we sent it to be overhauled and they told us it had been resealed anyway it worked fine. i hope you get it fixed

Update: Bought a new fuel return assy to swap in when this intermittent problem pops up.
Then !@#%^!@# broke off the plastic nipple on the fuel return block!!!!! Another $90 down the toilet!
Did the leak down test on all 4 injectors at hot and got pretty much the same rate at idle for all
4 of them (didn't surprise me since it started, the problem is looking at the injectors when it doesn't start).
Replaced #3 injector anyways (since I have 2 new ones) The bottom have was coated in crud. Is this normal.
This injector was suspect only because when I pulled off the return line a lot more fuel came out of this one than the
others. Buttoned up and it started right up, so far so good,,,,,,,,,

Today made a half dozen stops started every time until I stopped in for a burger, was in for about 20 minutes, came out
and no start! With the new injector in there started suspecting the fuel pressure solenoid on the fuel rail. tapped it a few
times with a rubber hammer and it started. So........could be the thermal problem cooled down enough (whether injector or valve)
OR the solenoid was stuck open and got free when tapped with the hammer (or cooled down)???

Other notes: I took a temp readings on the injectors at hot. They were 175-180 when it wouldn't start and when they cooled down
to about 160 deg or less it started. Does anyone know what the cal numbers on the injectors are? I know they program them into the ECU.

72Y28N looks to be the calibration number. I don't know if that is a correction factor for flow or some other variable. If the sticker is still readable, there was originally a sticker on the timing belt cover that had the injector cal numbers for the original injectors.

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Matt B.

05 Limited CRD. Bought it new. 112k on the clock now.

GDE Eco-tune, rear differential drain plug (drilled and tapped the pumpkin), transmission pan drain plug, Fumoto oil valve, fuel filler neck restriction removed, front hitch, Hayden fan clutch, Sears P1 battery since 08, Mobil 1 5w40, 5 volt glow plugs, DIY timing belt at 109k

Talked to Bill at Affordable German Auto Repair in Phoenix (who did a great job on my timing belt), he said that the injectors were most likely the problem and they usually replace the injectors on a VW TDI between 100-150K miles. So at his advice I put in the second new injector I had after doing a hot leakdown test and noting that #1 injector was leaking about 1/3 more than the others at idle including the #3 new injector. So far so good.

Over a month with no problems then Bam! It's back. Same issue: no hot start after sitting for about 20 minutes. Summary of whats been replaced in order: 1) New Fuel Head 2) Crank Sensor 3) Camshaft Sensor 4) Two Injectors. The two injectors seemed to have fixed the problem as a couple of times it acted like it didn't want to start but caught after about 20 seconds of cranking. Going to replace the last two injectors and the Fuel Rail pressure valve. Wish me luck!

Okay bought my last two injectors from BuyAuto for $420 ea OUCH! but that's cheaper than the Stealership!
Runs better than ever, hasn't failed to start (yet). Even changed the bad thermostat that was keeping the temp at 160 instead of 190 (190 was when it really acts up in hot weather). Will keep everyone informed in case the problem crops up again. BTW I bought a fuel control solenoid (back of the fuel pump) just in case. Changed everything else!

One question, does it take a while for the ECU to get used to the new injectors? My first tank was only 18.5 MPG. I was getting 23???


Thanks for all the valuable info on this forum!!!

IIRC you have to "tell" the ECU something in the way of injector codes when you add new ones. Check with GDE.

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Sold to LOST member my 05 Ltd, GDE Stg II turbo + TCM tune, SunCoast TC w. Transgo kit, Steiger window regulators, Samcos, Fumoto valve, 2nd gen filter head with Lub. Spec. bleeder, Hayden clutch & 11 blade fan, inverted spare, P-1 battery, BF Goodrich Long Trail TAs, Etecno1 glow plugs, timing belt at 50K miles/8 yrs

Glad to report that the new set of injectors are running great. No start issues. Talked to GDE about the injector codes and they only make a little difference (2% fuel flow correction) and the ECU must be sent to GDE to be programmed. Apparently it took a tank for the new injectors to tune because the last two tanks have been 25-26 MPG (mostly hwy at 75+mph). Now I can finally look into the GDE eco-tune and see what it can to to increase mileage further.