Q7 starting woes....Tdi

[mitchel]

Hi all, my first post and its a killer, lol. My name is Mitchel and I live in Perth, Australia. I'm a diesel mechanic during the week and at the moment a diesel mechanic on the weekend (just on a particular Audi)

I have a 2006 Q7 3.0 TDi which is very very reluctant to start. There is a story, always is.... Lent it to a friend and she filled it will some good ol unleaded. Problem, she has agreed to cover the repair so I just want it running. The story is, she filled it up and drove a couple hundred meters to the mall. Came out of said mall and it wouldn't start. I got it towed home, i have since drained the petrol and filled it will diesel. Done a fair bit of reading online so I bought a vcds, changed the fuel filter and did the correct bleed procedure, ie activated the electric in tank fuel pumps. After a bit of cranking and a squirt of start aid it runs and sounds okay. It does however throw up 004195 Fuel pressure regulation P1063 001 Control range not reached.

If I clear it while running it just returns. I am still learning on vcds but think I have found what appears to be what the specified fuel pump pressure is and what the actual pressure is.
At idle it should be +-480 bar, mines at +-135bar. Problem. If I rev it up to about 2000rpm the figures seem to be inline. Its thinking the HPFP is cactus but was wondering if anyone has had similar problems before? Its on 220 000km, would imagine the pump would be at its life limit? I'm assuming that the pump is not creating enough pressure at cranking speed. I dont have much experience on Audi common rail but did work for Mercedes Commercials for 8 years so have an idea of how common rail systems work.

Any help would be muchly appreciated!

[Tabletski]

Doesn't petrol damage pump internals? Maybe that's why you don't have the correct pressure.


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[mitchel]

Yeah mate, thats why I'm thinking the pump is dead. Was hoping for some confirmation before I cough up for a new/recon etc.

[mitchel]

On a side note, does anyone know how to test the injectors? On other bosch systems the amount of leak off or fuel return is an indicator if the injector is worn internally. Interesting to see how its done on Audi's.

Thanks