Adblue DPF Injector Crystallization

e909 · May 16, 2016

I noticed there is some crystallization around the adblue injector into the DPF on my 2.0 MK7 TDI. I was wondering if this is anything to be concerned of or if anyone else is having this happen?
picture at: http://i.imgur.com/hgB38Kx.jpg

WildChild · May 16, 2016

This isn't normal. I had mine replaced late last year. Be sure to have the dealer replace the injector. Mine replaced the feed line first because his TSB mentioned that even though the leak was clearly coming from the injector...

Matt927 · May 19, 2016

Not normal but it has been noted several times here. Off to the dealer you go.

ZippyNH · May 19, 2016

Not normal ....
Pretty bad actually...It means you are leaking...
Def is urea in a super saturated demineralized water solution...a tiny bit of evaporation can cause a mess...
That's why once a container of def is opened. The unused amount should be discarded...and the empty container NOT reused or stored.....a few crystals can cause a mess to start growing in the tank too...
I know many folks like to do diy refills using used Vw bottles...and they must be 100% clean....

meerschm · May 19, 2016

I do not think the DEF is a supersaturated solution. (where is that princess bride quote?)

the concentration is specified to keep the concentration of liquid the same as that frozen. (so the concentration does not change when temps are below 11 f and some of the stuff gets solid or slushy in the tank)

but your caution against leaving open containers is still a good one.

my bet is that the leak is of the normal solution, which evaporates after leaking in the original photo

do not think this leak would alter the % in the system, but should be repaired by the dealer while under warranty.

andyrooski17 · May 19, 2016

I'll leave this here:
http://forums.tdiclub.com/showthread.php?t=428991&referrerid=425269

Warranty Fix, but shouldn't blow the car up immediately.

ZippyNH · May 19, 2016

andyrooski17 said:
I'll leave this here:
http://forums.tdiclub.com/showthread.php?t=428991&referrerid=425269

Warranty Fix, but shouldn't blow the car up immediately.

Yup...just be aware that you might get a "low def" warning if it has been going on for a bit...
So if your appointment is not in the next 1500 miles or so, you might need to add a bit if you get the warning for low def...
But judging by how deserted the dealer was when I got my 20,000 mile service done, no appointment , in about 2 hours, I think you could get it done when you have an afternoon/morning....

e909 · May 21, 2016

Sorry for posting a known issue - didn't see the other threads documenting it . Thanks for the help though!

As an update, the dealer replaced the supply hose but not the injector. I'll see if that fixes it long term. They also applied an emissions update 2309? which thankfully has not impacted mileage.

Matt927 · May 23, 2016

Most say replacing the supply line will not fix the issue, let us know if the leak continues.

e909 · May 23, 2016

Matt927 said:
Most say replacing the supply line will not fix the issue, let us know if the leak continues.

There is more crystallization again since the supply hose was replaced.

Part of me wants to believe it's just residue from replacing the supply hose, but it seems to be growing.

What is the best way to clean the stuff off?

I'm going to try to clean it very thoroughly and see how much comes back.

JBell · May 23, 2016

Correct me if I'm wrong here. Crystallization is a result from exposure to air. How is this going to stop? Urea is very water soluble. Any luck using water to remove the deposits?

Matt927 · May 23, 2016

If any amount is leaking you need to go back and have them change the injector.

e909 · May 23, 2016

Philth said:
Correct me if I'm wrong here. Crystallization is a result from exposure to air. How is this going to stop? Urea is very water soluble. Any luck using water to remove the deposits?

I took a small water spray bottle and toothpick and it broke right off. Wiped the area clean and will drive another day or two and see if the buildup occurs again.

I suspect it will, and hopefully replacing the injector will fix the issue.

ZippyNH · May 24, 2016

Let it grow....to prove to the dealer it is still an issue.
Call the dealer....let them oder parts if they need too..make the appointment...
Just cleaning it is like hiding it.... don't do it...
The bigger the mess, the less issue you will have getting the proper fix.
The mess proves that the injector is leaking liquid , which is then drying...making the crystals...

andyrooski17 · May 24, 2016

e909 said:
I took a small water spray bottle and toothpick and it broke right off. Wiped the area clean and will drive another day or two and see if the buildup occurs again.
I suspect it will, and hopefully replacing the injector will fix the issue.

Yeah, if you haven't already, take a clean photo and then a photo later if/when it grows back.

When I had mine replaced they had to get the whole assembly from Germany, which took some time, so perhaps this is why they were hoping just the hose would fix it.

evolDiesel · May 28, 2016

This happened on my wife's BMW X5d. It was a leaky cap - local dealer just replaced the cap. No problems since.

Sent from my SM-G928V using Tapatalk

mr pepper · Mar 18, 2017

Experiencing the same with my 2.0L MK7 TDI at 39,200 miles.

Earlier this week my Check Engine Light and AdBlue refill warning light (600 mi) came on. Checked under the hood and found the crystallization buildup(pic below). Ran my OBDII Reader which displayed a P20E8 error code - "Reductant Pressure too Low."

Odometer is at 39,200 so about 3K Miles out of warranty. Took into dealer and they diagnosed as a crack in dpf seal. Parts are coming in Monday. They say they should have no problem getting this covered since I'm so close to warranty expiration and that they have tech notes of this happening on similar models.

I'll save fighting words for later if they deny coverage. Planning on doing buyback at some point next year, but a pricey fix could move up that date if there are bigger problems and they refuse to cover.

adjat84th · Mar 18, 2017

^These items are included in the new extended warranty that comes with the Phase 1 fix (reflash). Though you're looking to sell back, it should still be covered under the emissions warranty as it's vital to its function.

ejpomeroy · Sep 10, 2017

Injector crystaliztion

Matt927 said:
Most say replacing the supply line will not fix the issue, let us know if the leak continues.

Just had the urea supply line replaced under warranty (there is apparently a bulletin on it on file at VW for this car) - 2015 Passat TDi, did not fix the issue. Now scheduling to go and have the injector unit replaced.

740GLE · Sep 12, 2017

when we bought the '15 Passat it was on the service documentation they replaced the hose to that injector, due to crystallization. No leaking or crystals in the past 6K.

andyrooski17 · Feb 14, 2018

mr pepper said:
Experiencing the same with my 2.0L MK7 TDI at 39,200 miles.

Earlier this week my Check Engine Light and AdBlue refill warning light (600 mi) came on. Checked under the hood and found the crystallization buildup(pic below). Ran my OBDII Reader which displayed a P20E8 error code - "Reductant Pressure too Low."

Odometer is at 39,200 so about 3K Miles out of warranty. Took into dealer and they diagnosed as a crack in dpf seal. Parts are coming in Monday. They say they should have no problem getting this covered since I'm so close to warranty expiration and that they have tech notes of this happening on similar models.

I'll save fighting words for later if they deny coverage. Planning on doing buyback at some point next year, but a pricey fix could move up that date if there are bigger problems and they refuse to cover.

I've already had my DEF injector replaced at less than 10k miles. Up to 65k now, only a couple months from wanting to turn my car in. Just had a low AdBlue warning, as well as check engine light and P20E8 (low reductant pressure) code. I thought the tank just needed to be filled, so I put in 2.5 gallons, then the low AdBlue error went away, but the CEL remained. After driving for a while, the low AdBlue error came back.

I checked under the hood, and found lots of crystallized DEF:
https://dominijanni.files.wordpress.com/2018/02/file-1.jpeg

https://dominijanni.files.wordpress.com/2018/02/file1.jpeg

Going to take it to the dealer tomorrow, hoping for a warranty fix, because I don't want to spend any money on it, being so close to turning selling it back to VW. Also don't want to continue pouring DEF into the tank with such an apparently big leak.

jonferns · Feb 14, 2018

Thats quite a bit of crystallization. I found mine leaking at the same area, though not as bad as that. Had the tech look at it while I was at the dealer getting a key programmed. They ordered the Adblue injector and supply line, and I'll be going in on Saturday for repair. Covered under warranty.

andyrooski17 · Feb 14, 2018

jonferns said:
Thats quite a bit of crystallization. I found mine leaking at the same area, though not as bad as that. Had the tech look at it while I was at the dealer getting a key programmed. They ordered the Adblue injector and supply line, and I'll be going in on Saturday for repair. Covered under warranty.

What mileage? Still around 50k as indicated by your sig?

My original leak was much more tame, see post from late 2014

jonferns · Feb 14, 2018

Yes, just rolled 50k this morning. Here'a what it looks like:

740GLE · Feb 15, 2018

frosty

jonferns · Feb 17, 2018

Went in to get this repaired today. They replaced the Adblue injector. Checked it out when I got home and realized the tech broke the end cap on the supply line and taped it together

On top of that, there was coolant EVERYWHERE. Had to hose it off when I got home. Very sloppy tech at this dealer.

Called the dealer, they're ordering a new adblue supply line and will replace it next week. See what else they can do for me, for the trouble.

740GLE · Feb 20, 2018

how could coolant get everywhere?

jonferns · Feb 20, 2018

740GLE said:
how could coolant get everywhere?

There are two coolant lines that attach to the DEF injector. Tech must have made a mess while disconnecting them i'm assuming.

jonferns · Feb 23, 2018

Back to the dealer today for the repair. Replaced Adblue supply line, 5Q0131984E, about a ~3 hour job.

Lightflyer1 · Feb 24, 2018

Did they find a new clown to do the work?

Adblue DPF Injector Crystallization

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