Another 3.0 TDI Post. High fuel pressure 480 Bar on tick over and stalling

[dean warren]

Hi All, i have a friends A6 2004 3.0TDI in at the moment, its had various issues but the main one i cannot fix is a constant stalling. i have read the threads on this, many variations there are too!
the car sometimes is fine, it ran for a week with no issues, then it will go to only managing to tick over for 60 seconds before revs start to drop and it stalls.
VCDS did show the fuel pressure rising to 800bar then drops straight to 200Bar then climbs back up over 5 seconds or so. then after a minute as i said tickover can be heard to drop and it stalls with the Glow-plug light flashing. re starts instantly off key. i have added a snapshot after i updated the firmware all faults fixed except for the 17471 ones
31336

i have replaced the fuel filter, i have replaced the pressure switches on the rails i have opened both fuse boxes in the engine bay and there is no sign of water ingress, never the less i cleaned all the relay and contacts with circuit board cleaner. i have swapped the injectors from my 2006 car as i have read one chap had a faulty injector causing pressure issues. and up until yesterday it was still cutting out every 60 seconds even when cold. (doesnt stall when driving only at tickover)
now last night i was checking connectors and unplugging things while it was running, i disconnected the plug on the fuel pump, low and behold it stopped stalling, however went into limp mode and would not rev over 3200 RPM it sat outside running for 30 minutes and did not stall once. so i reconnected the connector, and it hasnt stalled since.
what is this part on the pump? is it pressure? or stop solenoid? (do they still have them?) anyway i have ordered new pins for this connector but im a little concerned as the pressure is still 480Bar and 29% even when warm, my other car is 280 cold "25% and 260 hot 19%
is the pump faulty? or the solenoid on the pump? the car has done almost 180k now if that makes any difference?

[dean warren]

Friday,01,April,2016,16:05:38:33186
VCDS -- Windows Based VAG/VAS Emulator Running on Windows 10 x64
VCDS Version: 15.7.4.1 (x64)
Data version: 20160216
Ross-Tech: Home (www.Ross-Tech.com)


VIN: WAUZZZ4F45N010246 License Plate: JIMBOB
Mileage: 287890km-178886mi Repair Order: after cd



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


Chassis Type: 4F (4F0)
Scan: 01 02 03 05 07 08 09 0E 15 16 17 19 42 46 47 4F 52 53 55 56
61 62 72 76 77

VIN: WAUZZZ4F45N010246 Mileage: 287890km-178886miles

00-Steering Angle Sensor -- Status: OK 0000
01-Engine -- Status: Malfunction 0010
02-Auto Trans -- Status: OK 0000
03-ABS Brakes -- Status: Malfunction 0010
05-Acc/Start Auth. -- Status: OK 0000
07-Control Head -- Status: Malfunction 0010
08-Auto HVAC -- Status: Malfunction 0010
09-Cent. Elect. -- Status: OK 0000
0E-Media Player 1 -- Status: OK 0000
15-Airbags -- Status: OK 0000
16-Steering wheel -- Status: OK 0000
17-Instruments -- Status: OK 0000
19-CAN Gateway -- Status: Malfunction 0010
25-Immobilizer -- Status: OK 0000
42-Door Elect, Driver -- Status: OK 0000
46-Central Conv. -- Status: OK 0000
47-Sound System -- Status: OK 0000
4F-Centr. Electr. II -- Status: OK 0000
52-Door Elect, Pass. -- Status: OK 0000
53-Parking Brake -- Status: OK 0000
55-Headlight Range -- Status: OK 0000
56-Radio -- Status: OK 0000
61-Battery Regul. -- Status: OK 0000
62-Door, Rear Left -- Status: OK 0000
72-Door, Rear Right -- Status: OK 0000
76-Park Assist -- Status: OK 0000
77-Telephone -- Status: OK 0000

-------------------------------------------------------------------------------
Address 01: Engine Labels: 059-907-401-ASB.clb
Part No SW: 4F0 910 401 F HW: 4F0 907 401 A
Component: 3.0L V6TDI G100AG 0030
Revision: --H01--- Serial number:
Coding: 0011772
Shop #: WSC 02335 823 60092
VCID: 1F478BA9CE3C7EC667-804A

5 Faults Found:
18061 - Please check DTC Memory of ABS Controller
P1653 - 002 -
Freeze Frame:
RPM: 0 /min
Torque: 0.0 Nm
Speed: 0.0 km/h
Duty Cycle: 1.0 %
Voltage: 11.93 V
Bin. Bits: 00101100
Torque: 81.9 Nm
Temperature: 67.5°C

17953 - Throttle Valve Controller
P1545 - 002 - Malfunction
Freeze Frame:
RPM: 0 /min
Torque: 0.0 Nm
Speed: 0.0 km/h
Voltage: 11.93 V
Duty Cycle: 92.7 %
Bin. Bits: 010
Mass Air / Rev.: 0.0 mg/str
Voltage: 0.000 V

17471 - Fuel Pressure Regulation
P1063 - 001 - Control Range Not Reached
Freeze Frame:
RPM: 756 /min
Torque: 46.8 Nm
Speed: 0.0 km/h
Duty Cycle: 1.0 %
Voltage: 13.91 V
Pressure: 262.7 bar
Duty Cycle: 27.2 %
Temperature: 31.5°C

17471 - Fuel Pressure Regulation
P1063 - 002 - Control Range Not Reached
Freeze Frame:
RPM: 756 /min
Torque: 46.8 Nm
Speed: 0.0 km/h
Duty Cycle: 1.0 %
Voltage: 13.91 V
Pressure: 262.7 bar
Duty Cycle: 27.2 %
Temperature: 31.5°C

17471 - Fuel Pressure Regulation
P1063 - 005 - Control Range Not Reached - MIL ON
Freeze Frame:
RPM: 756 /min
Torque: 46.8 Nm
Speed: 0.0 km/h
Duty Cycle: 1.0 %
Voltage: 13.91 V
Pressure: 262.7 bar
Duty Cycle: 27.2 %
Temperature: 31.5°C

Readiness: 1 1 0 0 0

-------------------------------------------------------------------------------
Address 02: Auto Trans Labels: 09L-927-760.lbl
Part No SW: 4F0 910 156 H HW: 09L 927 156
Component: AG6 09L 3.0lTDI RdW 0080
Revision: 00000001 Serial number: 0018796
Coding: 0000001
Shop #: WSC 00539 210 17457
VCID: 285590759B72B97E16-807C

No fault code found.

-------------------------------------------------------------------------------
Address 03: ABS Brakes Labels: 4F0-910-517.lbl
Part No SW: 4F0 910 517 A HW: 4F0 614 517 A
Component: ESP8 quattro H03 0330
Revision: 00000000 Serial number: 00000000000000
Coding: 0004488
Shop #: WSC 02335 785 00200
VCID: 2241825DFD4E532E48-8076

1 Fault Found:
00778 - Steering Angle Sensor (G85)
008 - Implausible Signal
Freeze Frame:
Fault Status: 01101000
Fault Priority: 2
Fault Frequency: 1
Reset counter: 26
Mileage: 287890 km
Time Indication: 0
Date: 2016.04.01
Time: 15:10:27

Freeze Frame:
Hex Value: 0x0280
Hex Value: 0x40A2
Hex Value: 0x0000
Hex Value: 0x0096
Hex Value: 0x00FF


-------------------------------------------------------------------------------
Address 05: Acc/Start Auth. Labels: 4F0-910-852.clb
Part No SW: 4F0 910 852 HW: 4F0 905 852 B
Component: FBSAUDIC6 ELV H30 0220
Revision: 31050601 Serial number: 10600300021983
Coding: 0000019
Shop #: WSC 00586 210 91538
VCID: 63CFC759A2D41A2603-8036

Subsystem 1 - Part No: 4F0 910 131 E
Component: FBSAUDIC6 EZS H43 0060

Subsystem 2 - Part No: 4F0 910 220 D
Component: FBSAUDIC6 IDG H35 0020

No fault code found.

-------------------------------------------------------------------------------
Address 07: Control Head Labels: 4F0-910-7xx-07-H.lbl
Part No SW: 4F1 910 732 D HW: 4E0 035 729
Component: Interfacebox H43 5570
Revision: 00000000 Serial number: 350EO047512758
Coding: 0000002
Shop #: WSC 02335 785 00200
VCID: 254B9941EC60A4162D-8070

Subsystem 1 - Part No: 4F0 910 609
Component: Bedienteil MMIC6H03 0870

Subsystem 2 - Serial number: 00000000009345

Subsystem 3 - Serial number: 0126.04.040000000100010095ÿ

Subsystem 4 - Serial number: 010095ÿ

1 Fault Found:
00003 - Control Module
005 - No or Incorrect Basic Setting / Adaptation
Freeze Frame:
Fault Status: 01100101
Fault Priority: 5
Fault Frequency: 1
Reset counter: 26
Mileage: 287890 km
Time Indication: 0
Date: 2016.04.01
Time: 15:10:27


-------------------------------------------------------------------------------
Address 08: Auto HVAC Labels: 4F0-910-043.clb
Part No SW: 4F0 910 043 HW: 4F2 820 043 C
Component: KLIMABETAETIGUNGH11 0060
Revision: 00000021 Serial number: 00000000018241
Coding: 0001046
Shop #: WSC 02335 785 00200
VCID: 5BBFFFB99AA422E64B-800E

1 Fault Found:
00256 - A/C Pressure/Temperature Sensor (G395)
002 - Lower Limit Exceeded
Freeze Frame:
Fault Status: 01100010
Fault Priority: 3
Fault Frequency: 1
Reset counter: 26
Mileage: 287890 km
Time Indication: 0
Date: 2016.04.01
Time: 15:10:32


-------------------------------------------------------------------------------
Address 09: Cent. Elect. Labels: 4F0-910-279.lbl
Part No SW: 4F0 910 279 HW: 4F0 907 279
Component: ILM Fahrer H14 0080
Revision: 00000000 Serial number: 4F0907279
Coding: 0003121
Shop #: WSC 02335 785 00200
VCID: 66C9DE4D51E66F0EE4-8032

Subsystem 1 - Part No: 4F2 910 113 Labels: 1KX-955-119.CLB
Component: Wischer AudiC6 H04 0150
Coding: 00062736
Shop #: WSC 02335

Subsystem 2 - Part No: 4E0 910 557 Labels: 8K0-955-559.CLB
Component: REGENLICHTSENSORH10 0040
Coding: 00141886
Shop #: WSC 02335

No fault code found.

-------------------------------------------------------------------------------
Address 0E: Media Player 1 Labels: 4E0-910-111.lbl
Part No SW: 4E0 910 111 F HW: 4E0 035 111
Component: CD-Changer H43 0470
Revision: 00000000 Serial number: AUZ5ZBD4000388
Shop #: WSC 00000 000 00000
VCID: 1C3DBCA5DF2A65DE82-8048

No fault code found.

-------------------------------------------------------------------------------
Address 15: Airbags Labels: 4F0-910-655-8R.lbl
Part No SW: 4F0 910 655 G HW: 4F0 959 655
Component: 20 AIRBAG AUDI8RH24 0110
Revision: 07H24000 Serial number: 00358D05BE8O
Coding: 0012848
Shop #: WSC 00539 210 17457
VCID: 2B5F6F798A849266FB-807E

Subsystem 1 - Serial number: 6332CSME02420C2D$

Subsystem 2 - Serial number: 6342CSME0261652C$

Subsystem 3 - Serial number: 6351HSME0230436B$

Subsystem 4 - Serial number: 6361HSME020C0354.

Subsystem 5 - Serial number: 6371VSME014801759

Subsystem 6 - Serial number: 6381VSME024C0075E

No fault code found.

-------------------------------------------------------------------------------
Address 16: Steering wheel Labels: 4F0-910-549.lbl
Part No SW: 4F0 910 549 HW: 4F0 953 549 A
Component: Lenksäulenmodul H06 0130
Revision: 00H06000 Serial number: 90025041200048
Coding: 0102141
Shop #: WSC 02335 785 00200
VCID: 66C9DE4D51E66F0EE4-8032

Subsystem 1 - Part No: XXXXXXXXXXX
Component: Lenkradmodul H04 0080

No fault code found.

-------------------------------------------------------------------------------
Address 17: Instruments Labels: 4F0-910-xxx-17.lbl
Part No SW: 4F0 910 900 A HW: 4F0 920 950 H
Component: KOMBIINSTR. M73 H07 0630
Revision: 00600000 Serial number: 49F36Y554
Coding: 0065443
Shop #: WSC 00428 067 57207
VCID: 1E39B6ADC93677CE6C-804A

No fault code found.

-------------------------------------------------------------------------------
Address 17: Instruments Labels: 4F0-910-xxx-17.lbl
Part No SW: 4F0 910 900 A HW: 4F0 920 950 H
Component: KOMBIINSTR. M73 H07 0630
Revision: 00600000 Serial number: 49F36Y554
Coding: 0065443
Shop #: WSC 00428 067 57207
VCID: 1E39B6ADC93677CE6C-804A

No fault code found.

-------------------------------------------------------------------------------
Address 19: CAN Gateway Labels: 4F0-910-468.clb
Part No SW: 4F0 910 468 A HW: 4F0 907 468 B
Component: Gateway H09 0030
Revision: 09 Serial number: 0800804424025B
Coding: ECFE73C41B1104
Shop #: WSC 02335 785 00200
VCID: 27579349966CB6061F-8072

1 Fault Found:
00470 - Company Comfort Databus in Single Wire
011 - Open Circuit
Freeze Frame:
Fault Status: 01101011
Fault Priority: 3
Fault Frequency: 1
Reset counter: 26
Mileage: 287890 km
Time Indication: 0
Date: 2016.04.01
Time: 15:10:29


-------------------------------------------------------------------------------
Address 42: Door Elect, Driver Labels: 4F0-910-793-42.lbl
Part No SW: 4F0 910 793 B HW: 4F0 959 793 B
Component: TSG FA H10 0020
Revision: 00000000 Serial number: 72
Coding: 0000538
Shop #: WSC 02335 785 00200
VCID: 295395718078807609-807C

No fault code found.

-------------------------------------------------------------------------------
Address 46: Central Conv. Labels: 4F0-910-289.lbl
Part No SW: 4F0 910 289 E HW: 4F0 907 289 E
Component: Komfortgeraet H14 0090
Revision: 00900014 Serial number: 01000177750000
Coding: 0131571
Shop #: WSC 02335 785 00200
VCID: 2C5D6C658F8A955EF2-8078

Subsystem 1 - Part No: 1K0 951 605 A
Component: LIN BACKUP HORN H01 1201

Subsystem 2 - Part No: 4F0 910 177
Component: Innenraumueberw.H01 0010

No fault code found.

-------------------------------------------------------------------------------
Address 47: Sound System Labels: 4F0-910-223-AS.lbl
Part No SW: 4F0 910 223 G HW: 4F0 035 223
Component: Amp.-ASK H09 0350
Revision: 11S00001 Serial number: 00705040010258
Coding: 0000001
Shop #: WSC 02335 785 00200
VCID: 2241825DFD4E532E48-8076

No fault code found.

-------------------------------------------------------------------------------
Address 4F: Centr. Electr. II Labels: 4F0-910-280.lbl
Part No SW: 4F0 910 280 HW: 4F0 907 280 A
Component: ILM Beifahrer H07 0040
Revision: Serial number: 00000000007571
Coding: 0001103
Shop #: WSC 02335 785 00200
VCID: 5EB9F6AD89B637CE2C-800A

No fault code found.

-------------------------------------------------------------------------------
Address 52: Door Elect, Pass. Labels: 4F0-910-793-52.lbl
Part No SW: 4F0 910 793 B HW: 4F0 959 792 B
Component: TSG BF H10 0020
Revision: 00000000 Serial number: x‘
Coding: 0000538
Shop #: WSC 02335 785 00200
VCID: 295395718078807609-807C

No fault code found.

-------------------------------------------------------------------------------
Address 53: Parking Brake Labels: 4F0-910-801.clb
Part No SW: 4F0 910 801 HW: 4F0 907 801
Component: EPB C63C0030 H03 0030
Revision: C63C0030
Coding: 0000321
Shop #: WSC 00539 210 17457
VCID: 5DBBF1A184B02CD635-8008

No fault code found.

-------------------------------------------------------------------------------
Address 55: Headlight Range Labels: 4F0-910-357.lbl
Part No SW: 4F0 910 357 A HW: 4F0 907 357 A
Component: AFS 1 H03 0010
Revision: 00000001 Serial number:
Coding: 0000016
Shop #: WSC 02327 785 00200
VCID: 244D8445E75A5D1E3A-8070

Subsystem 1 - Part No: 4F0 941 329
Component: AFS-Modul links H05 0010

Subsystem 2 - Part No: 4F0 941 329
Component: AFS-Modul rechtsH05 0010

No fault code found.

-------------------------------------------------------------------------------
Address 56: Radio Labels: 4E0-910-541.lbl
Part No SW: 4E0 910 541 T HW: 4F0 035 541
Component: TUNER EU/US/RDW H41 0630
Revision: 00000000 Serial number: 352DG047520903
Coding: 0000001
Shop #: WSC 02335 785 00200
VCID: 31637D11A8A8F8B6C1-8064

No fault code found.

-------------------------------------------------------------------------------
Address 61: Battery Regul. Labels: 4F0-910-181.lbl
Part No SW: 4F0 910 181 E HW: 4F0 915 181 A
Component: ENERGIEMANAGER H11 0490
Revision: 00000000 Serial number: 00000000011657
Shop #: WSC 00539 210 17457
VCID: 234F8759E2545A2643-8076

Subsystem 1 - Part No: 4F0 915 105 D
Component: von VA0 0404270089
Coding: 344630393135313035442056413030343034323730303839
Shop #: WSC 00000 640 00290

No fault code found.

-------------------------------------------------------------------------------
Address 62: Door, Rear Left Labels: 4F0-910-795.lbl
Part No SW: 4F0 910 795 A HW: 4F0 959 795 A
Component: TSG HL H09 0010
Coding: 0000002
Shop #: WSC 02335 785 00200
VCID: 2A516A7D857E8B6E00-807E

No fault code found.

-------------------------------------------------------------------------------
Address 72: Door, Rear Right Labels: 4F0-910-795.lbl
Part No SW: 4F0 910 795 A HW: 4F0 959 794 A
Component: TSG HR H09 0010
Coding: 0000002
Shop #: WSC 02335 785 00200
VCID: 2A516A7D857E8B6E00-807E

No fault code found.

-------------------------------------------------------------------------------
Address 76: Park Assist Labels: 4Fx-910-283.lbl
Part No SW: 4F0 910 283 HW: 4F0 919 283
Component: Parkhilfe 4-Kan H09 0020
Revision: --.--.-- Serial number: 11730412405139
Coding: 0001006
Shop #: WSC 02335 785 00200
VCID: 61C3CD51B8C8083611-8034

No fault code found.

-------------------------------------------------------------------------------
Address 77: Telephone Labels: 4E0-910-333.lbl
Part No SW: 4E0 910 333 F HW: 4E0 862 333 C
Component: TELEFONMODUL EU 0770
Revision: 00000003 Serial number: T2AUDX0307H3S4
Coding: 0000006
Shop #: WSC 02335 785 00200
VCID: 2241825DFD4E532E48-8076

No fault code found.

End-------------------------(Elapsed Time: 02:49)--------------------------

[MarkTM]

Dean, have a look at these two threads:

Engine struggles to start and cuts out when coasting (http://www.vwaudiforum.co.uk/forum/showthread.php/177554-Engine-struggles-to-start-and-cuts-out-when-coasting)

Fuel pump in fuel tank (http://www.vwaudiforum.co.uk/forum/showthread.php/134415-Fuel-pump-in-fuel-tank)

Like you I had fuel pressure issues.

[gupsterg]

now last night i was checking connectors and unplugging things while it was running, i disconnected the plug on the fuel pump, low and behold it stopped stalling, however went into limp mode and would not rev over 3200 RPM it sat outside running for 30 minutes and did not stall once. so i reconnected the connector, and it hasnt stalled since.
what is this part on the pump? is it pressure? or stop solenoid? (do they still have them?)

This is N290 , fuel metering valve , google SSP 351 ( The common rail fuel injection system fitted in the 3.0l V6 TDI engine ) page 12 has info ;) . Via the Audi dealer route you won't be able to buy the valve but you can via VW commercial dealer ;) (see this post (http://www.vwaudiforum.co.uk/forum/showthread.php/102358-audi-3-0tdi-engine-measurement-blocks?p=834224#post834224)). Not saying you need to replace it but just as info for yourself/another :) . Google SSP 350 as well, another handy PDF to have :) but 351 is better for context of CR system.

[dean warren]

Interesting, so it is pressure.
As you say though, still no idea if its that or not [emoji848] thanks anyway.


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[gupsterg]

No worries, sorry got no exact answer.

Wjam viewed his valve, post 11 (http://www.vwaudiforum.co.uk/forum/showthread.php/102358-audi-3-0tdi-engine-measurement-blocks?p=750685#post750685) . In his other thread (http://www.vwaudiforum.co.uk/forum/showthread.php/103259-common-rail-pump) it seems to me measuring block data (or if you tested the sensor via output test using VCDS) are showing basically ECU requests for it to open/close but not what it's actually physically doing, unless it failed electrically you may not get a fault code on it. This could also be true of N276. If you view MVB 22 that will have specified rail pressure (what ECU want) and actual (what rail sensor is reporting), window 4 of MVB 22 is telling you activation % of N276 IIRC (see the 3.0 TDI mvb thread) and window 4 of MVB 23 is telling activation % of N290 IIRC.

[dean warren]

Ive ordered a valve to try, as the other chap had exactly same pressure as mine, so worth a punt


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[MarkTM]

Any updates Dean?

I know the part no is 0928400572

But where is it actually fitted, the Fuel pressure regulator is on the left hand bank and the fuel pressure sensor on the right, but have traced back fuel lines and electrics and can't find anything that looks quite like that.

My problems have returned and my fuel pressure is approx the following on all 6 injectors:

Pressure: 745.5 bar
Duty Cycle: 57.2 %

[dean warren]

Its on the back of the pump.
It hasn't stalled since but to be fare i haven't used it much, its a second car and my insurance said i could only add it for 14 days.
I have a trade policy starting next month so will crack on then.
To fit i had to remove the bank one inlet for access and then 3 very tight torque screws hold it in.


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[dean warren]

My pressure still reads 470/480 bar on tickover, this is a 2004 car, our other two show 280bar but there 2006 and 2007 so think have a different revision pump.


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[MarkTM]

Yep I can see it, two screws accessible the third not so, hence the removal of the inlet.

The problem is I cannot hear the in tank fuel pump working, I've got a new one but methinks far less effort to fit that then this valve.

Have checked all fuses and the relays but would appreciate if you can remember if you could hear your pump working when you had the fault? Or does the valve actually tell the in-tank fuel pump when to run?

[dean warren]

I activated the pump in VCDS so knew it was working


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[MarkTM]

Well I've changed the valve on the front of the pump, along with the pressure sensor and the fuel pressure regulator and mine still won't start.

It is reading 745 across all 6

So potentially either

a) A fault with the cam follower in the pump, or
b) A faulty fuel filter (although I don't think this would manifest with such a high pressure

Car's been off the road for 3 weeks now :(

[Mindoza-lokis]

Hi men. Did you find the problem and fix the car? I have exactly same problem with 2 cars some time pressure is 227 than car drive well but most is 482 than rpm idle jumping when release accelerator.

[dean warren]

Mine was fixed once i changed the regulator on the pump, pressure stopped surging and it stopped stalling


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[Adnan1989]

Hello which regulator did you change where is location i have same problem

[dean warren]

Hello which regulator did you change where is location i have same problem

Read post #9 (https://www.vwaudiforum.co.uk/forum/usertag.php?do=list&action=hash&hash=9) for the answer. [emoji106]


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[Adnan1989]

I have change sensor on pump same issue (was hard to change) than on rail sensor same 😂 injector changed same fuel filter same... on idle rpm stalling and fuel pressure 480bar... i have read ECU could be one have same issue... problem is there is no fault codes any 😔😔