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  1. #1
    Veteran Member Four Rings tchuck's Avatar
    Join Date
    Apr 11 2010
    AZ Member #
    57497
    My Garage
    '04 A4 1.8T Avant tip
    Location
    Portland, OR

    Damaged injector harness (resolved)

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    I just wanted to post these pics for posterity in case anyone else experiences these symptoms. Luckily in my case the physical issue was right in front of my face... Anyway, it's been resolved so no troubleshooting needed. ;)

    I was driving through town earlier today and suddenly upon accelerating from a stop light I felt the telltale sign of a toasted coil pack. Rough idle, no power, flashing cel, and the sound of a subaru coming from my engine bay. I've been here before, and not having my laptop handy to read codes, I pulled over to swap some coil packs in a parking lot. After I grabbed a spare from the trunk, I pulled the harness off cyl #1 and started the car again - No change. "That was lucky" I thought to myself as I pulled the faulty pack from its home and installed the spare. I closed the hood, put the pulled pack away, and prepared to go home. Started the car - no change. Now I'm thinking how unlucky I am to have received a doa pack from the dealer last year. No problem, I have two spares.

    After swapping in the second spare and seeing no change I start poking around. Wiggling all the connectors, tracing the wires, checking hoses... That's when I found this:
    .

    .
    The insulation around my #1 injector harness had broken/melted away to the point that the wiring within shorted out. Seeing that the wires were indeed touching, I reinstalled my original coil pack and spread the wires apart being very careful to keep them away from the valve cover. Like this:
    .

    .
    I started the car to test my theory and she fired up perfectly. No rough idle, no subaru sound, no flashing cel. I grabbed some electrical tape and a zip tie from my roadside Macgyver kit, re-insulated the harness, and tied it back away from the likely culprit (valve cover), like this:
    .

    .
    I was going to repair it for real this evening but now it's dark and the wrong car is in the front of my single file driveway. I'll do it in the morning. I did take it out again to grab some groceries with my ghetto fix and all is well.

    Edit: Here are the codes it threw:
    .
    Last edited by tchuck; 05-26-2013 at 09:51 PM.
    ŠTimtronic

  2. #2
    Senior Member Four Rings iHaveBoost?'s Avatar
    Join Date
    Jul 26 2012
    AZ Member #
    97537
    My Garage
    JHM'd B6 S4
    Location
    Waltham, MA

    That's some good side of the road troubleshooting and repairing. But when the car is home you should probably splice/solder in some new wire in place of the stripped/frayed wires. I'd think for safety's sake.

  3. #3
    Veteran Member Four Rings tchuck's Avatar
    Join Date
    Apr 11 2010
    AZ Member #
    57497
    My Garage
    '04 A4 1.8T Avant tip
    Location
    Portland, OR

    Re: Damaged injector harness (resolved)

    Quote Originally Posted by iHaveBoost? View Post
    That's some good side of the road troubleshooting and repairing. But when the car is home you should probably splice/solder in some new wire in place of the stripped/frayed wires. I'd think for safety's sake.
    Thanks. I'm going to repair it properly tomorrow. No intention of rolling with electrical tape on the injector harness long term. ;)
    ŠTimtronic

  4. #4
    Veteran Member Four Rings Charles.waite's Avatar
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    Jun 27 2011
    AZ Member #
    77478
    Location
    Seattle, WA

    Damaged injector harness (resolved)

    What is tdsskiller?
    -CP
    2008 2.0t S-Line Ti 6MT Avant
    2017 Q7 3.0t
    SOLD -- 2012 Q5 2.0t - Stock Mommy Missile with new timing chains
    Former USP CLUB MEMBER #136
    2004 A4 1.8TQ 6MT USP - APR Stage 1+ - FSI Coils - BKR7EIX-11 - B6S4 Front + B7A4 Rear Brakes - 034 Street Trans Mount
    SOLD -- 2006 A4 2.0TQ Avant Tiptronic

  5. #5
    Veteran Member Four Rings evo_ski's Avatar
    Join Date
    Mar 15 2010
    AZ Member #
    56121
    Location
    Bothell

    I got some plastic coiled stuff from orelleys that i used on that exact spot. seems like it would be great insulation/stiffening agent to make that not happen again.

  6. #6
    Veteran Member Four Rings tchuck's Avatar
    Join Date
    Apr 11 2010
    AZ Member #
    57497
    My Garage
    '04 A4 1.8T Avant tip
    Location
    Portland, OR

    Re: Damaged injector harness (resolved)

    Quote Originally Posted by Charles.waite View Post
    What is tdsskiller?
    http://lmgtfy.com/?q=what+is+tdsskiller%3F
    ŠTimtronic

  7. #7
    Veteran Member Four Rings tchuck's Avatar
    Join Date
    Apr 11 2010
    AZ Member #
    57497
    My Garage
    '04 A4 1.8T Avant tip
    Location
    Portland, OR

    Re: Damaged injector harness (resolved)

    Quote Originally Posted by evo_ski View Post
    I got some plastic coiled stuff from orelleys that i used on that exact spot. seems like it would be great insulation/stiffening agent to make that not happen again.
    My inner nerd wants to rebuild that part of the harness with better wire, but I'll probably just end up doing the repair and hoping it doesn't happen again.
    ŠTimtronic

  8. #8
    Veteran Member Four Rings elewsader's Avatar
    Join Date
    Mar 24 2006
    AZ Member #
    11010
    My Garage
    2003 A4 1.8T Avant MTQ, 2001 Audi S4 Sedan
    Location
    Central, IL

    I had the same thing happen a few months back! Mine was on cylinder bank 2; I ended up splicing a wire extension in, and zip tying cables so they didn't move around so much. I was also planning on buying this kit and replicating 034's coilpack harness, but in fuel injector flavor.
    Ed

    why say lot word when few word do trick.

  9. #9
    Veteran Member Four Rings tchuck's Avatar
    Join Date
    Apr 11 2010
    AZ Member #
    57497
    My Garage
    '04 A4 1.8T Avant tip
    Location
    Portland, OR

    Whoa. I just realized I never updated this thread. I did rebuild that section of the harness (from about 3" behind the head) and have been trouble free ever since. I'll get some pics tomorrow if I remember.
    ŠTimtronic

  10. #10
    Veteran Member Four Rings iamshayan's Avatar
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    Jan 13 2010
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    53349
    Location
    Toronto Canada

    shouldn't you have these plastic things on your injectors



    and then the harness should be zip tied to that so it doesn't touch the VC.
    Instagram:iamshayan
    B6 @ 320awhp SOLD
    Bagged D2 SOLD
    B8S4 SOLD
    Photobucket ruined all my posts.

  11. #11
    Veteran Member Four Rings tchuck's Avatar
    Join Date
    Apr 11 2010
    AZ Member #
    57497
    My Garage
    '04 A4 1.8T Avant tip
    Location
    Portland, OR

    Quote Originally Posted by iamshayan View Post
    shouldn't you have these plastic things on your injectors



    and then the harness should be zip tied to that so it doesn't touch the VC.
    Not sure about the spacers - neither of my b6s ever had them. The harness is zip tied away from the vc now though.
    ŠTimtronic

  12. #12
    Veteran Member Four Rings Charles.waite's Avatar
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    Jun 27 2011
    AZ Member #
    77478
    Location
    Seattle, WA

    Quote Originally Posted by tchuck View Post
    Not sure about the spacers - neither of my b6s ever had them. The harness is zip tied away from the vc now though.
    I have those.
    -CP
    2008 2.0t S-Line Ti 6MT Avant
    2017 Q7 3.0t
    SOLD -- 2012 Q5 2.0t - Stock Mommy Missile with new timing chains
    Former USP CLUB MEMBER #136
    2004 A4 1.8TQ 6MT USP - APR Stage 1+ - FSI Coils - BKR7EIX-11 - B6S4 Front + B7A4 Rear Brakes - 034 Street Trans Mount
    SOLD -- 2006 A4 2.0TQ Avant Tiptronic

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