2012 golf lower fuel pressure

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sterlinggarageltd

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any help is much appreciated. we have replaced fuel filter, in-tank fuel pump and fuel rail pressure sensor. have removed solenoid on high pressure pump for swarf and small metal fillings but not visible. any help will be much appreciated to daiag if the high pressure pump is at fault. symptoms described by customer is coil light flashing and limp mode and occasionally struggles to start. replaced fuel filter first as not been replaced yet by dealer. after replaced the filter housing would not prime so tested the in tank pump wasnt working replaced the in-tank pump and the vehicle starts better but still goes to limp mode.

Code: 
Friday,01,September,2017,08:57:37:11898
VCDS -- Windows Based VAG/VAS Emulator Running on Windows 10 x64
VCDS Version: 17.8.0.1 (x64)
Data version: 20170721 DS276.2
www.Ross-Tech.com

Dealer/Shop Name: Sterling Garage Ltd

VIN: WVWZZZ1KZDW005536   License Plate: OV62GGE
Mileage: 91620km-56930mi   Repair Order: 


Chassis Type: 1K-VW36 (7N0)
Scan: 01 03 08 09 15 16 17 19 25 42 44 46 52 56 61

VIN: WVWZZZ1KZDW005536   Mileage: 91620km-56930miles

01-Engine -- Status: Malfunction 0010
03-ABS Brakes -- Status: OK 0000
04-Steering Angle -- Status: OK 0000
08-Auto HVAC -- Status: OK 0000
09-Cent. Elect. -- Status: Malfunction 0010
15-Airbags -- Status: OK 0000
16-Steering wheel -- Status: OK 0000
17-Instruments -- Status: Malfunction 0010
19-CAN Gateway -- Status: OK 0000
25-Immobilizer -- Status: OK 0000
42-Door Elect, Driver -- Status: OK 0000
44-Steering Assist -- Status: OK 0000
46-Central Conv. -- Status: OK 0000
52-Door Elect, Pass. -- Status: OK 0000
56-Radio -- Status: OK 0000
61-Battery Regul. -- Status: Malfunction 0010
 
-------------------------------------------------------------------------------
Address 01: Engine (J623-CAYC)       Labels:. 03L-906-023-CAY.clb
   Part No SW: 03L 906 023 MN    HW: 03L 907 425 C
   Component: R4 1.6l TDI   H43 9979  
   Revision: --H43---    Serial number: 00000000000000
   Coding: 08114014030501080000
   Shop #: WSC 01357 011 00200
   ASAM Dataset: EV_ECM16TDI02103L906023MN 003014
   ROD: EV_ECM16TDI02103L997557B.rod
   VCID: 7EF9CC85E1D90FB6F8-802A

3 Faults Found:
10116 - Fuel Rail/System Pressure 
          P0087 00 [096] - Too Low
          Intermittent - Not Confirmed - Tested Since Memory Clear
             Freeze Frame:
                    Fault Status: 00000001
                    Fault Priority: 2
                    Fault Frequency: 1
                    Mileage: 91619 km
                    Date: 2017.08.31
                    Time: 14:20:36

                    Engine speed: 1664.00 /min
                    Normed load value: 72.5 %
                    Vehicle speed: 49 km/h
                    Coolant temperature: 88 °C
                    Intake air temperature: 38 °C
                    Ambient air pressure: 1000 mbar
                    Voltage terminal 30: 13.440 V
                    Unlearning counter according OBD: 40
                    Fuel high pressure: actual value-FUP_FIL: 6.628 MPa
                    Fuel pressure regulator valve: specified value rail pressure-LV_PCV_CTL: 00000000 
                    Fuel level-FTL_CAN: 31 l
                    Fuel temperature-TFU: 54 °C
                    Fuel Metering Valve-VCV: 33.757 %
                    Fuel Pressure Regulator Valve-PCV: 38.693 %
                    Fuel high pressure commanded value_1-FUP_SP_KPA_ENVD: 123999.023 kPa

7478 - Fuel Metering Valve 1 Control Difference 
          P228C 00 [096] - Pressure too Low
          Intermittent - Not Confirmed - Tested Since Memory Clear
             Freeze Frame:
                    Fault Status: 00000001
                    Fault Priority: 2
                    Fault Frequency: 1
                    Mileage: 91619 km
                    Date: 2017.08.31
                    Time: 14:20:36

                    Engine speed: 1664.00 /min
                    Normed load value: 72.5 %
                    Vehicle speed: 49 km/h
                    Coolant temperature: 88 °C
                    Intake air temperature: 38 °C
                    Ambient air pressure: 1000 mbar
                    Voltage terminal 30: 13.440 V
                    Unlearning counter according OBD: 40
                    Fuel high pressure: actual value-FUP_FIL: 6.628 MPa
                    Fuel pressure regulator valve: specified value rail pressure-LV_PCV_CTL: 00000000 
                    Fuel level-FTL_CAN: 31 l
                    Fuel temperature-TFU: 54 °C
                    Fuel Metering Valve-VCV: 33.757 %
                    Fuel Pressure Regulator Valve-PCV: 38.693 %
                    Fuel high pressure commanded value_1-FUP_SP_KPA_ENVD: 123999.023 kPa

10119 - High Pressure Fuel Rail 
          P00C6 00 [101] - Minimum Pressure Not Reached
          Not Confirmed - Tested Since Memory Clear
             Freeze Frame:
                    Fault Status: 00000001
                    Fault Priority: 2
                    Fault Frequency: 9
                    Mileage: 91619 km
                    Date: 2017.08.31
                    Time: 18:09:06

                    Engine speed: 354.75 /min
                    Normed load value: 8.6 %
                    Vehicle speed: 0 km/h
                    Coolant temperature: 59 °C
                    Intake air temperature: 29 °C
                    Ambient air pressure: 1000 mbar
                    Voltage terminal 30: 11.407 V
                    Unlearning counter according OBD: 40
                    Fuel high pressure: actual value-FUP_FIL: 10.400 MPa
                    Fuel pressure regulator valve: specified value rail pressure-LV_PCV_CTL: 00000001 
                    Fuel level-FTL_CAN: 32 l
                    Time since engine start: 0 s
                    Fuel Metering Valve-VCV: 24.763 %
                    Fuel Pressure Regulator Valve-PCV: 42.184 %
                    Fuel high pressure commanded value_1-FUP_SP_KPA_ENVD: 25610.352 kPa

Readiness: 0 0 0 0 0 

-------------------------------------------------------------------------------
Address 03: ABS Brakes (J104)       Labels:. 1K0-907-379-60EC1F.clb
   Part No SW: 1K0 907 379 BL    HW: 1K0 907 379 BL
   Component: ESP MK60EC1   H31 0152  
   Revision: 00H31001    
   Coding: 133B200D092200FFC81004E7901F0091310000
   Shop #: WSC 01357 011 00200
   VCID: 7DFBCB89E4DF14AEE1-8028

No fault code found.

-------------------------------------------------------------------------------
Address 08: Auto HVAC (J301)       Labels:| 3C8-907-336.clb
   Part No SW: 7N0 907 426 BG    HW: 7N0 907 426 BG
   Component: AC Manuell    H20 0505  
   Revision: 00001018    
   Coding: 0010004003
   Shop #: WSC 01357 011 00200
   ASAM Dataset: EV_ACManueBHBVW36X A01010
   ROD: EV_ACManueBHBVW36X_VW36.rod
   VCID: 7AF1C095FDF12396C4-802E

No fault code found.

-------------------------------------------------------------------------------
Address 09: Cent. Elect. (J519)       Labels:. 1K0-937-08x-09.clb
   Part No SW: 1K0 937 085 P    HW: 1K0 937 085 P
   Component: BCM PQ35  B+  111 0709  
   Revision: AB111709    
   Coding: 48180A3A8025F190408800C0100400644B010288424D8160648087200041
   Shop #: WSC 01357 011 00200
   VCID: 3C7D068DBF45DDA696-8068

   Subsystem 1 - Part No: 5K2 955 119 
   Component: Wischer 14051  26  0512 
   Coding: 009795

   Subsystem 2 - Part No: 1K8 951 171 
   Component: DWA-Sensor 00  001 0104 

   Subsystem 3 - Part No: 1K0 951 605 C
   Component: LIN BACKUP HO  H05 1501 

2 Faults Found:
01598 - Drive Battery Voltage 
            011 - Open Circuit - Intermittent
             Freeze Frame:
                    Fault Status: 00101011
                    Fault Priority: 6
                    Fault Frequency: 48
                    Reset counter: 186
                    Mileage: 88457 km
                    Time Indication: 0
                    Date: 2017.07.01
                    Time: 08:22:29

             Freeze Frame:
                        Term 15 On
                    Voltage: 13.05 V
                        ON
                        ON
                        Term 50 On
                        OFF
                        OFF

00446 - Function Limitation due to Under-Voltage 
            002 - Lower Limit Exceeded - Intermittent
             Freeze Frame:
                    Fault Status: 00100010
                    Fault Priority: 6
                    Fault Frequency: 1
                    Reset counter: 186
                    Mileage: 91493 km
                    Time Indication: 0
                    Date: 2017.08.22
                    Time: 23:05:55

             Freeze Frame:
                        Term 15 Off
                    Voltage: 6.75 V
                        OFF
                        ON
                        Term 50 Off
                        OFF
                        OFF


-------------------------------------------------------------------------------
Address 15: Airbags (J234)       Labels:| 5K0-959-655.clb
   Part No SW: 5C0 959 655 B    HW: 5C0 959 655 B
   Component: AirbagVW10    013 0613  
   Serial number: 003G5RAKJN2$  
   Coding: 00004432
   Shop #: WSC 01357 011 00200
   ASAM Dataset: EV_AirbaVW10SMEVW360 A01014
   ROD: EV_AirbaVW10SMEVW360.rod
   VCID: 316327B9600720CE35-8064

   Crash sensor for side airbag: driver side: 
   Subsystem 1 - Part No SW: 5K0 959 354     HW: 5K0 959 354 
   Component: S.Sens.Fahr.V  H02 ---- 
   Serial number: 3572MSME30294268ZZZR

   Crash sensor for side airbag: front passenger side: 
   Subsystem 2 - Part No SW: 5K0 959 354     HW: 5K0 959 354 
   Component: S.Sens.Beif.V  H02 ---- 
   Serial number: 3582MSME4E617268ZZZ%

   Crash sensor for side airbag: rear: driver side: 
   Component: S.Sens.Fahr.H  --- ---- 
   Serial number: 3512QSME683D161AZZZ$

   Crash sensor for side airbag: rear: passenger side: 
   Component: S.Sens.Beif.H  --- ---- 
   Serial number: 3522QSME4606160FZZZU

No fault code found.

-------------------------------------------------------------------------------
Address 16: Steering wheel (J527)       Labels:| 5K0-953-569.clb
   Part No SW: 5K0 953 507 AS    HW: 5K0 953 549 C
   Component: Lenks.Modul   008 0080  
   Revision: --------    Serial number:  90422LEH0016K
   Coding: 5080040000
   Shop #: WSC 01357 011 00200
   ASAM Dataset: EV_SMLSNGKUDS A05001
   ROD: EV_SMLSNGKUDS_A05.rod
   VCID: 0103B7799027704E85-8054

No fault code found.

-------------------------------------------------------------------------------
Address 17: Instruments (J285)       Labels:| 5K0-920-xxx-17.clb
   Part No SW: 5K0 920 973 A    HW: 5K0 920 973 A
   Component: KOMBI         H05 0705  
   Serial number: 00000000000000
   Coding: 470B00
   Shop #: WSC 01357 011 00200
   ASAM Dataset: EV_Kombi_UDS_VDD_RM09 A04716
   ROD: EV_Kombi_UDS_VDD_RM09_A04_VW32.rod
   VCID: 2F6721C17633363E23-807A

1 Fault Found:
9453074 - Fuel Level Sensor 1 
          B103E 1B [008] - Resistance Too High
          Intermittent - Confirmed - Tested Since Memory Clear
             Freeze Frame:
                    Fault Status: 00000001
                    Fault Priority: 2
                    Fault Frequency: 1
                    Reset counter: 194


-------------------------------------------------------------------------------
Address 19: CAN Gateway (J533)       Labels:. 7N0-907-530-V2.clb
   Part No SW: 7N0 907 530 S    HW: 7N0 907 530 J
   Component: J533  Gateway H43 1632  
   Revision:   H43       Serial number: 140512F2003633
   Coding: 350003
   Shop #: WSC 01357 011 00200
   VCID: 4085727DD3ADB946CA-8014

No fault code found.

-------------------------------------------------------------------------------
Address 25: Immobilizer (J334)       Labels:| 5K0-920-xxx-25.clb
   Part No SW: 5K0 953 234     HW: 5K0 953 234 
   Component: IMMO          H05 0705  
   Serial number: 00000000000000
   Coding: 000000
   Shop #: WSC 01357 011 00200
   ASAM Dataset: EV_Immo_UDS_VDD_RM09 A03709
   ROD: EV_Immo_UDS_VDD_RM09_VW21.rod
   VCID: 6AD1F0D58D51931634-803E

No fault code found.

-------------------------------------------------------------------------------
Address 42: Door Elect, Driver        Labels:. 1K0-959-701-MIN3.clb
   Part No SW: 5K0 959 701 B    HW: 5K0 959 701 B
   Component: Tuer-SG         009 2120  
   Coding: 0131636
   Shop #: WSC 01357 011 00200
   VCID: 316327B9A80720CE35-8064

No fault code found.

-------------------------------------------------------------------------------
Address 44: Steering Assist        Labels: 1K0-909-14x-GEN3.clb
   Part No: 1K0 909 144 P
   Component: EPS_ZFLS Kl. 69     3305  
   Revision: 00H22000    
   Shop #: WSC 01357 011 00200
   VCID: 377719A14663FEFE7B-8062

No fault code found.

-------------------------------------------------------------------------------
Address 52: Door Elect, Pass.        Labels:. 1K0-959-702-MIN3.clb
   Part No SW: 5K0 959 702 H    HW: 5K0 959 702 H
   Component: Tuer-SG         009 2106  
   Coding: 0131636
   Shop #: WSC 01357 011 00200
   VCID: 38751A9D4B7DF18672-806C

No fault code found.

-------------------------------------------------------------------------------
Address 56: Radio (J503)       Labels:. 5M0-035-1xx-56.clb
   Part No SW: 1K0 035 186 AN    HW: 1K0 035 186 AN
   Component: Radio RCD310  042 0082  
   Revision: 00000001    Serial number: VWZ1Z2M4354625
   Coding: 05000400040005
   Shop #: WSC 01357 011 00200
   VCID: 72E1E8B5AD815BD68C-8026

No fault code found.

-------------------------------------------------------------------------------
Address 61: Battery Regul. (J840)       Labels:. 1K0-907-534.clb
   Part No SW: 7N0 907 534     HW: 7N0 907 530 J
   Component: Batt.regelung H43 1632  
   Serial number: 140512F2003633
   Coding: 030F1859
   Shop #: WSC 01357 011 00200
   VCID: 71E3E7B9A88760CE75-8024

   Subsystem 1 - Part No SW: 1K0 915 181 H    HW: 1K0 915 181 A
   Component: J367-BDM  H07 0180 
   Serial number: 00000000008900213002

1 Fault Found:
01598 - Drive Battery Voltage 
            003 - Mechanical Failure - Intermittent
             Freeze Frame:
                    Fault Status: 00100011
                    Fault Priority: 1
                    Fault Frequency: 53
                    Reset counter: 186
                    Mileage: 88457 km
                    Time Indication: 0
                    Date: 2017.07.01
                    Time: 08:22:30


End-------------------------(Elapsed Time: 02:04)--------------------------
 
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   #2  
R

Robski

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so if I'm reading correctly here a few parts have been hung but no actual testing ?

Time to RTFB & test & prove or pass the job on to someone that can, you owe the customer this at least.
 
   #3  
N

NJB AUTOMOTIVE

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Were there any signs of metal filings in the tank when you replaced the pump? Have you verified low pressure supply I know on these you need to remove the low pressure hose that goes to the HPFP, place hose in a bowl with measurements on the side, ensure battery in good condition and run fuel pump for 30secs.
Minimum is 600ml over a 30 second period, anything less will result in problems.
If this checks out ok, I normally go to the fuel rail pressure regulation valve N276 as its easy to get to. Remove the return line from the rail and start engine again measure in a bowl, at idle over 30 seconds 75ml is allowed, if this is over the amount the valve is defective. If you're in spec raise engine speed to 2000rpm and again measure you should have nothing coming out the return apart from a drop or two.
The leak off pipes also include a pressure retention valve which is critical to the piezo control it should hold 1bar of pressure on these. I rarely see these fail.
Have you done live data check of desired high pressure and actual pressure when the fault occurs?
My thoughts on this as I had something similar are that, if you have good low supply and no obvious signs of HPFP failure and you're not leaking excessive fuel back into the return which of course would lower fuel pressure then I would be going down the injector route. Any rough engine idle or smoke would confirm this. This is obviously only my opinion.
 
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