.
Why does it have a bent conrod?
Has it been driven through water? or has the injector seriously overfuelled filling the cylinder of diesel causing it to hydraulic?
Checking the heights through glow plug holes isn't very accurate.
First step before head removal would be a compression test to confirm its low on that cylinder.
One other thing is did it run ok prior to the injector failure?
It's unlikely a conrod has been bent whilst trying to start off the key or idling.

 

[silverfox]

Thanks Kev,
The car was running fine before the injector failure, no big bang when it happened, no big puddles, nothing.
So I don't see why I should have a bent conrod either. I'll see what the result of the compression test is.


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[Marshall]

Any news mate?

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[Flying_stevo]

Hi There

I have a Mk2 leon 2ltr Tdi 140. I have a problem where i seem to get a misfire at between 1250 rpm and 1500 rpm it is quiet noticable as the car sort of jerks, this happens in any gear at those Rpm's. Could this be linked to a faulty Injector or wiring loom??

Any help Would be gratefully received.

Stevo

 

[silverfox]

I doubt this is injectors related. Th (common) injectors problems seems to only affect PD170 engines and in my case was a total sudden failure, as opposed to misfiring etc. Could it be EGR valve related? Someone more knowledgable than me will probably comment soon......

 

[silverfox]

Just realised I never updated this thread at the time but may be useful to someone now.
My injector failure was pretty catastrophic - needed 4 new injectors, new wiring loom and a new ECU! Plus, after multiple garages trying to resolve it and loads of starting/stopping the engine to test fixes, the dreaded DPF got choked and needed replacing too!! All in all, about £5k in garage bills. Fortunately for me, Bannermans Seat in Inverness took on the work and fought my case with Seat Customer services. I ended up with a bill for about £1500 and Seat paid the rest.

Still, dealing with Seat Customer care has put me off ever buying another new Seat. Shocking to say the least.

Nothing but praise for Bannermans Inverness - great to deal with.