Fuel Injector Failures on Volkswagen 2.0T TSI

June 3, 2015
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2.0t TSI Bosch Fuel Injector

z fuel inj-

2.0t TSI OEM Fuel Injector

2.0t TSI OEM VW Audi Fuel Injector

 

The TSI engine (like many modern engines) uses direct injection, which places the fuel injector in the cylinder or combustion chamber.  Since this is where the spark and ignition of fuel that drives the engine, the injectors are subject to a pretty harsh environment.  In the picture below we are showing the previous port injection vs direct injection.  While it might sound like it would not make sense to place the injector inside the cylinder due to conditions, it has plenty of positives.  The benefits are fuel efficiency and control, which not only leads to better fuel mileage, but can give the ability to make more power due to the precision of direct injection.

 

direct injection

 

How do I know if I have bad injectors on my VW or Audi 2.0T TSI?

When an injector goes bad on a VW or Audi 2.0T TSI engine you can expect misfires.  This would result in fault codes like P0300, P0301(for cylinder 1), P0302(for cylinder 2) , P0303(for cylinder 3), P0304(for cylinder 4).  You would likely only get misfires on 1 or 2 cylinders, as its unlikely all 4 injectors will fail at the same time.  Generally when these fuel injectors fail they will get stuck open (consistently or sporadically) causing misfire issues. Before assuming you have a fuel injector issue you should confirm you DO NOT have issues with the following problems, Ignition Coils, Spark Plugs (changes every 40-60K) or Carbon build up.  All of the listed failures are more probable to cause misfires.  Once you have verified that not of those items are issues you should look into injectors.  To replace the fuel injectors on the TSI engine you will need to remove the intake manifold which we have a video on How to Remove the 2.0T TSI Intake Manifold(Shown below).

 

Find the Injector for you 2.0T TSI VW or Audi Here 

 

2.0T VW Audi TSI Injector

 

 

Paul Barrett

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53 Comments

on Fuel Injector Failures on Volkswagen 2.0T TSI.
  1. Boris
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    Hi there. I have Audi 2.0 FSI 2006 and there is a petrol smell in the car while cold. The smell comes from engine part. One of mechanics assumed that there is a problem with absorber. I cleaned it (I know that it is not servicable, but there are manuals over the net how to do it). So the smell is still there. The smell is a smell of fresh petrol. So my next consern is an injectors – replacing o-rings. My question is: what else do I need (gaskets or special tools) to fix this. Regards. Boris.

    • Paul Barrett
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      Im sorry but im not sure what you mean when you say absorber

  2. |

    my VW golf has been having misfiring issues and eventually (from the process of elimination) has been diagnosed with probably fuel injector issues. As there are 4 and I have been quoted roughly £250 each but is there a way of telling which one has gone as the mechanic I saw said not?

    • Paul Barrett
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      You would have misfires on the specific cylinder of the bad injector

  3. Madan
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    i have a mk6 gti 2010 150 000 km k04 conversion i am having misfire issues and there is no fault codes! i have changed the PCV valve and the purge valve recently the misfire is low down rev when my intake is taking in air and dumping it….my car between 2 -3000 rmp makes pinging noise ( prrrrrrrrrrrrrrrrr) not sure what the problem is ? we leaning towards fuel injectors . could you pls help with some info on what the problem could be? thanks

    • Paul Barrett
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      Most likely you need injectors but its tough to say for sure.

  4. Adam Roman
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    Hi, your videos are the most informative I have found. Okay, I have a 2013 vw gti with a 2.0 tsi engine with a bad fuel injector on cylinder #3. The car is stock with no modifications and only has 41k miles on it. My dealer claims that this is not considered a power train warranty and wants to stick me 852.00 for the injector and seals for the other 3 injectors. It doesn’t seem right but after exploring your YouTube channel and website I have found the necessary parts for the job but unable to find any videos relating to fuel injector replacement. Is this a common issue with 2.0 tsi engines?

    Thanks,

    Adam

    • Paul Barrett
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      This issue happens sometimes. We do not have a complete start to finish DIY but we do have this video which is a DIY on how to remove the intake manifold. In this we briefly discuss fuel injector seals and this is a great guide to help you replace your 2.0t tsi injectors. https://www.youtube.com/watch?v=c7c35MJq5e0

    • Bryan
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      Hi Adam,

      My VW GLI 2012 2.0 TSI had a failure on #3 also at 42k miles. The dealer is saying that it’s covered on the warranty, but wants to clean the the carbon for $360.00. To me, it seems a bit premature for a cleaning. However, my bigger curioisity is why 40k are we having failures with the fuel injectors regardless of the environment these car parts live in?

      I read a stat that 1 in 6 of 2.0 TSI’s have a failing fuel injector. To me this is BS and the warranty should be more robust.

      I’m curious how did you resolve your issue? Did you do the job yourself?

  5. kris
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    My car yesterday while i was driving started to missfire/stutter and lose power and basically it was slowing down to the point where it had only enough power to roll while stuttering and about to turn off. Is this fuel injector problem ?. It was blowing white and black smoke

    • Paul Barrett
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      Most likely you have a much larger issue. You should have a VW specialist take a look

    • Jeff
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      Yes, that is exactly the issue. I have had the issue twice on my Eos with 2.0 TSI, first time it was injector on #4, now today same issue on #3. THere is an extended warranty out to 120k miles, but they wont replace it under warranty until it goes bad. Terrible policy on VW’s part, as this has been a safety issue for me, and had to have the car towed in to the dealership.

      Class action anyone???

  6. Talal Al Khusaibi
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    Hi,

    My MK7 GTI completely switched off whilst I was driving at 120 Km/h. when tried switching it on again after waiting for 10 minutes, the car vibrated a lot, a really bad smell came from the AC, and the RPM didn’t go above 500. The car didn’t seem to fully start and so I switched it off and called a tow truck.

    When I towed it to the VW workshop, the service manger informed me that one of the injectors is faulty and the fuel pump is leaking, so they just replaced both. Is there anything else I should be worried about? like the status of the intake manifold, or the piston corresponding to that injector?

    Your support is highly appreciated, thanking you in advance.

    Regards,
    Talal Al Khusaibi
    talal.khusaibi@gmail.com

    • Paul Barrett
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      IM sorry thats a new model for us in the US and its still remains to be seen what common issues might happen.

  7. Roland
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    Two months ago my timing chain slipped paid 3200 to get it fixed . They also replaced fuel injector 1. Now I know my 2012 Vw cc 70,000 miles has extended warranty for fuel system covering the injectors. Dealership is not wanting to replace saying it could be anything spark plugs ignition coils. Why when I know number 1 went out and there’s fuel in the number 2 area will they not replace it seems like some scam.

    • Paul Barrett
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      Its not a scam. If everyone replaced something because other components failed it would cost more to do so. Replacing parts because they might fail can get very expensive very fast. I would not recommend that method generally.

  8. Chris
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    Hi, like the 1st comment above I get a fresh fuel smell in the car when cold coming through the aircon. It appears to be leaking fuel out from around the injector where it meets the block. The seals have been changed and it still persists. Have you heard of injectors fracturing or any other reason for a leak like that. Thanks.

  9. reuben
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    this was very helpful to me because i’m to this point. My 2009 cc will crank but not start. the day before it stopped running i could feel a little surging in the car going down the road and the next day i stopped to get gas and the car just will not start. I have spark but no fuel in the cylinders. not sure what to do but pull the injectors. Please any help or suggestions would be helpfull

  10. Lisa Smith
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    Hi, I own a 2013 Audi A4 sport and after having my car recently serviced it started stalling in reverse and blowing smoke the fuel smell was also very strong, I noticed the the centre console surged in and out with power. I have since returned my car to the dealer and have been advised that all four fuel injectors have failed and need to be replaced. My car has done 54,000 km. I am very concerned that it’s not just the injectors that are going to be the problem

    • Paul Barrett
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      I understand your concern but cant offer you much advice. You have to trust experts to diagnose the vehicle properly. If you dont trust that shop you should bring it to one you do. Sorry to hear about your troubles. Hope this helps.

  11. A Cummings
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    My golf mark 6 gti had £1400 of repairs in January injector stuck open intake manifold replaced two weeks ago car broke down another injector failed now i have been told I need a new engine because piston rings have damaged engine car has only done 54,000 miles new engine over £5000 full dealer service history be uk should pay for repairs

    • Paul Barrett
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      Im sorry is this a question? If so please rephrase as Im not sure.

  12. Suntee
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    Hello, I have a 2010 Passat wagon komfort 2.0. 60,000 miles I just bought at 57,000. I got on the 395 highway yesterday and the Ecp light came on then it started smoking then loss power. Pulled it to the side of the road and had it towed. The check engine light also came on and was blinking. The previous owner said it was meticulously maintained. The water pump was also replaced by the current owner.. What could it be?

    • Suntee
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      I also had the 60,000 mile maitanance done at the dealer at 59,800.

    • Paul Barrett
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      Sorry this is not enough info to offer you much advice.

      • Suntee
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        Turned out to be #1 fuel injector. Covered under warranty. They also recommended a carb clean. Thanks!

    • John smith
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      It’s your coils and spark plugs

  13. Steve
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    Hi there, I have GTI mk5 with about 108000km on it. I have just carried out a number of preventative repairs to the car (i.e. Timing belt, rear main seal, latest PCV value, spark plugs and coils, fuel oil air filters, cam follower, thermostat, battery, removed intake manifold to clear all carbon build up) I think that’s it. And in retrospect I wish I’d staged the work and not carried out al at once. The car stared up first turn of the key. But at high revs say above 3k it sounds almost like a diesel!! I rechecked the timing which I found to be correct. Now when I cleaned to inlet manifold I thought I’ll just pull the fuel injectors out as they’re right there. So I cleaned the ends of carbon build up reinstalled. I’m thinking that this noise has something to do with the injectors. Maybe they’re slightly miss firing or something. I’m not get any eng code etc. but I spoke to a local golf mechanic and he asked if I’d changed the seals on the injectors, which I hadn’t. He said maybe I should remove injectors and out new seals on them, which I’m more than happy to do. Basically my question is could this actually make the engine really noisy? Do the seals dry up and let in air or what could be happening?? I know I did a lot to the car all at once but with everything that I did do why would it start to sound literally like a Diesel engine. Do I need new fuel injectors? I think I have lost a little power in the same range as the noise also. Please help as I love my car and only want the best for it. I’m happy to pay for diagnosis but thought maybe you may have come across something like this in your experience with these beautiful cars.
    I really get a lot out of all your information and posts and look forward to hearing from you, maybe this could help other people also.
    Thank you in advance, really appreciate and look forward to any input or suggestions you may have. Hopefully you could help out pretty quick, just so I have some direction.
    Thank you Steve.

  14. Steve
    |

    Does anyone have any comment to the above questions? I went to the trouble of changing seals on fuel injectors, no difference. Then changed fuel injector, still no difference. It still sounds like a diesel. At high revs it’s really noisy. It’s sort of like there’s no lubrication on the top of the engine. Is there engine codes if the oil pump isn’t working properly or at all? I also changed the Diverter valve on the turbo. I can’t see why with any of the changes I have done, would make the car all of a sudden make heaps of noise.
    Any comments or input would be really appreciated.

    • Paul Barrett
      |

      I really advise bringing it to a VW specialist to check out.

  15. Richard
    |

    Hi there. I have a 2009 cc with about 145k on it. I replaced the rear main seal a few months ago and after that I thought I was having some fuel issues so I replaced the hpfp and then the module. I kept getting the p2293 code after changing both components. I hooked my car to vag-com yesterday and all it said was fuel pump intermittent and random misfires. I cleared all the codes and this morning the cel came back on with cylinder 1-3 misfires and random multiple misfires. After reading some of the above comments it’s looking more like an injector than the low pressure pump in the tank. Your thoughts ?

  16. Joe
    |

    What Audi s3 injectors do I need for the tsi engine on my 09 gli for a k04 swap?

  17. Chris Tunstall
    |

    2010 VW CC Turbo started misfiring, stalling in idle, went to replace spark plugs, and then the car wouldn’t start. Replaced battery, tested plugs and coils, seems plugs aren’t getting any fuel? Going in and coming out dry. Anything electrical in general area of ignition coils that could have gone bad or could it have been the fuel injectors instead of the plugs?

  18. carlos
    |

    I have a 09 audi a4 Quattro and I’m getting a
    P 2149 code injectors group b open circuit what does this mean

    • Paul Barrett
      |

      This means there is an electrical issue in the circuit. You will need to track down whats causing is.

      Could be a bad injector, wiring, and ECM a lose connection and more.

  19. alfredo castro
    |

    passat 2006 2.0t I have the problem that my car gasoline leak from the top of the injector 1 and change the seals 4 times and still pulling gas

  20. ashley
    |

    I have a 2012 VW Jetta GLI that started to have a slight barely noticeable misfire. It finally as it got worse threw a code for cylinder 1 missfire. I changed the spark plugs and could packs. Still the miss is progressively getting worse and the CEL is on almost all the time now. Occasionally it blinks also. It also will rub rougher than normal at times and then subside and it’s the as bad at others. Still the only code is for cylinder one misfire. I was told to change the cam shaft position sensor. I haven’t done that yet and after reading this website am beginning to feel more like its a carbon or injection problem. Some mechanic friends told me to run Seafoam through it and see if that helps. Will that fix the problem or should injector one just be replaced? Thank you for your help!!

    • Paul Barrett
      |

      I dont think the Cam sensor is going to help. If its only on cylinder 1 you probably have a bad injector

  21. brock
    |

    I recently purchased a 2012 VW GTI Autobahn DSG from a reputable Porsche dealership. The car was absolutely loaded and had 51k miles and some change on it. It was an absolute dream for about 3 weeks. Then one day the CEL starting blinking, the car started shuddering and shaking and before I could pull over and stop, the CEL went solid and the EPC light came on. Mechanic replaced coils and plugs w/ OEM and NGK plugs $440 but the car has ran like absolute shat since then. Then the other day I popped the hood and noticed a lake of coolant in the bottom of the engine bay and none in the container. Dealer is replacing under PT warranty but informed me that it just had one done back in January, yes 7 months ago. WTF could be the real underlying problem of running thru 2 water pumps in 7 months?? Dealer doesn’t want to deal with it but the car has had zero balls since replacement and RPMs have been shaky at all times after ignition. Couple that with the footwell lighting becoming brighter than normal randomly, the volume going max when trying to turn it down, the MPG sucking now, no power, 2 water pumps being replaced that I know of, and the moonroof spontaneously opening at horrible times, I think I’m up Shhh creek without a paddle. I need any and all advice you can recommend. Please help!!!!

    • Paul Barrett
      |

      You will have to let them diagnose the vehicle. Sounds like you have a few things going on that will need to be diagnosed. If you dont feel comfortable having that shop fix it find a new one.

  22. Nathan H
    |

    Hi, I have a mkv Gti with the tsi engine. Yesterday my car started sounding like a Subaru due to misfire. I believe I have it narrowed down to injector in cylinder #4. Now I am curious if I should be replacing all 4 injectors at the same time or if I should just do the 1. I have 205000 Km’s on my car.

    While checking the codes it first came up as just cylinder 4, but I had to get my car to my shop to be able to check any further then reading codes. After driving around 20 minutes and getting to my shop it said cylinder 2 and 3 were also misfiring. Though only the cylinder #4 plug had raw fuel on the end of it and the other plugs all seemed ok upon inspection.

    Thanks for your time.

    • Paul Barrett
      |

      On a high mileage car if you plan to keep it you should probably consider replacing them all.

  23. Kevin Vagi
    |

    2008 VW GTi BPY
    APR stage 2+
    187000kms
    I think I have an injector(s) issue. In process of diagnosing fuel trim and boost issues, I have replaced the in tank fuel pump, n75, PCV, fuel filter, MAF, and O2 sensor. The HPFP is with the 5 ohm spec, and rest of the fuel system is operating in spec. I still get very high partial fuel trims, which cuts boost from the engine, but I am not seeing my fuel mileage worsen. Does it seem my injector performance is compromised?

  24. David
    |

    Got the latest APR stage 2 tune recently. Coming from the previous stage 2 tune which ran fine 100%. I immediately had misfires in all cylinders and randomly throughout all 4 cylinders. Mostly at idle or stops. Few random ones during acceleration. My R8 red tops are about 20k old as are the plugs. I swapped to a new set of plugs just to check but that didn’t fix anything. Tried a carbon cleaning (55k on engine) and sure it ran smoother but I still get the random misfires. I’m gapped down to .026 now. Before I go any lower, do you guys have any suggestions? I might even go back to stock coils to try and eliminate more before I go with fuel injector troubleshooting.

  25. Murad
    |

    do I have to apply new firmware when replaced my old fuel injectors for new ones? I have Volkswagen CC 2011 2.0 TSI engine: CCTA

    Thank you in advance…

  26. Alain
    |

    Got a Mk5 GTI with AXX engine. Got a code for misfires in cylinder 3. Swapped coil, swapped plugs, misfires stay in cyl 3. Checked compression in all 4 cyl – compression is good and even. Put all 4 new coils and plugs, still having misfire on 3. Should I move on to injector next? Is there any way to physically test the injector? No codes at all for injector circuit.

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