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Adblue Injector replacement DIY request

18K views 52 replies 9 participants last post by  Dannyboy485  
#1 ·
I'm trying to replace the DEF injector on my 2010 TDI. I have the new part, I know how to remove everything except for the fluid line connecting to the injector. I have cleaned this a few times which gets rid of the (intermittent) CEL and random "450 miles left til car won't start" warning. I'm really hoping that the injector is the problem with this warning randomly coming on every few months and going away on its own. But who knows. The $100-ish part was worth it to me before taking to dealer.

However, I can't get the line off. Am I just being weak? Do you need to really pull on it like you want to break it? That's my fear with pulling too hard, I'd rather not break the line and have an unusable vehicle. It looks as if you pull the two plastic pieces on the clamp together and yank the line out, I just can't get it to budge.

If anyone is familiar with this PLEASE let me know. Otherwise, I'll probably have a shop do it.

See pics.
 

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#40 ·
I only found two vids of resetting Ad Blue on a 2010 TREG and just copied the procedure. I'll dig a little more and/or talk with ROSS-TECH Monday. Possibly start a new thread on here just for AD BLUE reset directions.
Here's the readiness results

Readiness Status: 00000000 00001111 11101011 11100011
MIL Status: MIL OFF
Comprehensive Components: Passed
Fuel System: Passed
Exhaust Gas Recirculation: Failed or Incomplete
Number of EOBD-related DTC(s): 0
 

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#46 ·
That's some really good info, Savage! I did pull the fuse and followed that procedure that went along with it. I did not take a drive. I was planning on cleaning the Adblue injector today but had stuff I had to do. Planning on doing that this week before a drive, just in case. To be clear, the link you sent me is for "engine start not possible" and the
Code:
Drive for 30km and 30min, maintain minimum 30 sec. at 3000 rpm in 4th-5th gear
should be done instead of the link? Just trying to make sure I follow to the T. I don't have a lot of chances. I'm guessing just over 100 miles. So i need to drive 30km(18.6 miles) and 30 minutes. You say minimum 30 seconds at 3000 rpm. So should I stay at 3k rpm all of the drive or higher/lower, fluctuate? Maybe overthinking it and it's simple? If I drive abt 50mph that would get me 25 miles in the 30 minutes. Is there a procedure you could send or just do this? Where did you find the Engine Start not Possible procedure? So this sounds like if I hit the end of the countdown I can start and do the procedure with my VCDS and drive? How many times?
Man, if this thing didn't pull our 24' camper all through the Rockies better than anything else I pulled with and handle beautifully I'm not sure it'd be worth it! It's my wifes car that I kinda fell in love with.
 
#47 ·
I'm not following.
The scan that you've shown, shows an OLD code.
You didn't show or mention the current odo reading (or you didn't post complete scan results) so I can't tell.
Judging by the FF data, it's old.
Have you driven it since you did the "reset"?
Based on what you've said in post #38, everything worked.... it's just your warning hasn't gone away.... which is why I'm saying go drive those 50mi on cruise.

After that, we can work on the code you're showing and the readiness status, IF they are still a thing.
 
#48 ·
I think now it may be sinking in. I initially thought that everything would reset in real time and yesterday after reading your messages I know that's not the case. I will drive the 50 miles on cruise tomorrow or the next day(been super busy) and that should satisfy this
Code:
Drive for 30km and 30min, maintain minimum 30 sec. at 3000 rpm in 4th-5th gear.
and hopefully erase the "Death Count"?
The confusion was from the two different procedures but I think I follow.
This is all new and somewhat foreign as far as troubleshooting vehicles with software etc. Again, I appreciate all the help. I would be lost without it and going 200 miles to the dealer is not an option financially or logistically at this point.
 
#49 ·
I will drive the 50 miles on cruise tomorrow or the next day(been super busy) and that should satisfy this
Code:
Drive for 30km and 30min, maintain minimum 30 sec. at 3000 rpm in 4th-5th gear.
Oh God... please grant me patience!
The 50mi drive on cruise is for getting your countdown reset.
The other, which is NOT a code, will be required to set your readiness.
They are TWO different things.

Clear codes.
Drive 50 miles to reset your countdown.
Scan again.
Post codes if anything new.

After that, worry about readiness.
 
#51 ·
Went on a 50mile drive @ 50MPH after trying to reset Adblue. Didn't reset. I ran another quick scan immediately after. I also pulled the injector off the line to see if it was wet. It didn't appear to be. By running the Injector for Reductant (N474) should it kick on the pump and spit out fluid or just activate the injector? It's pulsing and buzzing but dry.
I want to isolate the problem but I'm not sure if it's kicking on the pump which would possibly point to a clogged line or pump. I see a reductant pump and purge valve but would like to test further before purchasing replacement parts.


Code:
Sunday,03,December,2023,12:59:51:40630
VCDS -- Windows Based VAG/VAS Emulator Running on Windows 10 x64
VCDS Version: 23.11.0.0 (x64) HEX-V2 CB: 0.4643.4
Data version: 20231027 DS351.0
www.Ross-Tech.com


VIN: WVGFK7A93AD003975 License Plate:
Mileage: 162640km-101059mi Repair Order:



--------------------------------------------------------------------------------
--------------------------------------------------------------------------------


Chassis Type: A9 (6N0)
Scan: 01 02 03 05 08 09 0F 15 16 17 19 1C 22 46 56 65 68 6D 6E 76
77

VIN: WVGFK7A93AD003975 Mileage: 162640km-101059miles

01-Engine -- Status: Malfunction 0010
02-Auto Trans -- Status: OK 0000
03-ABS Brakes -- Status: Malfunction 0010
04-Steering Angle -- Status: OK 0000
05-Acc/Start Auth. -- Status: OK 0000
08-Auto HVAC -- Status: OK 0000
09-Cent. Elect. -- Status: OK 0000
0F-Digital Radio -- Status: Malfunction 0010
15-Airbags -- Status: OK 0000
16-Steering wheel -- Status: OK 0000
17-Instruments -- Status: Malfunction 0010
19-CAN Gateway -- Status: Malfunction 0010
1C-Position Sensing -- Status: OK 0000
22-AWD -- Status: OK 0000
42-Door Elect, Driver -- Status: OK 0000
46-Central Conv. -- Status: OK 0000
52-Door Elect, Pass. -- Status: OK 0000
56-Radio -- Status: Malfunction 1010
62-Door, Rear Left -- Status: OK 0000
65-Tire Pressure -- Status: Malfunction 0010
68-Wiper Electr. -- Status: OK 0000
6D-Trunk Elect. -- Status: OK 0000
6E-Ctrl Head Roof -- Status: OK 0000
72-Door, Rear Right -- Status: OK 0000
76-Park Assist -- Status: Malfunction 0010
77-Telephone -- Status: OK 0000
-------------------------------------------------------------------------------
Address 01: Engine (CAT) Labels:. 059-907-401-CAT1.clb
Part No SW: 7L0 907 401 T HW: 7L0 907 401 K
Component: 3.0TDI FSA G000AG 0140
Revision: 33H02--- Serial number: VWX3Z0J2910804
Coding: 0421002A590F0168
Shop #: WSC 30948 003 1048576
VCID: 3C21257FEA724C8A33B-5184
VINID: 9E65D66C74490D1500003247149C877C2E

3 Faults Found:
008250 - Reductant Level Sensor
P203A - 000 - Electrical Malfunction - Intermittent - MIL ON
Freeze Frame:
Fault Status: 10100000
Fault Priority: 2
Fault Frequency: 1
Reset counter: 255
Mileage: 162558 km
Time Indication: 0
Date: 2023.12.01
Time: 23:14:34

Freeze Frame:
RPM: 0 /min
Voltage: 12.39 V
Load: 2.0 %
Temperature: 2.7°C
0.0 bar
Temperature: 15.3°C

008332 - Control Circuit for Reductant Pump 1
P208C - 000 - Short to Ground - Intermittent - MIL ON
Freeze Frame:
Fault Status: 10100000
Fault Priority: 2
Fault Frequency: 1
Reset counter: 255
Mileage: 162558 km
Time Indication: 0
Date: 2023.12.01
Time: 23:14:34

Freeze Frame:
RPM: 0 /min
Voltage: 12.54 V
Load: 2.0 %
Temperature: 2.7°C
0.0 bar
Temperature: 15.3°C

008354 - Purge Valve for Reductant
P20A2 - 000 - Short to GND - Intermittent
Freeze Frame:
Fault Status: 00100000
Fault Priority: 2
Fault Frequency: 1
Reset counter: 255
Mileage: 162558 km
Time Indication: 0
Date: 2023.12.01
Time: 23:15:20

Freeze Frame:
RPM: 0 /min
Voltage: 11.55 V
Load: 2.0 %
Temperature: 2.7°C
0.0 bar
Temperature: 15.3°C

Readiness: 1 2 0 0 1

-------------------------------------------------------------------------------
Address 02: Auto Trans Labels: 09D-927-750.clb
Part No SW: 09D 927 750 LD HW: 09D 927 750 LD
Component: AL 750 6A 3405
Revision: 00H89000 Serial number:
Coding: 0004984
Shop #: WSC 30948 003 1048576
VCID: 7BA3E663AFFC8BB27A1-5160

No fault code found.

-------------------------------------------------------------------------------
Address 03: ABS Brakes Labels: 7L0-907-379-MK25E1.clb
Part No SW: 7L0 907 379 P HW: 7L0 614 517 C
Component: ESP ALLRAD MK25E1 0304
Revision: 00H53001
Coding: 0004354
Shop #: WSC 31414 790 00001
VCID: 46D54797A4EE065A55F-8012

1 Fault Found:
01826 - Sensor for Steering Angle (G85); Supply Voltage Terminal 30
000 - - - Intermittent
Freeze Frame:
Fault Status: 00100000
Fault Priority: 2
Fault Frequency: 4
Reset counter: 226
Mileage: 162558 km
Time Indication: 0
Date: 2023.12.01
Time: 23:11:54

Freeze Frame:
Count: 128
Count: 4865
Count: 294
Count: 1


-------------------------------------------------------------------------------
Address 05: Acc/Start Auth. Labels: None
Part No SW: 7L0 909 135 C HW: 7L0 909 135 C
Component: Kessy 6850
Revision: 00H22072 Serial number: VWX3Z0J2910804
Coding: 0000232
Shop #: WSC 31414 790 00001
VCID: 313F044B3D60B1E290D-8064

Subsystem 1 - Part No: XXXXXXXXXXX
Component: ELV XXXX

No fault code found.

-------------------------------------------------------------------------------
Address 08: Auto HVAC Labels: 7L6-907-040.clb
Part No: 7L6 907 040 AL
Component: CLIMAtronic R/L 4537
Coding: 0023030
Shop #: WSC 31414 790 00001
VCID: 7AADE367A096B2BA617-802E

No fault code found.

-------------------------------------------------------------------------------
Address 09: Cent. Elect. Labels:. 7Lx-937-049-V2.clb
Part No SW: 7L6 937 049 AF HW: 7L6 937 049 AF
Component: J519 2004
Revision: -0004--- Serial number: --------------
Coding: 230002002F00BC000000000000000000
Shop #: WSC 31414 790 00001
VCID: 0059918FC64AE86A2F3-8054

No fault code found.

-------------------------------------------------------------------------------
Address 0F: Digital Radio Labels: None
Part No SW: 8E0 035 593 Q HW: 8E0 035 593 Q
Component: SDAR SIRIUS H08 0160
Revision: 00000000 Serial number: AUZ4Z7M0616558
Coding: 0000000
Shop #: WSC 00000 000 00000
VCID: 372B3A53D3446FD2DE9-8062

2 Faults Found:
02635 - Tuner Not Enabled/Activated
000 - -
Freeze Frame:
Fault Status: 01100000
Fault Priority: 7
Fault Frequency: 1
Reset counter: 226
Mileage: 162558 km
Time Indication: 0
Date: 2023.12.01
Time: 23:12:31

01304 - Radio
004 - No Signal/Communication - Intermittent
Freeze Frame:
Fault Status: 00100100
Fault Priority: 5
Fault Frequency: 1
Reset counter: 11
Mileage: 162558 km
Time Indication: 0
Date: 2023.12.01
Time: 23:14:48


-------------------------------------------------------------------------------
Address 15: Airbags Labels: 7L0-959-655.lbl
Part No SW: 7L0 959 655 A HW: 7L0 959 655 A
Component: J234__0D VW8T 0270
Revision: 92013027 Serial number: 003C6001FBHM
Coding: 0012356
Shop #: WSC 31414 790 00001
VCID: 3B232663EF2C4BB23A1-806E

Subsystem 1 - Part No: 7L0 959 339 E
Component: BF-Gewichtsens. 007 0009

Subsystem 2 - Serial number: 52670

Subsystem 3 - Serial number: 0001.01.000000700000000000Ăż

Subsystem 4 - Serial number: 000000Ăż

No fault code found.

-------------------------------------------------------------------------------
Address 16: Steering wheel Labels: 7L6-953-549.lbl
Part No: 7L6 953 549 F
Component: J527 3601
Coding: 0010011
Shop #: WSC 31414 790 00001
VCID: 42DD5B8788C63A7A797-8016

No fault code found.

-------------------------------------------------------------------------------
Address 17: Instruments Labels: 7L6-920-xxx-7L6.lbl
Part No SW: 7L6 920 972 A HW: 7L6 920 972 A
Component: J285 KOMBI-INST. 9833
Revision: KHH05V46
Coding: 0007201
Shop #: WSC 80093 222 71269
VCID: 372B3A53D3446FD2DE9-8062

1 Fault Found:
01304 - Radio
004 - No Signal/Communication - Intermittent
Freeze Frame:
Fault Status: 00100100
Fault Priority: 6
Fault Frequency: 1
Reset counter: 11
Mileage: 162558 km
Time Indication: 0
Date: 2023.12.01
Time: 23:14:43


-------------------------------------------------------------------------------
Address 19: CAN Gateway Labels:. 6N0-909-901-7L.clb
Part No SW: 6N0 909 901 HW: 7L6 920 972 A
Component: J533 GW-K-CAN TP20 9833
Coding: 57E2F799E1066002
Shop #: WSC 80093 222 71269
VCID: 70B9C14FF6AAF8EADF3-8024

1 Fault Found:
01304 - Radio
004 - No Signal/Communication - Intermittent
Freeze Frame:
Fault Status: 00100100
Fault Priority: 6
Fault Frequency: 1
Reset counter: 11
Mileage: 162558 km
Time Indication: 0
Date: 2023.12.01
Time: 23:14:43


-------------------------------------------------------------------------------
Address 1C: Position Sensing Labels: 7L6-919-879.lbl
Part No SW: 7L6 919 879 B HW: 7L6 919 879 B
Component: Kompass 001 0001
Revision: 00001000 Serial number: 1439802T1F1502
Shop #: WSC 00000 000 00000
VCID: 46D54797A4AE065A55F-8012

No fault code found.

-------------------------------------------------------------------------------
Address 22: AWD Labels: None
Part No: 0AD 927 755 BG
Component: TRANSFERCASE 0126
Shop #: WSC 00000 000 00000
VCID: 015F948BCD10E16220D-5160

No fault code found.

-------------------------------------------------------------------------------
Address 46: Central Conv. Labels: 7L0-959-933.clb
Part No: 7L6 959 933 A
Component: 4M HSG 0601
Coding: 0000085
Shop #: WSC 31414 790 00001
VCID: 40D9518F869A286A6F3-4B1E

Subsystem 1 - Part No: 7L0 959 701 M
Component: Tuersteuergeraet FS 6304

Subsystem 2 - Part No: 7L0 959 702 M
Component: Tuersteuergeraet BF 6304

Subsystem 3 - Part No: 7L0 959 703 C
Component: Tuersteuergeraet HL 0201

Subsystem 4 - Part No: 7L0 959 704 C
Component: Tuersteuergeraet HR 0201

No fault code found.

-------------------------------------------------------------------------------
Address 56: Radio
Cannot be reached

-------------------------------------------------------------------------------
Address 65: Tire Pressure Labels:. 7L6-907-273.lbl
Part No SW: 7L6 907 273 E HW: 7L6 907 273 E
Component: J0502 RDK 0006
Revision: 00004006 Serial number: 00000600013677
Coding: 0040008D8D0000000000000000
Shop #: WSC 31414 790 00001
VCID: 3A2D2367E01672BA217-806E

1 Fault Found:
02214 - Tire Pressure Warning
000 - -
Freeze Frame:
Fault Status: 01100000
Fault Priority: 1
Fault Frequency: 1
Reset counter: 226
Mileage: 162558 km
Time Indication: 0
Date: 2023.12.01
Time: 23:13:16

Freeze Frame:
(no units): 63.0


-------------------------------------------------------------------------------
Address 68: Wiper Electr. Labels: 7L0-955-119-V2.clb
Part No: 7L6 955 119 B
Component: J400__ Front Wiper 5301
Coding: 0001397
Shop #: WSC 31414 790 00001
VCID: 392F3C6BE55079A228D-806C

Subsystem 2 - Part No: 1K0 955 559 AH Labels: 1K0-955-559-AG.CLB
Component: RLS 140210 054 0403
Coding: 00208941
Shop #: WSC 31414

No fault code found.

-------------------------------------------------------------------------------
Address 6D: Trunk Elect. Labels: 7L6-959-107.clb
Part No SW: 7L6 959 107 B HW: 7L6 959 107 B
Component: J605 HECKKLAPPE 1310
Revision: --H05--- Serial number: --------051887
Coding: 0122110
Shop #: WSC 31414 790 00001
VCID: 3A2D2367E01672BA217-806E

No fault code found.

-------------------------------------------------------------------------------
Address 6E: Ctrl Head Roof Labels: None
Part No SW: 7L6 919 044 AD HW: 7L6 919 044 AD
Component: J702 Dachdisplay 0401
Revision: 1030006S Serial number: 00000000153765
Shop #: WSC 00000 000 00000
VCID: 79AFFC6BA5D0B9A268D-802C

No fault code found.

-------------------------------------------------------------------------------
Address 76: Park Assist Labels: Redir Fail!
Part No: 7L0 919 283 F
Component: 0L Einparkhilfe 1108
Shop #: WSC 00000 000 00000
VCID: 392F3C6BE51079A228D-806C

7 Faults Found:
00434 - Left Front Inner Parking Aid Sensor (G332)
009 - Open or Short to Ground
01548 - Sensor for Parking Aid; Rear Right (G206)
009 - Open or Short to Ground
01547 - Sensor for Parking Aid; Rear Mid-Right (G205)
009 - Open or Short to Ground
00437 - Rear Right Inner Parking Aid Sensor (G335)
009 - Open or Short to Ground
00436 - Rear Left Inner Parking Aid Sensor (G334)
009 - Open or Short to Ground
01546 - Sensor for Parking Aid; Rear Mid-Left (G204)
009 - Open or Short to Ground
01545 - Sensor for Parking Aid; Rear Left (G203)
009 - Open or Short to Ground

-------------------------------------------------------------------------------
Address 77: Telephone Labels: 5P0-862-335.lbl
Part No SW: 1Z0 035 729 E HW: 1Z0 035 729 E
Component: FSE_2P8x H40 0190
Revision: 00000000 Serial number: 00000005196094
Coding: 0002077
Shop #: WSC 31414 790 00001
VCID: 3A2D2367E05672BA217-806E

No fault code found.

End----(Elapsed Time: 02:10, VBatt start/end: 12.1V/12.0V. VIgn 12.0V)-----
 

Attachments